'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.
Dirtbag454
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

'00 S-80 heater hose removal

Postby Dirtbag454 » Mon Apr 23, 2012 3:10 am

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

537playing
Posts: 204
Joined: Sat Jun 16, 2007 12:43 am
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Re: '00 S-80 heater hose removal

Postby 537playing » Tue Apr 24, 2012 1:58 am

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.

Dirtbag454
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » Mon Apr 30, 2012 7:07 am

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
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » Thu May 10, 2012 6:26 am

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

User avatar
dcarlson12
Posts: 487
Joined: Wed Jul 02, 2008 8:34 pm
Year and Model: 1999 S80 T6
Location: Surrey, BC, Canada

Re: '00 S-80 heater hose removal

Postby dcarlson12 » Thu May 10, 2012 6:30 pm

Would photos of the old hoses/their construction/installation help others if you were to post some?

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yuckuJackD
Posts: 128
Joined: Thu Jan 13, 2011 1:49 pm
Year and Model: XC70; S80; S40
Location: Ruse, Bulgaria
Flag: Bulgaria

Re: '00 S-80 heater hose removal

Postby yuckuJackD » Sun May 13, 2012 8:30 pm

Did you saw this topic?
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Dirtbag454
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » Mon May 14, 2012 1:03 am

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
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » Mon May 14, 2012 1:34 am

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.
Attachments
IMG_0780.JPG
View of lugs after rotating the collar. the lugs are a part of the collar, so when it moves, they move as well.
IMG_0783.JPG
Retaining collar rotated about 1/4" CCW. This is enough to withdraw the retaining lugs and remove the hose.
IMG_0781.JPG
retaining lugs visible, collar is in "closed" position
IMG_0782.JPG
Collar in "closed" position. Molding line on arrow is in line with the one on the elbow.
'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
Posts: 58
Joined: Sat Apr 07, 2012 8:41 am
Year and Model: S-80 2000, C70 2004
Location: United States

Re: '00 S-80 heater hose removal

Postby Dirtbag454 » Sun May 27, 2012 5:02 am

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

hender40
Posts: 12
Joined: Thu Mar 11, 2010 2:39 am
Year and Model: S80 T6, 1999
Location: fresno CA

Re: '00 S-80 heater hose removal

Postby hender40 » Mon Sep 17, 2012 7:32 pm

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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