So what's the secret to replacing the water pump on a 1985 2.3L non-turbo? My car was obviously neglected by a P.O., when replacing the leaking radiator, I found the inlet of the water pump corroded so badly there was a notch the size of a quarter missing. I replaced it with NAPA because I like the lifetime warranty and access nationwide. The grommet in the top isn't sealing. The pump fits on two studs in elongated holes, allowing it to be pushed up so the aforementioned grommet will seal. I've had this apart twice, and have to replace the gasket each time because I used sealant on it. And don't even get me started on that steel heater line... Just wanna get this old girl back on the road!

 

I wouldn't use a NAPA pump! Most likely this is your problem. Plenty of other sources and not much more cost.

 

+1 - start with Volvo/euro friendly web stores for a replacement part. Three that I have used: IPD USA, FCP Euro and AZ Autohaus... All will offer a genuine Volvo part for $150 or so or an OEM aftermarket for $50-75. Also general guidance is to not use sealant on a water pump gasket or rubber o-rings - just make sure the surfaces are clean. So it may be best to do some research on this to see what's proper for your install.

 

I just replace the seal and gasket on my '93 940 and it was fairly easy. Here's a good youtube video
I didn't go as far as he did with sealant on the gasket but I did start the bolts and nuts on the lower holes and the heater pipe. Then I put a bottle jack under the pump and slowly raised it till the upper holes lined up and bolted them up and once they were all started I took the jack away and slowly tightened everything while watch the o ring squash to make sure it stayed under the opening and didnt squash at some weird angle.

 

Maybe my head seal washer rolled or something. I lubed it and the seal for the heater pipe with dish soap, but I didn't use a jack to press the pump against the head, either. Gotta get a new pump gasket for the next attempt.

 

I've always used a tiny bit of clear silicone (rubber) on the top and bottom of the upper seal and the heater tube seal. Used both as a lubricant and hopefully a sealant for the top seal later. Not a spread, or squeeze/squirt, or anything really visible, just rub the seals with your fingers after putting a dab of silicone on your finger tips. (I'm sure I've installed many hundreds of the those pumps from 1980 - 2018) -

To push the pump up, I use a small #1 Phillips head screwdriver placed in a lower bolt hole and pull up to place the pump in the correct position, then tighten the 2 nuts (that you previously installed 1 turn from being tight). Then install the remaining bolts.