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Heater Hose Replacement: Anyone done this? How?

Help and Advice on Volvo's extremely popular car line, powered by Volvo's nearly indestructible, versatile inline 5-cylinder engine.
1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

Heater Hose Replacement: Anyone done this? How?

Postby Skatehouse » 07 Nov 2009, 20:52

Well-I found my heater hose to be leaking. How to you gain access into this tight area? Do I need to remove the air intake into the turbo? Can anyone outline the process please? Thanks!
1994 850 Turbo Wagon 260,000mi.

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Re: Heater Hose Replacement: Anyone done this? How?

Postby MadeInJapan » 08 Nov 2009, 21:38

Remove all of that and then unscrew the clamp at the turbo- I assume you're talking about your accordion hose from the airbox to the turbo?
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Re: Heater Hose Replacement: Anyone done this? How?

Postby Skatehouse » 11 Nov 2009, 18:53

Yes-the intake to the turbo. (probably needs to come out to gain access to the heaterhose connections right?). Are they just "hose-clamped" under there?

Also-I was trying to pull-out the hose where it goes into the firewall and cracked the plastic part. Now I need to replace that thing too! I just replaced my heater core so I know how to get into that area-no fun :cry:
Just cost myself another hour of work!
1994 850 Turbo Wagon 260,000mi.

17" Pegs, Speedtuning 17psi chip, Slater endlinks, Weitech Coilsprings, Magnecore Wires, Magnaflow exhaust
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Re: Heater Hose Replacement: Anyone done this? How?

Postby mapaed850 » 12 Nov 2009, 01:06

I have this same repair in my near future (as soon as the hoses arrive). I already took off the air filter box and battery (probably not necessary). I haven't removed the air intake hose yet. I was able to get both hoses off without incident. I'll be replacing the clips and o-rings because I don't want to do this repair again. Did you break the housing in the fire wall? Mine looked as if it were made from metal rather than plastic. Is this possible?
When installing the new hoses into the firewall should I lube the o-rings or is this not necessary?
Any thoughts on whether to install the firewall side first or the engine side first? I was thinking engine side but would appreciate anybody's experiences too.
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Re: Heater Hose Replacement: Anyone done this? How?

Postby dbo550 » 12 Nov 2009, 01:18

mapaed850 wrote:I have this same repair in my near future (as soon as the hoses arrive). I already took off the air filter box and battery (probably not necessary). I haven't removed the air intake hose yet. I was able to get both hoses off without incident. I'll be replacing the clips and o-rings because I don't want to do this repair again. Did you break the housing in the fire wall? Mine looked as if it were made from metal rather than plastic. Is this possible?
When installing the new hoses into the firewall should I lube the o-rings or is this not necessary?
Any thoughts on whether to install the firewall side first or the engine side first? I was thinking engine side but would appreciate anybody's experiences too.


If you are replacing the hoses hook them up on the engine side first then push them into the fire wall. That metal part you are seeing is just a plate that covers the plastic part. This is a pretty easy repair, and if you order the hose coupling kit you won't have to order anymore o rings or anything because everything is included inside the kit.
On a side note the hardest part of the coupling replacement on my 98 v70 was figuring out how to get the gas pedal off, it went as smooth as butter after that.
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Re: Heater Hose Replacement: Anyone done this? How? DONE!!!

Postby Skatehouse » 14 Nov 2009, 01:03

Posting the update to the Heater Hose repair. Ordered parts from FCP Groton. I ordered both heater hoses and the hose junction thingy. It came complete with everything necessary to do the job. The job iteslf wasn't very hard, just a beyotch to get to the hoses on the engine block. had to remove quite a few hoses to gain access. Once I got access, the repair went smoothly. I forgot which hose went where :?: but the connections on the ends of the hoses make this "dummy" proof. One end is longer than the other. I saw that others posted having to reove the gas pedal to change the junction thing. I found that by depressing the pedal all the way down, I was able to manipulate it through the tight space with no problems. I found it easier to make all the connections on the inside 1st, then assemble the gasket and coverplate. It was much more stable to deal with. Before closing everything back up, Start car, warm up and check for leaks under pressure. Looks good?, grab a beer and feel good about saving hundreds of dollars. Over the last year I've changed every inch of coolant line this car has. They all seem to decay all at once. The trickiest I've encountered were for the turbo. Accessed underneath. Bear claw hands need not apply. This heater hose repair was only diffucult because they're not easily accessible and hard to diagnose in the 1st place. If these go bust far from home...you're probably best to tow it home or shop.

I hope this will help anyone else experiencing this problem. Too often we grab what we need from Matthew's AWESOME Volvo site, never to be heard from again. LAME. The learning on this site comes from a nice conclusion to a problem solved.

CHEERS to MATTHEW!!! :D
1994 850 Turbo Wagon 260,000mi.

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Re: Heater Hose Replacement: Anyone done this? How?

Postby mapaed850 » 21 Nov 2009, 18:34

So I got my heater hoses installed and plugged the outlet hose into the coupler and much to my surprise the whole hose came right back out with a large peice of the coupler :( .
It looks like I will now need to replace the coupler. From the above this doesn't sound too difficult but I'm not sure if we have compareable mechanical skills. I'm not terrible but every so often get in over my head. Is there a step by step of this repair anywhere?
Before I order the coupler, is the crux of this repair removing the gas pedal? Otherwise is is it just a matter of removing the pipes from the inside (easy?), removing the backing plate, installing the coupler, and plugging it all back in?
From the above this all sounds promising for me, I'm just worried about any hiccupps along the way?
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Re: Heater Hose Replacement: Anyone done this? How?

Postby Ozark Lee » 21 Nov 2009, 21:39

There is an extra spacer and O ring in the socket when you remove the OEM hoses. If you are replacing stuff with the Yellow quick connect clamp kit remove the old stuff out of the socket first or things won't snap back together correctly.

...Lee
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Re: Heater Hose Replacement: Anyone done this? How?

Postby confused_al » 21 Nov 2009, 22:40

lg_921c1cee-7818-4af4-b8b1-23635395d54f.gif


There are three different Volvo kits you can buy from eEuroparts (similarly priced as FCP):
#8 p/n 3545662, (all the o-rings) in the fig; $30
#7 p/n 3522035, (#8 plus coupler and its o-rings); $36
#6 p/n 9134978, (the whole thing)$63, which I got from DW volvo for $42.

I dont understand why people want save that $6?
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Re: Heater Hose Replacement: Anyone done this? How?

Postby mapaed850 » 21 Nov 2009, 23:24

I did remove the old o-rings and spacers. I think I did the demage when I removed the old hose. I got the gas pedal off and I'm pretty sure I am in good shape going forward. I'm having trouble getting the heater pipes off the coupler though. I popped the clips with a screw driver and I dropped the heater core to give me some room to wiggle. How did you seperate the pipes from the coupler. Do the pipes come off the heater core easily? Can you then easily get them off the coupler?
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Re: Heater Hose Replacement: Anyone done this? How?

Postby Ozark Lee » 21 Nov 2009, 23:43

Can you throw up a couple of pictures or what you are dealing with? I am having trouble figuring out if the problem is with the quick connect clamps at the firewall junction (on the hose side) or the firewall junction itself.

If it is the latter you are basically screwed until you get the new pipe kit. You can - if you need the car - just go buy a chunk of heater hose and bypass the heater core at the block temporarily.

...Lee
'94 850 N/A
'96 850 N/A
'96 Platinum Edition Turbo
'98 S70 T5
'99 V70XC
Previous: 1989 740 GLT
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Re: Heater Hose Replacement: Anyone done this? How?

Postby Skatehouse » 22 Nov 2009, 06:04

You're on "hold" basically until you get the new junction thing. I pM'd you to call me since I JUST finished this whole endeavor...easier to verbally explain than snail post back and forth...oh well, good luck.
1994 850 Turbo Wagon 260,000mi.

17" Pegs, Speedtuning 17psi chip, Slater endlinks, Weitech Coilsprings, Magnecore Wires, Magnaflow exhaust
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Re: Heater Hose Replacement: Anyone done this? How?

Postby jdawg » 13 Dec 2009, 23:58

Skatehouse wrote:You're on "hold" basically until you get the new junction thing. I pM'd you to call me since I JUST finished this whole endeavor...easier to verbally explain than snail post back and forth...oh well, good luck.




can i remove heater hoses on 1995 850 without removing the quick disconnet coupling r do i have to install a new coupler when replacing just the heater hoses. how do u remove hoses from coupler
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Re: Heater Hose Replacement: Anyone done this? How?

Postby Ozark Lee » 14 Dec 2009, 00:42

It is kinda like a Dirty Harry movie - do you feel lucky? In theory you can unplug the heater hoses from the firewall junction via the quick connect couplers and then snap them back in place. If you are buying new hoses they should come with a new connector kit anyway, if they don't come with the hoses order new connector kits and replace them as a part of the job.

...Lee
'94 850 N/A
'96 850 N/A
'96 Platinum Edition Turbo
'98 S70 T5
'99 V70XC
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