98 V70 T5 Replacing the Coolant Hoses in Pics

[songzunhuang]

OK, I may has well post the pictures of the hoses I created.

First, I took a dremel and cut a slot in the crimp from the original hose. I'm going to use the brass ends on the new hoses. After cutting a slot, I used a screwdriver to pry it apart. One of the hosed was fused onto the brass. I had to scrape it off.

After cutting off both hoses and cleaning up the ends, I approximated the silicon tube length I would need and cut the shorter one first.

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Here's a close up of the ends and the new clamps I got. The clamps are blue so I thought it would be a nice complement to the hose. I cleaned up the ends with some 400 grit sandpaper.

WARNING - note that I am using the old yellow clips off my car. I order new clips from IPDUSA, but they were not the same! I tried to put them in several times at different angles and couldn't get them to fit. Finally in a fit or frustration, I put the old ones back on. It was then that I noticed that the replacements they sent me were taller than the original clips! What a pain.

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After mounting the end on the hose, here's what we have before I snake it through. Attaching the end without the brass fitting to the metal coolant line was a major PITA.

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Here's what it looks like after both hoses are attached. If I recall, the factory hoses point at the 6 o'clock position whereas these new hoses point at 3 o'clock. This was due to the routing to prevent kinks.

The route I used for the inlet hose (longer one) was longer than factory to prevent any kinks. The factory hose goes under the air inlet as it's got a tight molded bend. As you can see, I went around the air inlet. There was plenty of space.

So these were the hoses I replaced today. It was interesting to note their condition in each case.
Here's a few thoughts form top to bottom.
* Turbo coolant hose - definitely was ready to go. I pulled on the hose trying to separate it from the metal coolant line and the hose just split and broke off! Although not leaking, it was not long for this world.

* Heater outlet hose - replaced with blue silicon. Attaching to metal coolant line was major PITA. The original was a bit swollen, but didn't seem to have obvious areas that were emminent for failure.

* Heater inlet hose - replaced with blue silicon. This was the hose that failed and started all this mess. This hose was bulging and the end going into the engine block had a hole that was spurting coolant when under pressure.

* Lower radiator hose - the lower portion was a pain to reconnect. It's tight in there. The original hose was probably serviceable. There was no obvious areas of stress or failure on the hose. I replaced it anyway since it's been a while.

* Upper radiator hose - Super easy to change. The original seemed in great shape. I probably didn't need to replace this one.

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[cn90]

Good Job!

This is exactly what I mentioned above. When you think of it, it costs Volvo (or whoever the maker is) about $10 to make the hose, and they charge us $80-$100, what a rip off.
All it is: metal elbow, hose, crimp, not rocket science.
By going this way (generic heater hose or the blue silicone), you save a truck load of money.

I replaced my ATF cooler lines using generic trans cooler hoses and I paid $10 instead of $200 ($100/cooler hose!).

Now it is time to get rid of the that yellow plastic clip, just cut the pipes near the heater core, run another short hose and you are done. No more O-ring, plastic clips, firewall coupler.

[songzunhuang]

Yeah, I thought about that when my darn yellow clips didn't fit. IPD is definitely getting those back. They charged my $32 for the clips and O-rings.

I replaced my heater core a few months ago and that would have been a good time to get rid of the coupler, but I didn't know about it then. If my O-rings at the firewall ever leak, they will be disposed of. I do have a bit of the silicon hose left...

Thanks for the tip.

[cn90]

Search forum, there was an instance (cmblackburn if I remember correctly), the yellow clip broke, all coolant gone in minutes.

This is why I say this is the time to get rid of all the knicks knacks. Go to the cabin, get the pipe cutter (same stuff plumbers use) cut the pipes (search for erikv11 photos) about 4-5" from the heater core. Run generic heater hoses + clamps.

The car will be good another 1,000 years. By that time, we will be all gone from this earth.

[j-dawg]

Now it is time to get rid of the that yellow plastic clip, just cut the pipes near the heater core, run another short hose and you are done.

Time for me to chime in!

I hacksawed off the aluminum tubes to the firewall coupling and cleaned up the edge with a Dremel tool. 5/8" heater hose slipped over the pipe and was clamped in place.

I got these beauties in the mail a few days ago from McMaster-Carr (item 91355K55, 5/8" barbed hose elbows).

In the engine bay:

The system uses a total of eight hose clamps: two at the engine, four at the firewall junction, and two more at the heater core. Except for the two at the block, all are fairly easily accessible.

This is probably overkill, but I had already ordered the elbows by the time I was told the factory elbows were safely reusable, and they felt nice in my hands, which is obviously the best way to make decisions about what parts go in your cooling system.

Everything works nicely. It's nice to have heat again.

[cn90]

@j-dawg,

Your setup is what I have been saying all along, it takes a little bit of work and about $10-$20. You will never do this again.

Just beautiful. In fact, many cars come from the factory the way you modified it. Only Volvo engineers did this goofy design.

[mecheng]

Nice work, that's what I had in mind for the heater hose.
Looks like you missed one of the turbo coolant hoses; the short one on passenger side. Not to worry it's the easy one but it is failure prone. The dealer hose is specially reinforced

[Ben850]

@j-dawg,

Your setup is what I have been saying all along, it takes a little bit of work and about $10-$20. You will never do this again.

Just beautiful. In fact, many cars come from the factory the way you modified it. Only Volvo engineers did this goofy design.

Needs to be Blue. Ha.

[songzunhuang]

Just a word of warning for forum dwellers.

I ordered the factory clip kit from IPDUSA (P#112518 for $32). It turns out that they did not fit my car! I guess my frustration was magnified by the hours getting the hoses off only to find that I couldn't put them back on because of the kit being the wrong size.



Luckily for me, the original clips were still in good shape and I just re-used them.
So it appears that the junction may have been redesigned at some point in time. I was still using the unit that came with my car (bought new in 1998) so I didn't change anything.

If that junction ever leaks (it was bone dry before all this), I'll just do what any others have done and delete that junction all together, using stock hoses and the original metal fittings at the firewall.

UPDATE: I have been informed that my clip didn't fit because I have to replace all the parts (o-rings, plastic spacer, etc) along with the clip. I tried to test fit the new clip before I removed all the old stuff. So, my observation may be incorrect. I returned my clip kit so I can't verify this.

[Ben850]

They are not actually wrong.
You have to use the combination of spacers and O-rings that come in the kit.

It is the newer combination which is an upgrade from the original.
Trust me on this one. look at my earlier thread.

Edit:

Here.

Closer look.

It was a fun day, don't get me wrong.

Edit 2: New hoses in photos courtesy of "abscate".

Thank you Steve. Not forgotten.