2002 s80 non turbo water pump removal

s80lovenhate · Post by **s80lovenhate** » 11 Jan 2009, 16:28

OK, I am feeling stupid.

I am in the middle of timing belt and water pump change. water pump is loose BUT I cannot get it out of engine compartment (no clearance). So, do i need to pull the rear timing belt shield (held with one bolt by timing belt tensioner and then two bolts on side of engine up high. One of them I cannot get a wrench or socket to.

It seems that if the engine would just magically move 1/8 inch or so away from right fender, I would be able to get the pump out.

On a seperate question, which cylinder is number one?? The timing marks are all lined up but the piston that I thought would be number one is not at top dead center.

Thanks for any insight and it seems that this shuld not be so hard.

Post by **MadeInJapan** » 11 Jan 2009, 17:28

Welcome to MVS...I have the VADIS instructions but all it says after you unbolt it is to take it out...this has me stumped to. Could it be that if you turn it a certain way it will magically fall out? #1 piston is the one closest to the side of the engine where the timing belt is. Did you line up the timing mark at the bottom (crank shaft)?

Well after a bit more searching, it appears that how you dealt with your timing belt and particularly brackets and so forth is impacting you now on your water pump removal. Right before it says to unscrew the water pump and take it out, it says to follow the timing belt removal procedure, so here it is from VADIS:

S80 Non Turbo 02 Timing Belt.pdf: (213.25 KiB) Downloaded 409 times

s80lovenhate · Post by **s80lovenhate** » 11 Jan 2009, 19:49

OK.............. I don't get it, I had those instructions open and I am not sure what I did (or what you are refering to).

yet more, I feared what you said on the timing marks and number one location. All the marks are lined up but number one is not at TDC. I hve the old belt carefully marked with whitout that corresponds to the pulleys so tat I can recreate the way it was, but the way it was does not make sense.

thoughts???

Post by **MadeInJapan** » 11 Jan 2009, 20:20

Can you take a picture and post it up?
And you didn't move the cam gears after removing the belt?

s80lovenhate · Post by **s80lovenhate** » 11 Jan 2009, 20:29

will take picture of timing marks and get it up, may take a bit. Have not moved anything (call me chicken)

Post by **MadeInJapan** » 11 Jan 2009, 20:36

While you were posting I was busy making sure that Cylinder 1 is the one closest to the timing belt side and I'm right...all Volvo's are that way...start with 1 at front of engine and count up to 5 (in my case) or 6 in yours closest to the driver's side or rear of the engine.
I know on some Volvo engines the timing gears (both exhaust and intake) can be installed completely 180 off- has someone done some work on your S80 before and done this? In other words, you might be at BDC (bottom dead center) even though the timing marks are straight up and down, but if both timing gears are this way, you still can't go wrong.

EDIT: I posted the instructions for the TB because it mentions the cover (more like a guide to me) for the service belt (I call that the serpentine belt) on the inside of the crankshaft that needs to come out. Did you take it out? could be what's not allowing you room to take the water pump out if it's still in. Also, it mentions some other things from above that need to be taken loose- wondering if in your car's case, the water pump comes out of the top rather than the bottom.

The other issue- in reading about Cylinder 1 and TDC (top dead center), VADIS instructions say to turn (before taking the TB off) the crankshaft clockwise until the marks line up at the top, THEN go another quarter turn...THEN turn back (counter clockwise) until the marks line up and then take the belt off...is this what you did, or did you just get them lined up and take the belt off? I'm thinking that this last step of turning back counter clockwise might be the step you really needed to see TDC. Gee- this car is so much different than the 5 cylinders I'm used to dealing with. Anyway... see if this helps. I hate to tell you, but you might have to put the belt back on to do this. Good luck and let us know how things go.

s80lovenhate · Post by **s80lovenhate** » 11 Jan 2009, 21:31

photos below show the problem

s80lovenhate · Post by **s80lovenhate** » 11 Jan 2009, 21:40

Got the interior cover off no problem .

Their is an instruction to slide off an Oil cover or something, never figured that out, but do have a second cover that is toward the rear of the engine off.

I did do the magic with the 1/4 turn past tdc and then back. I am lost in terms of the timing. if I have it on the right marks, then number one should be at tdc. If I am on the wrong marks, I should not have found the timing marks on the cam in the right place.