Volvo Truck 2003-05

Removal & Installation

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6-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Raise the car.
  6.  
  7. Remove the lower engine splash guard.
  8.  
  9. Open the engine nipple. Drain the coolant into a container. Close the nipple.
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the bolts holding the pump at the cylinder block.
  14.  
  15. Tap the pump wheel using the shaft of a hammer. Remove the pump.
  16.  

To install:

  1. Carefully clean the gasket face.
  2.  
  3. Install a new gasket and the coolant pump. Tighten crosswise. Tighten to 13 ft. lbs. (17 Nm).
  4.  
  5. Install the timing belt.
  6.  
  7. Remove the lock grip pliers from the lower coolant hose.
  8.  
  9. Install the lower engine splash guard.
  10.  
  11. Remove the lock grip pliers from the upper coolant hose.
  12.  
  13. Fill coolant and check the level.
  14.  
  15. Check the power steering fluid level.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Raise the car.
  6.  
  7. Remove the lower engine splash guard.
  8.  
  9. Open the engine nipple. Drain the coolant into a container. Close the nipple.
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the bolts holding the pump at the cylinder block.
  14.  
  15. Tap the pump wheel using the shaft of a hammer. Remove the pump.
  16.  

To install:

  1. Carefully clean the gasket face.
  2.  
  3. Install a new gasket and the coolant pump. Tighten crosswise. Tighten to 13 ft. lbs. (17 Nm).
  4.  
  5. Install the timing belt.
  6.  
  7. Remove the lock grip pliers from the lower coolant hose.
  8.  
  9. Install the lower engine splash guard.
  10.  
  11. Remove the lock grip pliers from the upper coolant hose.
  12.  
  13. Fill coolant and check the level.
  14.  
  15. Check the power steering fluid level.
  16.  

8-Cylinder Engine



  1. Remove the expansion tank cap.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove protective plate
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  6.  
  7. Remove the 6 bolts.
  8.  
  9. Lift and slide the protective plate forward.
  10.  
  11. Remove the protective plate.
  12.  
  13. Draining coolant
  14.  
  15. Open the cock on the lower left edge of the radiator.
  16.  
  17. Drain the coolant into a clean receptacle.
  18.  
  19. Close the cock.
  20.  
  21. Install the protective plate.
  22.  
  23. Loosen the 4 bolts of the coolant pump belt pulley a few turns.
  24.  
  25. Remove the belt.
  26.  
  27. Remove the 4 bolts of the belt pulley.
  28.  
  29. Remove the 7 bolts of the coolant pump and the coolant pump. Discard the gasket.

    Click image to see an enlarged view

    Fig. Protective plate-8-cylinder engines

    Protective plate-8-cylinder engines
  30.  

To install:

Click image to see an enlarged view

Fig. Water pump-8-cylinder engines

Water pump-8-cylinder engines

  1. Clean the gasket surface for the coolant pump.
  2.  
  3. Install a new gasket and the coolant pump. Tighten the M6 bolts to 88 inch lbs. (10 Nm).
  4.  
  5. Position the belt pulley but do not tighten the bolts.
  6.  
  7. Install the auxiliary belt.
  8.  
  9. Tighten the 4 M6 bolts of the belt pulley to 88 inch lbs. (10 Nm).
  10.  
  11. Fill with coolant.
  12.  
  13. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluid as necessary.
  14.  

5-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cover
     
    Fuel line clips
     
    Expansion tank
     
    Accessory drive belts
     
    Vibration damper guard
     
    Front wheel
     
    Inner fender panel
     
    Front timing cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Timing belt
     
    Front timing cover
     
    Inner fender panel
     
    Front wheel
     
    Vibration damper guard
     
    Accessory drive belts
     
    Expansion tank
     
    Fuel line clips
     
    Spark plug cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  


    Click image to see an enlarged view

    Fig. Water pump and gasket

    Water pump and gasket

    Click image to see an enlarged view

    Fig. Water pump installation

    Water pump installation

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cover
     
    Fuel line clips
     
    Expansion tank
     
    Accessory drive belts
     
    Crankshaft damper guard
     
    Front wheel
     
    Inner fender panel
     
    Front timing cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Timing belt
     
    Front timing cover
     
    Inner fender panel
     
    Front wheel
     
    Crankshaft damper guard
     
    Accessory drive belts
     
    Expansion tank
     
    Fuel line clips
     
    Spark plug cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Water pump and gasket

    Water pump and gasket

    Click image to see an enlarged view

    Fig. Water pump installation

    Water pump installation
  6.  

 
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