Volvo Truck 2003-05

Oil Pump

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Removal & Installation



8-Cylinder Engines
  1. Remove the timing chain.
  2.  
  3. Install the front engine bracket.
  4.  
  5. Remove the oil pan.

    Click image to see an enlarged view

    Fig. Oil delivery pipe-V8

    Oil delivery pipe-V8
  6.  
  7. Remove the oil delivery pipe. Discard the gasket.

    Click image to see an enlarged view

    Fig. Oil pump mounting-V8

    Oil pump mounting-V8
  8.  
  9. Remove the 3 M7 bolts and the oil pump. Discard the O-ring and the gasket for the oil delivery pipe.
  10.  

To install

  1. Install a new O-ring and the oil pump.
  2.  
  3. Install the oil delivery pipe using a new gasket.
  4.  
  5. Install the oil pan.
  6.  
  7. Install the timing chain.
  8.  

6-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the timing belt.
  4.  
  5. Check the tensioner and idler pulleys.
  6.  
  7. Carefully pull crankshaft timing gear pulley free. Remove the four oil pump bolts.
  8.  
  9. Carefully pry upward diagonally between the stop lugs and the cylinder block.
  10.  
  11. Lift out the oil pump.
  12.  

To install:

  1. Install a new gasket.
  2.  
  3. Carefully insert the oil pump over the end of the crankshaft.
  4.  


NOTE
The sealing ring in the oil pump is very easy to damage if not installed correctly.

  1. Install four new bolts as a guide.
  2.  
  3. Pull in the oil pump with tool 999 5455, or equivalent, and the crankshaft center nut.
  4.  
  5. Tighten the oil pump bolt. Tighten to 84 inch lbs. (10 Nm).
  6.  
  7. Install the timing gear pulley. Carefully tap alternately around the timing gear pulley until reaching its end position.
  8.  


NOTE
The timing gear pulley can only be in one position on the crankshaft end splines.

  1. Install a new timing belt.
  2.  
  3. Install the pulley for the auxiliary belt. Locate the steering gear on the locating pin in the timing gear pulley.
  4.  
  5. Install the auxiliary belt.
  6.  
  7. Install counterhold 999 5433.
  8.  
  9. Tighten crankshaft center nut. See the torque chart.
  10.  
  11. Install the vibration damper. Use the crankshaft center nut as a counterhold.
  12.  
  13. Check the engine oil level.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the timing belt.
  4.  
  5. Check the tensioner and idler pulleys.
  6.  
  7. Carefully pull crankshaft timing gear pulley free. Remove the four oil pump bolts.
  8.  
  9. Carefully pry upward diagonally between the stop lugs and the cylinder block.
  10.  
  11. Lift out the oil pump.
  12.  

To install:

  1. Install a new gasket.
  2.  
  3. Carefully insert the oil pump over the end of the crankshaft.
    NOTE
    The sealing ring in the oil pump is very easy to damage if not installed correctly.

  4.  
  5. Install four new bolts as a guide.
  6.  
  7. Pull in the oil pump with tool 999 5455, or equivalent, and the crankshaft center nut.
  8.  
  9. Tighten the oil pump bolt. Tighten to 88 inch lbs. (10 Nm).
  10.  
  11. Install the timing gear pulley. Carefully tap alternately around the timing gear pulley until reaching its end position.
    NOTE
    The timing gear pulley can only be in one position on the crankshaft end splines.

  12.  
  13. Install a new timing belt.
  14.  
  15. Install the pulley for the auxiliary belt. Locate the steering gear on the locating pin in the timing gear pulley.
  16.  
  17. Install the auxiliary belt.
  18.  
  19. Install counterhold 999 5433.
  20.  
  21. Tighten crankshaft center nut. See the torque chart at the beginning of this chapter.
  22.  
  23. Install the crankshaft damper. Use the crankshaft center nut as a counterhold.
  24.  
  25. Check the engine oil level.
  26.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fuel line clips
     
    Coolant recovery tank
     
    Accessory drive belts
     
    Right front wheel
     
    Inner fender liner
     
    Front cover
     
    Timing belt
     
    Crankshaft timing sprocket
     
    Front crankshaft seal
     
    Oil pump
     

  4.  

To install:

  1. Install the oil pump using special tool 999-5455. Use the oil pump bolts to guide the pump. Use the crankshaft nut to press the pump in until it is seated fully. Tighten the oil pump bolts to 88 inch lbs. (10 Nm).
  2.  
  3. Remove the crankshaft nut and the press tool.
  4.  
  5. Install or connect the following:

    Front crankshaft seal
     
    Crankshaft timing sprocket and tighten the nut to 133 ft. lbs. (180 Nm)
     
    Timing belt
     
    Front cover
     
    Inner fender liner
     
    Right front wheel
     
    Accessory drive belts
     
    Coolant recovery tank
     
    Fuel line clips
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Oil pump installation

    Oil pump installation
  8.  

Inspection



Check the oil pressure produced by the engine. The engine should be at normal operating temperature. If the oil quality and type or oil filter condition cannot be determined, replace the oil and filter before testing the oil pump and oil pressure.

  1. Connect instrument kit 999 5270 to the oil pressure sensor duct on the cylinder block.
  2.  
  3. Start the engine and check the oil pressure at different engine speeds (RPM).
  4.  
  5. The oil pump is capable of producing the following pressure readings:
    1. 5-Cylinder Engines-43 psi at 2000 RPM
    2.  
    3. 6-Cylinder Engines-50 psi at 4000 RPM
    4.  
    5. 8-Cylinder Engines-68-109 psi at 2000 RPM
    6.  

  6.  
  7. If the oil pressure is low, remove oil pump and inspect:

    Oil pump case for cracks or damage or oil seepage
     
    Relief plunger for smooth operation
     
    Relief spring for deformation or a break
     

  8.  
  9. Inspect the surface that mates with the oil filter for any damage
  10.  

 
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