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.