How To Change a B28F Water Pump
...or Another Reason to Avoid the PRV V-6

If you don't have several days to spare or are faint of heart, have your favorite garage perform the water pump replacement. Volvo rates this job at 5.75 hours of labour and the water pump costs about $225 (Canadian). Add to this amount if any of the hoses are 4 years old and expect to replace many ancillary hoses, belts, sending units, etc.
If on the other hand you would like to save the high cost of labour ($55 per hour plus 15% tax in Canada) and also a chance to know the job is done properly, read on.
  • 1. Drain the antifreeze and remove all hoses connected to the radiator. Detach the oil lines into the radiator if your have an automatic transmission.

  • 2. Remove the fan and centrifugal clutch now or wait until Step 9.

  • 3. Remove the bottom splash pan, if attached, then loosen the alternator bolts and remove the fan belt(s) from the water pump pulley.

  • 4. Remove the front intake to the intake manifold (5 bolts) to expose the thermostat housing and upper rad hose.

  • 5. Prepare to remove the intake manifold by removing all vacuum hoses, grounds, electrical switches, throttle, kick-down and cruise control cables (if installed) and the air filter.

  • 6. Remove the spark plug wires and pry up on all fuel injector from their seats. You will likely want to replace the spark plugs and at least clean the fuel injectors. Remove the anti-knock sensor from the left side and remove the air bypass regulator from the right side of the engine. Leave the cold start valve on the brass tube, but disconnect the electrical connector and vacuum hoses.

  • 7. Remove the four bolts and/or nuts holding the intake manifold in place, then lift the manifold from the from, placing a tire spanner in the intake valley to support it, as seen below. See a picture of this? (21K) or a larger image? (46K)

  • 8. Remove the side hoses into the cylinder heads, then loosen the clamps on the 2 rear hoses. If the hoses were changed within the last four years, they should be OK. If in doubt, order new hoses from the dealer. You can remove the temperature sensor and the brass plug now or wait until you have the pump in a vise. Remove the 3 bolts holding the water pump to the front of the engine. Remove the old water pump, then take a rest.

  • 9. Place the old pump in a vise, face down and remove the rear casing with 6mm hex key (unless the replacement water pump has the casing already installed). You can order the water pump from your Volvo dealer or buy an aftermarket pump, such as; GRAF 152 9147. Clean the surface of the rear casing and use GE Hi Temp silicone gasket sealer (or sealer of your choice) on both metal surfaces, between the 2 halves of the pump casing. I used 242 Loctite on all bolts and the temperature sensor and the brass plug. Clean any corrosion from the hose pipes and smooth if necessary. Do you want to see an image of the water pump front (19K) and rear? (16K)

  • 10. Install the new water pump in reverse order. Make sure all hose connections are tight. Install the pulley, alternator belt(s), tighten the alternator and attach the fan. It should look like this. (21K)

  • 11. Clean the intake manifold ports and you must replace the O-ring seals (Volvo part no. 947381-0). Replace or install new spark plugs and install the injectors into their ports on the right side only.

  • 12. Carefully lower the intake manifold into place. This is tricky and took me three attempts. Watch that nothing gets caught under the manifold and verify that the bolt threads are clean. Next reassemble the left injectors, anti-knock sensor, ground wires, all other hardware and vacuum hoses. Install the thermostat housing, then reconnect all throttle cables. Install the front intake port and reinstall the radiator. Make all hose connections, fill with new 50% antifreeze solution through the expansion tank then start the engine.

  • 13. If everything appears to be in order, replace the bottom pan and take your Volvo for a trial run. Inspect the connections again and top up the antifreeze and automatic transmission fluid if necessary.

  • 14. This job took the better part of 3 days, since I also installed a transmission cooler and replaced the starter. I also had problems with the intake manifold alignment, a sensor wire under the manifold and a stud that was installed instead of an intake manifold bolt. This made alignment difficult and eventually had to be "tap and died".

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