Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Oil Pump

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REMOVAL & INSTALLATION



B20 and B30 Engines

The oil pump may only be removed with the engine elevated in the car or removed from the car. Do not attempt this procedure if you cannot properly lift and support the engine.

  1. Remove the oil pan as described previously.
  2.  
  3. Crank the engine to TDC at no. 1 cylinder. Remove the distributor.
  4.  
  5. Remove the oil pump retaining bolts.
  6.  
  7. Detach the oil pump from the delivery tube by unscrewing the connecting flange. Be careful not to discard the rubber sealing rings from the sealing flange.
  8.  
  9. Unscrew the connecting flange and remove the delivery tube from the block.
  10.  

To install:
  1. Fit the delivery tube with its sealing rings to the oil pump, and then to the block. If the tube does not seat properly in the block, it may be tapped lightly with a soft mallet. Tightly screw the connecting flanges together.
  2.  
  3. With no. 1 cylinder at TDC, install the oil pump drive and distributor. Make sure that the shaft goes down into its groove in the pump shaft. Tighten the oil pump retaining bolts.
  4.  
  5. Install the oil pan with a new gasket and fill the crankcase.
  6.  

B21, B23 and B230 Engines

See Figures 1, 2, 3 and 4

  1. Remove the oil pan as described previously.
  2.  



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Fig. Fig. 1: Remember to wear safety goggles as you look up to remove the two bolts to the oil pump

  1. Remove the two oil pump retaining bolts, and pull the delivery tube from the block.
  2.  



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Fig. Fig. 2: Lower the oil pump, pulling the delivery tube to a point where you can better access it



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Fig. Fig. 3: Remove the delivery tube to free the oil pump-replace the sealing ring with a new one

  1. When installing, use new sealing rings at either end of the delivery tube.
  2.  



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Fig. Fig. 4: Replace the delivery tube sealing ring on the engine side of the tube as well

B234 Engine
  1. Remove the timing belt following the procedures outlined in Timing Belt Removal and Installation.
  2.  
  3. Using a counterholding device such as Volvo tool No. 5039 or similar, remove the oil pump drive pulley.
  4.  
  5. Thoroughly clean the area around the oil pump. Place sheets of newspaper or a container on the splash guard to contain any spillage and remove the oil pump mounting bolts. Remove the pump from the engine.
  6.  
  7. Remove the seal from the groove in the block. Clean the area with solvent, making certain there are no particles of dirt trapped in the pump area.
  8.  
  9. Install the new seal in the groove and install the new oil pump. Lubricate the pump with clean engine oil before installation. Tighten the mounting bolts to 7.5 ft. lbs. (10 Nm).
  10.  
  11. Using the counterhold, install the drive pulley and tighten the center bolt to 15 ft. lbs. (20 Nm) PLUS 60° of rotation.
  12.  
  13. Clean the area of any oil spillage; remove the paper or container from the splash guard.
  14.  
  15. Install the timing belt following the procedures outlined in Timing Belt Removal and Installation.
  16.  

B27, B28 and B280 Engines

See Figures 5, 6 and 7

The oil pump body is cast integrally with the cylinder block. It is chain driven by a separate sprocket on the crankshaft and is located behind the timing chain cover. The pick-up screen and tube are serviced by removing the oil pan. To check the pump gears or remove the oil pump cover:

  1. Disconnect the negative battery terminal. Drain the coolant by opening the drain cock on the left side of the engine. A radiator hose may also be disconnected to speed draining.
  2.  

  1. After removing any electrical leads to the radiator, disconnect the oil cooler lines to the radiator on cars with automatic transmissions. Remove the fan shroud from the radiator, disconnect the hoses and remove the radiator. Remove the fan shroud.
  2.  
  3. Remove the splash shield under the engine. Loosen the alternator and power steering belts.
  4.  
  5. Remove the power steering pump from its bracket and secure it with wire out of the way. Do not disconnect any lines or hoses. After the pump is moved and secure, remove the bracket from the engine.
  6.  
  7. Detach and secure to one side the air conditioning compressor, if so equipped. Don't disconnect any lines or hoses.
  8.  
  9. Remove the fan, fan pulley and drive belts.
  10.  
  11. After removing the air intake duct and the vacuum pump, remove the left valve cover.
  12.  
  13. Using a 5mm Allen wrench, remove the fuel pressure regulator and lay it on the intake manifold. Disconnect the main ignition wire (near the right side shock tower) and remove the oil filler cap. Remove the right valve cover.
  14.  
  15. Turn the crankshaft to the overlap position on cylinder No. 1. This means the rocker arms for cylinder No. 1 do NOT have clearance and the first mark on the crank pulley is aligned with the O mark on the pointer.
  16.  



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Fig. Fig. 5: Upper: set to the "overlap" position on cylinder No. 1 and set the crankshaft pulley to "0." Lower: lock the flywheel in place-Volvo special tool shown

  1. Using either Volvo special tool No. 5112 or an acceptable substitute, lock the flywheel in position so that the engine cannot be moved out of position.
  2.  
  3. By using a 36mm socket, remove the crankshaft pulley. Take care that the small locking (Woodruff) key on the crankshaft does not fall into the lower part of the engine.
  4.  
  5. Move the wiring harness on the timing cover to one side and remove the timing cover. The timing chains, gears, sliders and tensioners will be exposed. Do not loosen or meddle with any components or you may cost yourself great time and expense.
  6.  



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Fig. Fig. 6: Remove the oil pump sprocket and its chain-B28 and B280 engines

  1. Remove the oil pump sprocket and its chain. This is the outermost drive system and can be removed with no disturbance of the other chains. The oil pump itself may now be removed by loosening its retaining bolts and carefully lifting it away from the engine. Clean all the parts before reinstallation. Clean the housing in the cylinder block. Install the pump and tighten its mounting bolts to 7-11 ft. lbs. (9-15 Nm).
  2.  



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Fig. Fig. 7: Exploded view of the oil pump and mounting position-B28 and B280 engines

  1. Using a plastic (not metal) scraper, clean the gasket surfaces on the timing cover, the valve covers, and the front of the engine block. Tap the center seal out of the timing cover and replace it with a new one.
  2.  
  3. Reinstall the oil pump drive pulley and its chain. Use a light coat of locking fluid on the pulley retaining bolts.
  4.  
  5. Install the timing gear cover with a new gasket. Apply a light coat of locking fluid to the four lower bolts; tighten all the bolts to 10-11 ft. lbs. (14-15 Nm).
  6.  
  7. Install the crankshaft pulley. Tighten to 190-200 ft. lbs. (258-271 Nm). Remove the locking device from the flywheel.
  8.  
  9. Apply new gaskets and reinstall both valve covers.
  10.  
  11. On the right side of the motor, replace the oil filler cap, the ignition lead and the fuel control pressure regulator.
  12.  
  13. Close the drain cock on the left side of the engine.
  14.  
  15. On the left side of the motor, reconnect the vacuum pump (with a new gasket) and the air inlet duct.
  16.  
  17. Reinstall the fan, pulley, and drive belts. Replace the bracket and the power steering pump with its belt. Adjust all the belts to the correct tension.
  18.  
  19. Install the air conditioning compressor and set the belt tension.
  20.  
  21. Install the fan shroud and the radiator. Connect the oil cooler lines to the radiator (cars with automatic transmission), and connect all the hoses to the radiator. Reconnect any wiring to sensors on the radiator.
  22.  
  23. Install the splash guard under the car.
  24.  
  25. Double check all installation items, paying particular attention to loose hoses or hanging wires, loose nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  26.  
  27. Reconnect the battery cable. Fill the cooling system with a 50-50 mixture of coolant and water. Start the engine and check for leaks. After the engine has fully warmed up, check the coolant level and top up as needed.
  28.  

D24 and D24T Diesel Engines

See Figures 8, 9, 10, 11, 12 and 13



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Fig. Fig. 8: Exploded view of the diesel oil pump assembly

The use of the correct special tools or their equivalent is REQUIRED for this procedure. This procedure covers removal of both the oil pump and the oil pan. While it is easier to do this with the engine out of the car, the repair can be performed with the engine lifted and supported while still in the vehicle.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant system by disconnecting the lower radiator hose at the radiator and disconnect the lower hose of the cold start device.
  4.  
  5. Remove the radiator. Remove the cooling fan with its spacer and pulley.
  6.  
  7. Remove the fan belt(s) and the power steering drive belt.
  8.  
  9. Remove the timing gear cover. When this cover is removed, the timing belt will be exposed. Do not allow fluids, dirt or oil to contact the belt. It must be kept clean and dry or premature wear and breakage may result.
  10.  
  11. Remove the large center bolt in the center of the vibration damper (pulley) and the crankshaft. Do not allow the pulley to turn while removing the nut. Volvo has two special tools available to accomplish this.
  12.  



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Fig. Fig. 9: Turn the engine about 1/4 turn counterclockwise to transfer the slack in the timing belt

  1. When the nut is removed, turn the pulley (and therefore, the engine) about 1 / 4 turn counter clockwise. This transfers the slack in the timing belt to the opposite side, making it easier to remove.
  2.  
  3. Using a 6mm Allen wrench, remove the four small bolts holding the crank damper and remove the damper. Note that the crankshaft gear may stick to the damper. When the damper is off, remove the lower timing gear cover.
  4.  
  5. Loosen and remove the three bolts holding the bracket for the alternator and cooling fan. Place the assembly to one side and secure it out of the way.
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  7. Mark the position of the timing belt relative to the timing gears. Mark the belt, camshaft gear and crankshaft gear. Identify the outside and topside of the belt. It is critical that the belt be reinstalled in exactly the same position as it was found.
  8.  



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Fig. Fig. 10: Mark the timing belt and gears to enable installation in the exact same position

  1. Loosen the water pump mounting bolts and and the timing belt. Some coolant may leak out when the bolts are loosened. Remove the timing belt.
  2.  
  3. Remove the idler pulley. Use a pulley puller; do not pry on the idler.
  4.  
  5. Remove the seal from the oil pump. Remove all the retaining screws from cover, but do not remove the cover at this time.
  6.  
  7. Lift the dipstick about 2 1 / 2 inches and remove the upper retaining bolt from the steering joint. Remove the wire from the oil level sender if so equipped.
  8.  
  9. Install the lifting equipment or chain hoist on the engine. When securely mounted, raise engine slightly.
  10.  
  11. Loosen the bolts holding the front axle crossmember at both sides.
  12.  
  13. Drain the engine oil. Replace the drain plug when draining is complete.
  14.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the swaybar retaining bolts from the side members.
  2.  
  3. Loosen the wiring harness clamp on the right side of the engine, and loosen the clamp holding the battery cable (near the right engine mount).
  4.  
  5. Remove the retaining nuts for the engine mounts. Lower the sidemember and detach the steering column from the joint.
  6.  
  7. Disconnect the oil return line from the oil pan.
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  9. Remove the retaining bolts for the oil pan. Note that the bolts you remove are different sizes. It is important to record location of each bolt. Proper gasket sealing during reassembly depends on use of the correct bolt. The rear and center bolts are reached through openings in the flywheel. Remove the four bolts from the flywheel casing. Remove the oil pan.
  10.  



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Fig. Fig. 11: Location of the oil pump retaining bolts-D24 and D24T engines



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Fig. Fig. 12: Record each original diesel oil pan bolt position to enable correct installation of the different size bolts

  1. With the pan removed, disconnect the oil tube bolts at the oil pump. The tube may manipulated by loosening the bolts which hold it to the block.
  2.  
  3. Remove the bolts remaining in the oil pump and remove the pump. Take care not to damage the pump body.
  4.  
  5. Remove the gaskets for the oil pan and pump. Clean the mating surfaces.
  6.  
  7. When installing the new pump, always use a new gasket. Make sure the pump gear aligns with the crankshaft flange. Secure the pump with three bolts, the longest of which goes in the right-side hole.
  8.  
  9. Connect the oil pump tube. Use a new gasket and tighten to 7 ft. lbs. (9 Nm). Tighten the tube retaining bolts on the block.
  10.  
  11. Install the oil pan with a new gasket. Hold the gasket in place with a light coating of grease. Remember to install the proper size bolt in the proper spot.
  12.  
  13. Using a new gasket, reconnect the oil return line to the pan.
  14.  
  15. Raise the front axle crossmember with a jack and position the steering shaft joint. Guide the engine mounts into position. Loosely attach the crossmember retaining nuts and attach the nuts to the engine mounts. The jack may be removed when the pieces are secured.
  16.  
  17. Reconnect the wiring harness clamp and the clamp for the battery lead.
  18.  
  19. Tighten the mounting bolts for the front crossmember to 60 ft. lbs. (81 Nm). Double check engine mount nuts and relieve tension on the lifting equipment. Disconnect and remove the lifting equipment.
  20.  
  21. Reconnect and secure the steering shaft joint. Reconnect the wire to the oil level transmitter and push in the dipstick.
  22.  
  23. Replace the cover retaining bolts, the idler pulley, and the oil pump seal.
  24.  
  25. Remount the bracket for the cooling fan and alternator.
  26.  
  27. Install the timing belt. Align the marks on the upper and lower gears with the marks on the belt. It is critical that the belt be refitted exactly as it was removed.
  28.  
  29. Draw tension on the belt by moving the water pump by hand. Tighten the water pump mounting bolts.
  30.  
  31. Install the lower timing gear cover and the vibration damper. Note that the damper can only be fitted one way--the pin on the crank gear must fit into the damper. Tighten the four bolts to 15 ft. lbs. (20 Nm). Install the large center nut, using the special tools as before. Tighten the center nut to 255 ft. lbs. (345 Nm).
  32.  
  33. Turn the engine clockwise 1 / 4 turn. Use a belt tension gauge to check the timing belt tension. Adjust the tension by moving the water pump as necessary. If using Volvo tool No. 5197, the correct tension is 12.5 units.
  34.  



Click image to see an enlarged view

Fig. Fig. 13: Move the water pump as necessary to adjust belt tension-D24 and D24T engines with special Volvo tool installed

  1. Reinstall the front timing gear cover. Install the fan with its spacer and pulley. Tighten the fan bolts to 7 ft. lbs. (9 Nm).
  2.  
  3. Install the belts for the fan and power steering pump. Adjust the belts to the proper tension.
  4.  
  5. Reinstall the radiator. Connect the hoses to the radiator and the hose to the cold start device. Refill the coolant system with a 50-50 mixture of antifreeze and water.
  6.  
  7. Double check all installation items, paying particular attention to loose hoses or hanging wires, loose nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  8.  
  9. Reconnect the negative battery cable. Start the engine and check for leaks.
  10.  
  11. Disconnect the upper hose to the cold start device. Place a collecting pan or jug beneath the hose and hold the hose level with the top edge of the expansion tank. Allow the engine to come to normal operating temperature with the cap off the expansion tank. Add coolant as necessary as the engine warms up.
  12.  
  13. When the coolant level is stable and no air is coming from the disconnected hose, shut the engine off. Reconnect the upper hose to the cold start device, top up the coolant in the expansion tank and put the cap back on the tank.
  14.  

 
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