Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



B20 and B30 Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system and remove the radiator.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the fan belt by slackening the alternator adjusting bolt. Remove the fan belt; remove the fan.
  2.  
  3. Remove the housing bolts from the water pump. Carefully remove the aluminum housing from the engine along with all the old gasket material. Remove the sealing rings.
  4.  

To install:
  1. Position the water pump assembly to the block, using a new housing gasket and water resistant sealer. Make sure that the sealing rings on the upper side of the pump are seated fully. Press the pump upward against the cylinder head extension to seat the seals. Hand-tighten the housing bolts until snug. Do not tighten the bolts more than 1 / 2 turn further to avoid cracking the housing or breaking the bolts.
  2.  
  3. Install the fan and adjust the (drive) belt tension.
  4.  
  5. Install the radiator as previously described. Fill the cooling system.
  6.  
  7. Attach the negative battery cable. Start the engine and check for leaks.
  8.  

B21, B23 and B230 Engines

See Figures 1 through 8

  1. Disconnect the negative battery cable. Remove the overflow tank cap. Drain the cooling system by opening the cylinder block drain cock (beneath the exhaust manifold) and disconnecting the lower radiator hose.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the fan and fan shroud.
  2.  



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Fig. Fig. 1: Remove the nuts that retain the fan to the hub



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Fig. Fig. 2: When free, remove the fan to a safe location

  1. Remove the alternator and air pump drive belts. Remove the water pump pulley.
  2.  



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Fig. Fig. 3: Having already loosened the drive belt, remove the pulley wheel from the water pump

  1. Remove the timing belt cover.
  2.  
  3. Remove the lower radiator hose.
  4.  



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Fig. Fig. 4: Remove the hose clamp and pull off the lower radiator hose

  1. Remove the retaining bolts for the coolant pipe (beneath exhaust manifold) and pull the pipe towards the rear of the car.
  2.  



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Fig. Fig. 5: Remove all the bolts holding the water pump to the housing

  1. Remove the retaining bolts and lift off the water pump.
  2.  



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Fig. Fig. 6: Remove the water pump and set aside-all gasket surfaces must be clean before installation



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Fig. Fig. 7: Scrape all gasket material without gouging the aluminum surfaces

  1. Clean the gasket contact surfaces thoroughly. When reassembling, the use of new gaskets and O-rings is required.
  2.  
  3. When reinstalling pump, make certain that it seats firmly in position and that all gaskets and seals are properly located.
  4.  
  5. After the pump is securely mounted, replace and secure the lower pipe and bracket, the radiator hoses and the timing belt cover.
  6.  
  7. Attach the water pump pulley and all the drive belts. Adjust the belts to the proper tension.
  8.  
  9. Install the fan and fan shroud. Close the drain cock on the side of the engine and replace the expansion tank cap. Fill the cooling system with a 50-50 mixture of antifreeze and water.
  10.  
  11. Reconnect the negative battery cable. Start the engine and check for leaks. After the engine has reached normal operating temperature, check the expansion tank for the proper coolant level; add fluid if necessary.
  12.  



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Fig. Fig. 8: Position the water pump as shown-B21, B23 and B230 engines

B234 Engine
  1. Set the heater control for maximum heat, remove the cap on the expansion tank and open the draincock on the right side of the engine block.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the bottom radiator hose from the pump. Close the draincock when the system is empty.
  2.  
  3. Remove the alternator drive belt, the radiator fan and pulley.
  4.  
  5. Remove the retaining bolts and nuts and remove the water pump from the engine.
  6.  
  7. Clean the joint faces and mating surfaces.
  8.  
  9. During reassembly, use new gaskets and seals. Place the O-ring on the return tube and the gasket on the block. Make sure the ring is seated in the groove. Fit the pump into position and install the two nuts just tight enough to hold the pump against the block.
  10.  
  11. Press the pump vertically against the cylinder head and install the remaining bolts and washers. Reconnect the return pipe.
  12.  
  13. Install the bottom radiator hose, the radiator fan and pulley and the alternator drive belt.
  14.  
  15. Fill the system with coolant, cap the expansion tank and run the engine to normal operating temperature to check for leaks.
  16.  

B27F and B28F Engines

See Figure 9

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front and main sections of the intake manifold.
  4.  
  5. Remove the overflow tank cap and drain the cooling system by opening the drain cock on the side of the block and disconnecting the lower radiator hose.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect both radiator hoses. On automatic transmission cars, disconnect the transmission cooler lines at the radiator. Remove the radiator and fan shroud.
  2.  
  3. Remove the fan.
  4.  
  5. Remove the hoses from the water pump to each cylinder head.
  6.  
  7. Remove the fan belts. Remove the water pump pulley.
  8.  
  9. Loosen the hose clamps at the rear of the water pump.
  10.  
  11. Carefully remove and transfer the thermal time sender and temperature sensor to the new pump.
  12.  
  13. Remove the water pump from the block (three bolts).
  14.  
  15. Transfer the thermostat cover, thermostat, and rear pump cover to the new pump. Clean all mating surfaces and remove any trace of old gasket material. Check all coolant hoses and replace them if stiff or cracked.
  16.  
  17. Using new gaskets, install the water pump onto the block. Do not overtighten the bolts. Correct torque is 11-15 ft. lbs. (15-20 Nm).
  18.  
  19. Connect and secure all hoses to the water pump.
  20.  
  21. Position the drive belts and install the pulley and cooling fan. Adjust all belts to the correct tension. Reconnect wiring to the electrical components on the water pump.
  22.  
  23. Reinstall the intake manifold. See Intake Manifold, Removal and Installation elsewhere in this section.
  24.  
  25. Install the radiator and fan shroud. Connect the radiator hoses to the radiator. On cars with automatic transmissions, reconnect the oil cooler lines to the radiator. If the car has electric fans, remember to connect the wiring to the temperature sensor in the radiator.
  26.  
  27. Put the cap on the expansion tank and close the drain cock in the side of the engine. Reconnect the negative battery cable.
  28.  
  29. 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.
  30.  
  31. Refill the cooling system with a 50-50 mixture of antifreeze and water.
  32.  
  33. Start the engine and check for leaks. Allow the engine to reach normal operating temperature and check the coolant level; add fluid if needed. Inspect and top-up the fluid level in the automatic transmission if so equipped.
  34.  



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Fig. Fig. 9: Different styles of water pump pulleys for B27 and B28-make sure to match up any replacement part(s) with the original(s)

B280 Engine

See Figures 10 and 11

The B280 engine, introduced in 1987, is a variant of the B28. The steps to replace the water pump are essentially the same as the B28, but the intake manifold DOES NOT need to be removed. The spark plug wires and various small hoses and brackets need removal for access, but the steps above (B28) will guide you through. Simply omit the steps for removal and installation of the intake manifold.



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Fig. Fig. 10: Exploded view of the water pump assembly-B28F engines



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Fig. Fig. 11: Exploded view of the water pump assembly-B280 engine

D24 and D24T Diesel Engines

See Figures 12, 13 and 14

The use of the correct special tools or their equivalent is REQUIRED for this procedure. This procedure requires the removal of the timing belt. If the special tools needed are not available, do not attempt to remove the water pump.

  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.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the radiator. Remove the cooling fan with its spacer and pulley.
  2.  
  3. Remove the fan belt(s) and the power steering drive belt.
  4.  
  5. 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.
  6.  
  7. 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.
  8.  



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Fig. Fig. 12: Turn the engine clockwise 1/4 turn 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.
  6.  
  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. 13: Carefully mark the timing belt and gears before removing the belt. Exact reinstallation is critical to prevent motor damage

  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 cover panel and bolts holding the water pump. Move the panel to one side and remove the pump. Be careful not to crack the panel.
  4.  
  5. Dry off spilt coolant from the block, gears, etc. Clean the contact surfaces on the block. Make sure no sealing material remains on the surface.
  6.  

To install:
  1. Lightly grease the new O-ring and place it on the pump. Do not use any other sealer. Carefully move the cover plate aside and install the new pump on the engine. Attach the pump retaining bolts; leave them loose at this stage.
  2.  
  3. Replace the cover plate retaining bolts and remount the bracket for the cooling fan and alternator.
  4.  
  5. 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.
  6.  
  7. Draw tension on the belt by moving the water pump by hand. Tighten the water pump mounting bolts.
  8.  
  9. 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).
  10.  
  11. 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.
  12.  



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Fig. Fig. 14: Use a belt tension gauge and move the water pump as necessary to adjust the timing belt-Volvo special tool shown

  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. Reconnect the negative battery cable. Start the engine and check for leaks.
  8.  
  9. 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.
  10.  
  11. 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.
  12.  

 
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