Water Pump, Removing/Installing
Drain cooling system
Vehicles with AC: Disconnect vacuum hose from water valve to ensure that valve opens fully.
Move heater control to "warm". Remove expansion tank cap. Unscrew drain tap on right-hand side of cylinder block. Disconnect hose from bottom of radiator.
Disconnect battery ground lead.
Remove fan, preheating hose clip beneath fan shroud (if applicable), and fan shroud.
Remove drive belts and water pump pulley
- loosen belt tensioners
- remove all drive belts
- remove pump pulley
Remove upper timing gear cover
1. M6 bolts
2. M8 bolt
3. panel screw
Disconnect return pipe from water pump
Remove bolt, washer, gasket and nut.
Remove water pump
Remove all bolts, washers and nuts.
Clean gasket face and contact faces
Remove all traces of gasket from block and water pump. Clean rubber ring contact face, cylinder head side.
Install water pump
Place a new gasket between pump and cylinder block.
Place new O-ring on water pump.
Secure pump by two nuts. Make sure that O-ring is correctly positioned and not damaged. Tighten nuts until pump can just be pushed upwards.
Pry water pump against cylinder head
Fit remaining washers and bolts. Tighten bolts and nuts.
Reconnect return pipe
Fit a new rubber seal.
Fit upper timing gear cover
1. M6 bolts
2. M8 bolt
3. panel screw
Reinstall:
- water pump pulley
- drive belt (loosely)
- lower radiator hose
- fan shroud
- preheating hose clamp
- fan.
Tighten drive belts
It should be possible to depress belt 5-10 mm (3/16 - 3/8 in.) with thumb when correctly tightened.
Reconnect battery
Fill with Volvo Type C coolant mixed 50/50 with clean water.
Tighten drain tap.
Fill expansion tank to max.
Warm-up engine (make sure that heater control is set to max heat). Check for leaks. Top-up coolant as required.
Reconnect vacuum hose to water valve.
Refit original expansion tank cap.