Power Steering Pump Upgrade
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    1. #1
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      Power Steering Pump Upgrade

      I know - strange title right. First off, I canít take an credit for this (Potentially) brilliant idea. @antherzoll mentioned it to me and before he had a chance to try it I jumped on it.

      So here the deal: many of our XC70s suffer from steering thatís on the heavy side. A very small number of us (maybe only Antherzoll) have slammed an XC90 front suspension into our XC70. This results in steering system having to work harder. If you tow, steering is also tougher.

      Well it turns out that the XC90 pump is the same pump except for the pulley. The XC90 pulley is smaller. Iím addition the aux belt is same for both models. This results in more pressure being generated in the system as the smaller pulley spins at a higher rpm (roughly 9% faster).

      So with this info in hand I decided to give this Antherzoll idea a shot. Went to yard and got a first pump. Installed. But I got strange knocking noises from it. See clip.

      Then I refused to give up and went to second yard and got a second pump. Worked silently for a few min and then knocking...again.

      So got myself a cheap mechanics stethoscope and poked it around and the noise does seem to be loudest on the pump.

      I also tried taking the xc90 pulley only off the doner pump with an autozone ps tool. Got one gear off but could not get other off. I would not recommend trying this unless you have proper volvo tool whatever it is.

      Oh but hereís the good part. Even though itís noisy the steering is just beautiful. I can properly steer with index and thumb with moderate pressure and turning is so much smoother. Note that I had previously installed a ps cooler from an XC90 so temps rising should not be an issue).

      Next step is to put old pump back on on the off chance that this issue was already present and unrelated to pump replacement.

      Did I just get VERY unlucky and source two bad xc90 pumps?
      Do bad pumps even make a ticking noise? Never heard of such a thing?
      Is it possible rack is restricting flow back to pump or something resulting in ticking?
      Are there other possibilities?

      There is no bubbling, fluid level remains good, and no whining from pump.

      https://youtu.be/HSiVDNjma_g


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      Last edited by bigtimemcalpine; 03-21-2020 at 07:37 AM.
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

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    3. #2
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      Sounds like it's hitting on something? Is the pump clearence the same? Could the inside inside of the pulley? Or shaft play perhaps?

      Sent from my Pixel 3 XL using Tapatalk

    4. #3
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      If the XC90 pulley is spinning 9% faster, does that mean fluid is moving thru system faster?
      Is the pump possibly being starved for fluid?
      Are the reservoirs and total volume of the 90 and 70 systems the same? Maybe it doesn't matter.

      Just thinking off the top of my head. I don't have a lot of expertise with this stuff...

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    6. #4
      Member LloydDobler's Avatar
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      Did you switch to a shorter belt? The tensioner might be slapping around if it's too loose. I'm not sure your statement that the belts are the same is correct, as there are a few different ones, and I've seen people accidentally get the wrong one and not be able to get it on.

      I could be wrong but worth a double check.
      Last edited by LloydDobler; 03-21-2020 at 08:08 AM.
      2003 C70 T5M Convertible - Eibachs, Koni FSDs, Enkei RSF5s, OBX downpipe, Snabb intake, RIP kit, & drop-in intercooler, Quaife LSD, 19T, Green Giants, 22 psi Hilton tune.
      2006 V70 2.5T - Ice White - Oak Arena, (almost) bone stock daily driver.
      1966 122s - Collectible project, restoration and many mods on the way.
      2005 V50 T5 AWD - Daughter's first car. No mods unless she does 'em herself.

    7. #5
      Senior Member ScottishBrick's Avatar
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      1999's have a smaller pulley too and a shorter belt. Could source one of those as well.
      2003 V70 T5 - Mystic/Graphite - M56LK - 205k - K24/Greens/Do88/Quaife/SMF/P2R Clutch/DW300C/H&R/Bilstein TC/316mm & 308mm Brakes - SteveO Tuned
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 298k - Daily/Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 177k - Rescued
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 243k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 218k - Sisters

    8. #6
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      Quote Originally Posted by Osmossis View Post
      Sounds like it's hitting on something? Is the pump clearence the same? Could the inside inside of the pulley? Or shaft play perhaps?

      Sent from my Pixel 3 XL using Tapatalk
      Yeah, thatís my sense too. I wondered if tensioner might be knocking on something. Thing is tension is good and strong and position of belt and tensioner is identical to that of the xc90 I took the equipment off of. It almost sounds like I have a 12mm bolt lost somewhere down there and itís rattling against the tensioner!


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    9. #7
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      Quote Originally Posted by bigtimemcalpine View Post
      It almost sounds like I have a 12mm bolt lost somewhere down there and itís rattling against the tensioner!
      Cavitation?

    10. #8
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      Quote Originally Posted by vtl View Post
      Cavitation?
      I wondered that but all literature online says auto ps pump cavitation creates the whine that we are all familiar with not knocking like water pipes.


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    11. #9
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      Quote Originally Posted by bigtimemcalpine View Post
      Yeah, thatís my sense too. I wondered if tensioner might be knocking on something. Thing is tension is good and strong and position of belt and tensioner is identical to that of the xc90 I took the equipment off of. It almost sounds like I have a 12mm bolt lost somewhere down there and itís rattling against the tensioner!


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      Pressure relief valve inside pump?

    12. #10
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      Quote Originally Posted by bigtimemcalpine View Post
      I wondered that but all literature online says auto ps pump cavitation creates the whine that we are all familiar with not knocking like water pipes.
      Yeah, I watched the video finally - the pump is not cavitating.

      I think it's the pressure valve is sticking/binding. In Eastern Europe people fight heavy steering with a replacement valve that I can't find on ebay. Part number is MSG FO044VALVE. See pics here: https://www.drive2.ru/l/501007317676852595/

    13. #11
      Member Antherzoll's Avatar
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      I thought it may be the relief valve, but I wonder why it's opening. Considering it's the same pump only spinning 9% faster, wouldn't it just be outputting the same pressure as the XC70 a lower RPM?

      Maybe the valve needs to be swapped from the XC70 pump to the XC90?
      2005 XC70 Crystal Green | Hilton | 16T | Bad Swede | 145k mi

    14. #12
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      Quote Originally Posted by Antherzoll View Post
      I thought it may be the relief valve, but I wonder why it's opening. Considering it's the same pump only spinning 9% faster, wouldn't it just be outputting the same pressure as the XC70 a lower RPM?

      Maybe the valve needs to be swapped from the XC70 pump to the XC90?
      Spinning faster means the flow has increased. maybe???, the increased flow is causing back pressure in the system thereby increasing the pressure at the valve.???

    15. #13
      Member Antherzoll's Avatar
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      Yes, but the stock pump will spin faster on a revving engine and not cause this noise. I wonder if the XC90 rack control valve has less resistance and that the relief valve is specified for this?
      2005 XC70 Crystal Green | Hilton | 16T | Bad Swede | 145k mi

    16. #14
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      Quote Originally Posted by Antherzoll View Post
      Yes, but the stock pump will spin faster on a revving engine and not cause this noise. I wonder if the XC90 rack control valve has less resistance and that the relief valve is specified for this?
      If the pumps on the XC70 & XC90 are the same except for the pulley diameter then the XC90 rack is designed for higher flow throughout the range.
      If the XC70 rack is designed for a lower flow (throughout the range) what does the pump do when the XC70 rack says "your giving me more than I can Handle"? Don't know (I'm not a PS expert). Does the internal relief valve chatter?

    17. #15
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      Power Steering Pump Upgrade

      The plot thickens. Had a bit more light out today and got braver with the stethoscope. I think the tensioner may be close to its limit is tapping on something next to it. Sound goes away when AC compressor comes on which suggests that just a sliver more tension is all that is needed. Also doesnít happen when car is cold and belt is ever so slightly tighter.

      So I think what I need is an ever so slightly larger tensioner pulley!


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      Last edited by bigtimemcalpine; 03-21-2020 at 01:36 PM.
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    18. #16
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      Good!, that was fun

    19. #17
      Member Antherzoll's Avatar
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      Belt and tensioner kit are the same for all 2.5T engines. Wonder what makes the difference? Maybe tensioner spring has worn into it's original position and is happy there?
      2005 XC70 Crystal Green | Hilton | 16T | Bad Swede | 145k mi

    20. #18
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      Quote Originally Posted by Antherzoll View Post
      Belt and tensioner kit are the same for all 2.5T engines. Wonder what makes the difference? Maybe tensioner spring has worn into it's original position and is happy there?
      I wonder if the harmonic balancer is maybe a touch bigger...itís certainly different looking!


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    21. #19
      Member Antherzoll's Avatar
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      Nope, it's the same, but if it were it would drive the belt even faster... too bad.
      2005 XC70 Crystal Green | Hilton | 16T | Bad Swede | 145k mi

    22. #20
      Member Antherzoll's Avatar
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      Wonder of it's the aftermarket tensioner? That, or are the mounts for the accessory bracket different?
      2005 XC70 Crystal Green | Hilton | 16T | Bad Swede | 145k mi

    23. #21
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      Quote Originally Posted by GRUENDIG View Post
      Spinning faster means the flow has increased. maybe???, the increased flow is causing back pressure in the system thereby increasing the pressure at the valve.???
      I would think a pressure relief valve with a higher setting would create easier steering, and sure if the pulley is 9% smaller a higher pressure might be reached at a marginally slower rpm. But Volvo power steering systems appear to steer easily at idle.

      From A ZF brochure -

      "Relief Pressure Settings 1500, 1750, 2000, 2175 and 2320 psi
      100, 120, 140, 150 and 160 bar"

      I don't own a 01-07 anymore so I can't look on mine but I seem to remember a pressure value printed on a tag on the pump when i have sourced used ones previously.


      OR, Why not just swap the pressure relief valve into your existing pump?

    24. #22
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      Quote Originally Posted by bigtimemcalpine View Post
      The plot thickens. Had a bit more light out today and got braver with the stethoscope. I think the tensioner may be close to its limit is tapping on something next to it. Sound goes away when AC compressor comes on which suggests that just a sliver more tension is all that is needed. Also doesnít happen when car is cold and belt is ever so slightly tighter.

      So I think what I need is an ever so slightly larger tensioner pulley!


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      I think that`s it. Getting the pulley you need will test your patience.

    25. #23
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      Quote Originally Posted by Thommykent View Post
      I think that`s it. Getting the pulley you need will test your patience.
      Change the pressure relief valve throttle body! I did this when I used to sell Maserati parts which used a ZF power steering pump. The model pump which i had was also used in a BMW and the pumps were identical in every respect with the exception of the pressure relief valve throttle body which had a different diameter opening changing the pressure! If you know who makes the pump you can check to see the exploded drawing of it and see the different part numbers available for the throttle body (Valve) and get the one with the highset pressure (smallest valve opening). You could check wit the tech support department of the company making the pump for assistance.

    26. #24
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      Do you know if you have the 6DK-1841 or the shorter 6DK-1825 belt in there now? There are two different belts depending on years and models.
      Maybe if it is the longer, you could try with the shorter as a test.

    27. #25
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      Quote Originally Posted by SWEDECAR View Post
      Do you know if you have the 6DK-1841 or the shorter 6DK-1825 belt in there now? There are two different belts depending on years and models.
      Maybe if it is the longer, you could try with the shorter as a test.
      Hmmm, do you know which one is shorter? Having now done a search with a different model year XC70 I do see that FCP Euro has two belts listed, 6DK1841 and 6DK060725. I've reached out to them to see if they could help in figuring out which one is shorter.

      Buuuuut, having read some of this info about the pressure release valve, I'm now curious whether these are in fact transferable. Having looked at the pump, I don't see anything removable on there. Does it mean taking one apart altogether?
      Last edited by bigtimemcalpine; 04-01-2020 at 03:32 PM.
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    28. #26
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      Quote Originally Posted by ghibliss View Post
      Change the pressure relief valve throttle body! I did this when I used to sell Maserati parts which used a ZF power steering pump. The model pump which i had was also used in a BMW and the pumps were identical in every respect with the exception of the pressure relief valve throttle body which had a different diameter opening changing the pressure! If you know who makes the pump you can check to see the exploded drawing of it and see the different part numbers available for the throttle body (Valve) and get the one with the highset pressure (smallest valve opening). You could check wit the tech support department of the company making the pump for assistance.
      How do you do that? Take pump apart?
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    29. #27
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      Quote Originally Posted by bigtimemcalpine View Post
      Hmmm, do you know which one is shorter?
      6DK is the width (maybe 6 splines) and 1841 or 1825 or XXXX is the length. So a 1825 is 16mm shorter than a 1841.

    30. #28
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      Quote Originally Posted by hoonk View Post
      6DK is the width (maybe 6 splines) and 1841 or 1825 or XXXX is the length. So a 1825 is 16mm shorter than a 1841.
      Oh man I really hope I have the 1841 already on there! Pretty sure that 16mm is exactly what I need! Thanks for the info.


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    31. #29
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      @swedecar and @honk - winner winner chicken dinner! Guys you ROCK!


      https://youtu.be/gftc2hWOKb0


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    32. #30
      Junior Member db130's Avatar
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      Do you feel an improvement with the XC90 PS pump? I've only driven an P2 XC70 on a shop loaner car basis, so I don't have much to compare with, but I didn't think it was all that bad.

      I've also driven an NA V70 with a failed PS pump and I didn't think it was all that bad either.

      Then again, I've also owned a couple of cars that didn't have factory power steering, so maybe I'm not the best judge of things.
      2002 V70 T5a 190k RTI/Hilton Stage 1/336mm brakes/Bilstein B8s/H&R springs
      2002 V70 NA 274k HU-803/T5 suspension/305mm brakes
      2003 V70 T5m 250k Hilton Stage 2/Delrin subframe bushings/R front sway bar/R manifold/Jetex catback/Re-Volv DP/Simota CCI
      2013 S60 T6 R-Design 68k IPD RSB

    33. #31
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      Power Steering Pump Upgrade

      Quote Originally Posted by db130 View Post
      Do you feel an improvement with the XC90 PS pump? I've only driven an P2 XC70 on a shop loaner car basis, so I don't have much to compare with, but I didn't think it was all that bad.

      I've also driven an NA V70 with a failed PS pump and I didn't think it was all that bad either.

      Then again, I've also owned a couple of cars that didn't have factory power steering, so maybe I'm not the best judge of things.
      Yes, definitely an improvement. Iíd say 10% easier to turn and manage on straights. Funny thing is, the pump still struggles just as much at full turn as it did before. I suppose that has more to do with the lower RPM than anything else.


      2002 V70XC, 2003 V40, 2004 S60, 2010 V70
      Last edited by bigtimemcalpine; 04-02-2020 at 05:08 PM.
      2010 V70 3.2 125,000miles
      2002 V70XC, 175,000 miles
      2004 S60 2.5T, 160,000 miles

    34. #32
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      The pump on my 2003 V70 D5 was 110 bar, the XC90 one was 120 bar.
      I fitted the shorter belt, as the XC90 had a smaller pulley.
      The later V70 cars had the smaller pulley the same as the XC90 one.

      Also Volvo changed the pressure hose fitted on the later cars.
      Saffron V70R 1998 Auto FWD,
      Silver 2006 V70 D5 manual FWD, fixing slowly.
      Silver S60 D5 manual , need a petrol one. Good parts for the V70 D5.

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