D5 (D5244T to 2005) Engine Swap Coolant leak

[Dave18050]

Hi,

Still new to this, so not sure if I have posted this correctly or in the right place, but I need some help.

To cut a long story short, the Auxiliary Belt failed on my 2004 V70 D5, due to Power Steering Pump issue, which caused CAM Belt to slip and thus the Engine to be severely damaged. I live in the South of France and the repair costs were astronomic, so just bought a LHD XC90.

However, my old V70 has been faithful and decided, as a project, to have a go at swapping the engine myself! Did loads of research, on this forum and other sites, not to mention the trusty Haynes Manual.

Now, after a few weeks work everything is back together and was refilling the coolant when a noticed a big leak from the back of the engine. I have narrowed it down to the alloy pipe that runs across the back of the engine into the back of the water pump and I believe this connection is where the leak is coming from. Thinking back now I do remember when I swapped the pipe to the new engine that it did not feel very secure. I believe the O ring is not doing its job, probably because I was not sure exactly where it went. In front of the pipe? around the pipe?

Either way it will need to be sorted out. I cannot find any advice/help on this site or on any other, nor can I find a site to buy a new O Ring. Any help is welcomed. My questions are:

1. Where exactly does the O Ring Fit?
2. Where can I buy one?
3. Do I need to remove the pipe, which will mean at least the Turbo and Manifold being removed (again!) or does it need to be done from inside the Water pump, which will mean the CAM Belt being removed, a smaller job but not somthing I want to do untill I know the second hand engine I baught is not a dud?

Sorry for the war and peace storey.

[jim jordan]

just done this on my d5,manifold off/turbo,turbo oil feed pipe then you can get at it one small 10mm holding that water pipe half way along back of engine and two 10mm bolts holding top of pipe to head,various pipes to undo then pull pipe out of rear of water pump,o-ring goes onto pipe in the grove easy to see when off,got mine from volvo the o-ring plus the little gasket that goes on connector to head from pipe,have fun i did'nt lol

[Dave18050]

Jim, thank you for your time. I thought I would need to go in from the back of the engine thus turbo and manifold off. I clearly did not look close enough at the pipe when I swapped it from the original engine, as I can’t remember seeing a groove. I also can’t remember a gasket on the small pipe to the engine block. Oh well better started.

On the plus side I started my V70 for the first time for over a year and it’s a runner. Very pleased with myself for changing the engine. Just need to get the leak sorted now.

Thanks again for your help. I will let you know how I get on.

[Dave18050]

I have spent a few hours, following the advice given by Jim, first removing the Turbo and Manifold which gave me access to the coolant pipe at the back of the engine. I did not have any real issues.

1. Drained Coolant.
2. Removed Turbo. I left the Turbo sitting resting to the rear of the engine resting on the RH Drive Shaft, which saved me having to remove the drive shaft.
3. Removed EGR pipe from Manifold. EGR pipe was a bit of a pain to get off the manifold as I did not want to damage the clamp. Got there in the end.
4. Removed Manifold. The manifold came off easy enough but found that I had to remove the first stud closest the water pump to allow me to slide the coolant pipe away from the rear of the water pump.
4. Removed Coolant Pipe. Needed a good pull and a bit of wiggling but it came out eventually.

Guess What? As I suspected there was no O Ring on it, which is clearly the reason for it leaking!!!

Ordered the new Gasket and O-ring from Germany, I could not find a site in UK. I live in France, which just don't do Volvo parts online.

One question. When I fit the new O-Ring should I add a bit of grease or gasket sealant to help the pipe slide into place? I don't want to damage the O-ring and clearly want a good seal.

[jim jordan]

Originally Posted by Dave18050

I have spent a few hours, following the advice given by Jim, first removing the Turbo and Manifold which gave me access to the coolant pipe at the back of the engine. I did not have any real issues.

1. Drained Coolant.
2. Removed Turbo. I left the Turbo sitting resting to the rear of the engine resting on the RH Drive Shaft, which saved me having to remove the drive shaft.
3. Removed EGR pipe from Manifold. EGR pipe was a bit of a pain to get off the manifold as I did not want to damage the clamp. Got there in the end.
4. Removed Manifold. The manifold came off easy enough but found that I had to remove the first stud closest the water pump to allow me to slide the coolant pipe away from the rear of the water pump.
4. Removed Coolant Pipe. Needed a good pull and a bit of wiggling but it came out eventually.

Guess What? As I suspected there was no O Ring on it, which is clearly the reason for it leaking!!!

Ordered the new Gasket and O-ring from Germany, I could not find a site in UK. I live in France, which just don't do Volvo parts online.

One question. When I fit the new O-Ring should I add a bit of grease or gasket sealant to help the pipe slide into place? I don't want to damage the O-ring and clearly want a good seal.

i just put a bit of grease just a smear and trust me it slides it easy alot easy'er then it came out makes you think did that go in lol,bit of a fiddly job tho aint it

[Dave18050]

Thanks again for your helpand yes it is a bit fiddly!!! However, I have spent since the beginning of Jan swapping the engine, just a few hours at a time, so I know my way around the under side of the car very well. My New O-ring and Gasket have now arrived so I am going to have a play this weekend. Fingers crossed.

[Dave18050]

Well, I fitted the new O ring, replaced the pipe and put the coolant system back together by reconnecting all hoses etc...

Thankfully I left the Turbo and Manifold off because when I filled the cooling system with water to test for leaks, yep, same leak, same place. Grrr

Spent another hour removing the pipe again and found that the New O Ring had split. Not sure how this happened, was I to aggressive with the pipe? was it a dud O ring? not sure.

Fortunately I bought 2 from SKANDIX, because of the high postage costs, I thought I might as well as the postage was more than the product.

Anyway, 2 hours wasted, back to square one, try again over the weekend.

[jim jordan]

did you smear abit of grease around the o-ring and no harm in dabbing abit around in the hole pipe slots into,strange it split mine went in easy but i bought a genuine one from volvo was cheap enough think it was £1-75 fingers crossed it goes ok next time

[Dave18050]

Originally Posted by jim jordan

i just put a bit of grease just a smear and trust me it slides it easy alot easy'er then it came out makes you think did that go in lol,bit of a fiddly job tho aint it

I found out that I was pushing the pipe in too far which is clearly how i broke 2 o-rings. I had another attempt yesterday afternoon and lone behold no more leaks!!! just got to put everything back together now.

[Dave18050]

Originally Posted by jim jordan

did you smear abit of grease around the o-ring and no harm in dabbing abit around in the hole pipe slots into,strange it split mine went in easy but i bought a genuine one from volvo was cheap enough think it was £1-75 fingers crossed it goes ok next time

Getting Volvo parts in France is not easy, not all of the dealers do not have a parts department. cracked it now though, no more leaks.