2003 s80 nonturbo Removing water pump

moose1 · Post by **moose1** » 14 Nov 2015, 14:31

Although a normally competent amateur mechanic for 50+ years, I am finally stumped while changing the timing belt & water pump. Water pump is unbolted & loose, but I can't get maneouver it out past the rear plastic timing belt cover, steel body pontoon, etc. Tensioners for serpentine & timing belts are out, along with the timing belt idler. Crank pulley for serpentine is off, leaving just the four-tab base that is splined onto the crankshaft The casting that has the timing mark on it. What else can be taken off to ease out the old water pump?.

Wichitas80 · Post by **Wichitas80** » 14 Nov 2015, 16:12

Thermostat housing

oldironsights · Post by **oldironsights** » 14 Nov 2015, 16:55

I had to rotate the water pump to remove it from below. I did not touch the thermostat housing.
When removing the water pump from below, there is not enough room between unibody & engine to remove or install water pump (WP) in the correct orientation.
One must flip the water pump to where the drive pulley is facing the engine, not the shock tower in order to maneuver the WP down & out of the car. There is just enough room in my 2.9 to accomplish this task.
Install is just the reverse.
Gotta use your imagination! Remember that from your younger days?
I wish you success!

oldironsights · Post by **oldironsights** » 14 Nov 2015, 16:55

It is quite tight in there.
If the job did not draw blood, you put in too little effort!

Cees Klumper · Post by **Cees Klumper** » 14 Nov 2015, 23:58

What I concluded from my tribulations with my T6 thermostat replacement is that the engineers somehow forget that all these components are a lot easier to install before the new engine is dropped into the engine bay. You can imagine how easy all this would be if the engine were sitting on a bench. I wonder what comments Volvo mechanics make every time training gets underway for these routine maintenance jobs on every new car generation.

moose1 · Post by **moose1** » 16 Nov 2015, 10:22

Thx, gents for the wisdom and encouragement. I will review my four letter word vocabulary and will then dive into/under the beast this afternoon.

moose1 · Post by **moose1** » 16 Nov 2015, 17:59

Success in a matter of a minute via the 180 degree rotation. A no obscenity operation. Thanks again gents & to Old Ironsight for his iron insight. I should go into the shed and joyfully confirm the working space under the hood of my 1959 544.

oldironsights · Post by **oldironsights** » 17 Nov 2015, 19:33

Outstanding! Moose1.
Glad you got er done.

oldironsights · Post by **oldironsights** » 17 Nov 2015, 19:34