oil pump replacement

DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

3.2007 221 53 1(13)

Trucks

Oil PumpReplacement

D16F

Oil Pump, Replacement

W2005772

Contents• “Special Tools” page 2• “Oil Pump, Replacement” page 3

Note: Information is subject to change without notice.Illustrations are used for reference only and can differ slightly from the actual vehiclebeing serviced. However, key components addressed in this information arerepresented as accurately as possible.

PV776-20179587 USA25441.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 3.2007 221 53 2(13)

ToolsSpecial ToolsFor special tools ordering instructions, refer to ToolsInformation, group 08.

9996201Tie Rod Separating Tool



Service Procedures2211-03-02-01

Oil Pump, Replacement

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Special tools: 9996201

Removal1Apply the parking brake and place the shift leverin neutral.

2

W2003815

Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

3

W2003873

Using a hydraulic jack, lift the front axle until the frontwheels are off the ground. Position jackstands of asuitable size and capacity under the front axle to supportthe vehicle.

4Depending on chassis installation, remove the cotter pinand locknut from the left-side tie rod.

Note: This step is only required on chassis equippedwith a rear sump oil pan.



5

W2004875

Depending on chassis installation, remove the tie rodfrom the left-side steering knuckle using a tie rodseparating tool. Disconnecting the tie rod allows moreclearance for oil pan removal.

Note: This step is only required on chassis equippedwith a rear sump oil pan.

9996201

6Place an approved container under the oil pan. Drainthe oil by removing the drain plug.

Note: Use only hand tools when removing and installingthe drain plug. Do not use an air ratchet or similar air tool.

7

W2004874

Remove the transmission cooler line bracket nuts andseparate the brackets from the oil pan fasteners. Positionthe cooler lines out of the way.

Note: Mark the transmission oil cooler bracket studlocations to aid in reassembly.

8Pull the dipstick partially out of the dipstick tube. Removethe dipstick tube fastener and tube from the oil pan.Remove and discard the O-ring.

9

W2004884

Remove the oil fill tube fasteners and tube from the oilpan. Remove and discard the tube O-ring.



10

W2004876

Disconnect the oil level/temperature sensor connector.

11

W2005226

Remove the two bolts marked A. Loosen the two boltsmarked B but do not remove. Remove all other bolts.

12With assistance, remove the two remaining bolts (B) andcarefully lower and remove the oil pan.

13

W2004958

Remove the oil supply tube from the oil pump to theengine block. Loosen the tube nut at the engine block.



14

W2004952

Remove the bolts securing the oil strainer and remove thestrainer and suction pipe.

15

W2004955

Remove the bolts securing the oil pump and remove thepump and oil supply tube as an assembly.

16Separate the oil supply tube from the oil pump housing.



17

W2004956

Remove the O-rings from the oil supply and pickup tubesand replace with new O-rings. Lubricate with engine oil.

18Separate the oil suction tube from the oil strainer.

InstallationNote: Clean the oil pump mounting surface on thecylinder block before installing the new oil pump. Cleanand inspect the oil strainer and suction pipe for cracks.Replace if necessary.

1Insert the oil supply tube with new O-ring into the oilpump housing.

2

W2004955

Assemble the pump and oil supply tube to the cylinderblock. Align the pump with the dowel pins. Looselyinstall the pump bolts.



3

W2004958

Loosely install the oil supply tube nut by at least afew threads.

Note: Make sure the supply tube nut is not crossthreaded.

4Tighten the oil pump mounting bolts to 35 ± 3 Nm (26± 2 ft-lb) plus 90 degrees rotation.

35 ± 3 Nm (26 ± 2 ft-lb)Plus 90 degrees

5Tighten the oil supply tube nut at the cylinder blockuntil it bottoms out at approximately 10 Nm (7.4 ft-lb).Tighten the supply tube nut to a final torque of 201 ±20 Nm (148 ± 15 ft-lb).

201 ± 20 Nm(148 ± 15 ft-lb)

6

W2004957

Place the oil strainer on the suction pipe with newO-ring. Lubricate the O-ring.



7

W2004952

Install the oil strainer and suction pipe to the oil pumphousing. Tighten the bolts to 27 ± 3 Nm (20 ± 2 ft-lb).

27 ± 3 Nm(20 ± 2 ft-lb)

8

W2004878

Inspect the rubber oil pan gasket for damage and replaceif necessary. Clean the oil pan and the engine blockflanges.

9

W2005222

Apply a two mm (0.079 inch) bead of Volvo sealant to theseams between the flywheel housing and the timing gearmounting plate and between the timing gear mountingplate and the engine block.



10

W2005223

Apply a two mm (0.079 inch) bead of Volvo sealant to theseam between the front seal cover and the engine block.

11

T2017887

Position the spring assembly on the oil pan bolts so thatthe washer faces the oil pan end of the assembly.

12

W2005226

With assistance, position the oil pan to the bottom of theengine block and install the two bolts marked B. Install allother bolts except those marked A.

Note: Press the pan toward its rearmost position beforetightening the bolts.

Note: Use caution not to damage the oil pickup.



13

T2020557

Tighten the oil pan bolts to 24 ± 4 Nm (18 ± 3 ft-lb) inthe sequence shown.

Note: Before tightening the oil pan bolts, make sure theoil pan gasket is seated properly in the groove.

24 ± 4 Nm(18 ± 3 ft-lb)

14Install the drain plug. Tighten the oil drain plug to 60± 10 Nm (44 ± 7 ft-lb).

Note: The drain plug must not be installed with a copperwasher. Always use the steel washer.

Note: Do not use an air impact ratchet or similar air toolto remove or install the oil drain plug.

60 ± 10 Nm(44 ± 7 ft-lb)

15

W2005190

If removed, connect the tie rod into the left-side steeringknuckle and tighten the locknut to 200 ± 30 Nm (148 ± 22ft-lb). Insert the cotter pin and bend it to lock it in place.

200 ± 30 Nm(148 ± 22 ft-lb)

16

W2004876

Plug in the oil level/temperature sensor connector.



17

W2004884

Install a new fill tube O-ring and position the fill tube ontothe side of the oil pan. Install the oil fill tube fastenersand tighten to secure.

18

W2005086

Install a new O-ring on the dipstick tube, then installthe dipstick tube and secure with the fastener. Installthe dipstick.

19

W2004874

Position the transmission oil cooler line brackets onto theoil pan fastener stud locations. Install the cooler linebracket nuts and tighten to secure.

20Install all previously removed cables to the ground(negative) battery terminals.

21Using a hydraulic jack, raise the front axle and removethe jackstands from under the front axle. Lower the frontaxle and remove the hydraulic jack.

22Fill the engine with approved oil to the full level onthe dipstick.



23Start the engine, check the oil pressure, run the engineuntil operating temperature is reached and check for oilleaks.