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'00 S-80 heater hose removal

Help, Advice, Owners' Discussion and DIY Tutorials on the Volvo S80 model. Sometimes called an "executive car", the S80 was and continues to be Volvo's top-of-the-line passenger car.

'00 S-80 heater hose removal

Postby Dirtbag454 » 23 Apr 2012, 03:10

My S-80 has a perforated heater hose. I need to replace same, and cannot figure the secret handshake for this project. I have seen a Vadis pdf that shows the hoses and indicates a twisting motion on the housing, which either unlocks it, or locks it. I have tried to twist it right or left, but it doesn't want to budge. Is there a trick to releasing the collar? These things are usually simpler that they appear, once you know the secret.
I also need to replace the O-rings that seal the inlet and outlet tubes on the heater core. The fix is pretty straight-forward but the glitch is how to effectively remove the horseshoe clip that secures the tube. I assume that these things are reusable, so I have to be careful. Will a pair of straight circlip pliers sneak it out of its plastic housing? Stuff the jaws in the little loop and squeeze to spread them?
Any advice/experience will be greatly appreciated
'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
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Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby 537playing » 24 Apr 2012, 01:58

I did this job about a month ago and I consider this to be that hardest job I've done on this car. Timing Belt, struts, axles, control arms I'll do anyday than these two washers in the heater coil.
To release the hoses just turn the housing. It will come loose.
I would recommend new horseshoe clips as mine did get distorted when trying to pry off. Perhaps I didn't have the right tool such as the one you mentioned.
Because of the location makes the job very difficult. Replacing the clips was very difficult as you can't see and press in the clips at the same time.
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Re: '00 S-80 heater hose removal

Postby Dirtbag454 » 30 Apr 2012, 07:07

I have since received one of my new heater hoses. The design of the fitting is considerably different than the original hose,so I'll be destroying the perforated one just to remove it and see how it differs from the replacement. I expected that the horseshoe clip replacement would be a booger. just trying to remove them is daunting. I can only imagine what it is going to be like replacing those, as visibility and access are mutually exclusive. I am considering removing the heater core just for the purpose of fitting up the clips while I have it on a bench. Perhaps I can/should modify a pair of pliers for the task. thank God for Harbor Freight and cheap tools!
'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
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Posts: 51
Joined: 07 Apr 2012, 08:41
Location: United States
Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » 10 May 2012, 06:26

Today's update: I removed the heater hoses, and made a tool to pop the clips off the aluminum tubes. Worked great, except it won't work in reverse. Damn!
There's another post that I made today. requesting insight on removal of those heater hose tubes (hard aluminum). Putting the tube, O-rings and clips back in place will be a challenge. I figure, "What the hell, Volvo mechanics do it all day long...why should I be any more challenged?"
Oh, and for the record, I NEVER got the hoses off by following the rules. I finally got pissed and said "WTF, I'm not gonna reuse those hoses...", so I cut the outer ring on the hoses and popped them off. I now see how they fit. I'd still be dicking around with them. Good riddance. I hope the reassembly goes smoother.
'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
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Posts: 51
Joined: 07 Apr 2012, 08:41
Location: United States
Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby dcarlson12 » 10 May 2012, 18:30

Would photos of the old hoses/their construction/installation help others if you were to post some?
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Re: '00 S-80 heater hose removal

Postby yuckuJackD » 13 May 2012, 20:30

Did you saw this topic?
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Re: '00 S-80 heater hose removal

Postby Dirtbag454 » 14 May 2012, 01:03

yuckuJackD wrote:Did you saw this topic?


Yes, I have seen the VADIS pdf. it is very helpful, but does not go into great detail. Removing the brake light switch was the challenge that I gave up on. I didn't pull the core, I'll live with the possibility of gunk trapped inside. The VADIS pdf does show the CCW rotation of the collar on the heater hoses, but doesn't do into detail. I took some photos of a hose end so that those who are interested can see just exactly what the retainer lugs look like, and how they withdraw when rotated CCW. I'll put those in the following reply to this thread.
Thanks for pointing me in the direction of the pdf. Also, I broke that same part as you did. Now I'm trying to determine the best repair method. How did you get that bellcrank out of the heater box? does it just pull straight out? Don't know if I want to risk damaging the other lever connection. Can't see where the end of that one goes either.
'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
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Posts: 51
Joined: 07 Apr 2012, 08:41
Location: United States
Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » 14 May 2012, 01:34

Here are some photos of an OEM heater hose end, showing the retainer lugs and how far you have to rotate the collar to remove the booger. It ain't as far as you think!
The comments on the photos should tell the story, but just in case, here it is again.
I did not realize that the rotation of the collar was so slight. Maybe counter-clockwise (CCW)1/4" or more, that's all. Press in on the fitting to relieve the pressure on the retaining lugs, and twist CCW. Pull off.
The replacement hoses have a redesigned retainer lug that should be a lot easier to remove, if the need ever arises again. I did see some of the original design advertised on Volvo parts sites, but they might be using an old photo. In any event, if you're replacing the hose, just cut the collar with diagonal cutters, or tin snips. I used a knife with a non-locking blade. Almost got a new nickname. Almost went from "Dirtbag: to "Three-Fingered Dave". Use snips...
And one more thing. The sequence that I uploaded these photos changed during posting. Fortunately, I discovered the change, and made the appropriate corrections to the comments.
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'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
Forum Member
Forum Member
 
Posts: 51
Joined: 07 Apr 2012, 08:41
Location: United States
Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » 27 May 2012, 05:02

The new heater hoses are finally in place, coolant replaced, and no apparent leaks. It is amazing how unpleasant that job got to be. Access could probably be better, and I don't know why I didn't just cut the hose coupling in the first place. I was going to replace both hoses anyway. Duh. Replaces both heater core O-rings. That was an interesting process, as I was spending a lot of time contorting myself into the drivers footwell. I did manage to break some unrelated parts which necessitated some unconventional repairs, but that's another thread.
Regarding, the heater hose couplings: if you're doing an r&r, you should pay close attention to the images above, because you are going to need to be able to reinstall the same hose(s). If you're replacing them, cut the bastards. Don't spend any more time than absolutely necessary removing them. Oh, and that yellow coupling that the parts illustration shows (Eeuroparts, at least), that's just a protective cover over the coupling. Doh!
'04 C70 Ragtop (103K)
'00 S80 T-6 (donated @ 140K)
'95 850 (traded @ 120k)
'83 240DL (crashed @ 303k)
And then there's the '70 240Z and the '58 Chevy Apache, not to mention the motorcycles...
2013 BMW K1600GTL
Dirtbag454
Forum Member
Forum Member
 
Posts: 51
Joined: 07 Apr 2012, 08:41
Location: United States
Model and Year: S-80 2000, C70 2004

Re: '00 S-80 heater hose removal

Postby hender40 » 17 Sep 2012, 19:32

I'm about to replace heater hoses on '99 S80-T6. New hoses show a 90 deg plastic?? fitting at the firewall connection. It is attached to the hose with a hose clamp. What would be wrong with just removing the fitting and connect the new hose to the old fitting and leave the old fitting in place ?? Could it be that the fitting itself is the source of the leak. My leak appears to be at the hose to fitting joint. Advice and other experiences requested. The fitting and it's removal seems to be the main source of irritation for this changeout so why change it ???
Don H-Fresno
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Re: '99 S-80 heater hose removal

Postby hender40 » 27 Sep 2013, 16:33

Now have new Volvo OEM replacement heater hoses. Connector is very different from original. Do you just push it straight on as it appears to be spring loaded ie, only squeeze tabs for removal ??, turn or twist required ?? or squeeze tabs, push on and release tabs which will seal joint ?? This joint doesn't appear to be designed for a good ,pressure tight seal ?? Please help as I'm ready to replace

Don H
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Re: '00 S-80 heater hose removal

Postby shea44 » 17 Jan 2014, 22:00

No one has responded as to the new hose ends being so different and how they fit on there? I posted some pics of the old and new heater hose ends. Mostly to see if I had the right part? What is the trick please
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Re: '00 S-80 heater hose removal

Postby MyS40T4 » 17 Jan 2014, 23:46

Hello,

I thought I'd ordered the wrong bits when I first got them... They do fit, but need to be firmly pushed onto the pipe in the bulkhead. Look at the end of the hose and squeeze/twist the release, you should see the bits that latch onto the bulkhead pipe move. (I'll have to look at the spare new hose I have tonight to provide more detailed info). To make sure they're secure, gently pull on the hose to make sure it doesn't come off.

Cheers,

Chris
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Re: '00 S-80 heater hose removal

Postby shea44 » 18 Jan 2014, 03:48

thank you Chris for the reassurance that the new pipes will fit!!! They just look totally different. I posted the pics on a new topic I posted. Again, thank you
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