Thermostat housing replacement

way01 · Post by **way01** » 25 Oct 2009, 22:21

I have a 2001 Volvo S80 T6. I have a coolant leak and found that the hose from coolant tank to top of thermostat housing must have been cracked. As soon as I was taking the plastic shield off to get a better look the plastic connector at top of thermostat housing broke. At this point I can get the car towed to a repair shop or fix it myself. I am not an auto mechanic but I was an aircraft mechanic for years in the Air Force. With the proper instructions I can fix anything mechanical. I have searched for a repair manual but it seems there is not one available for an S80 past the 1990s.
First, is this a job that I can do myself, any special tools required? Second, where can I get some instructions?

I am a newbie here and I hope someone out there can help me out.

Post by **OEMVolvoParts** » 26 Oct 2009, 09:48

There are probably better directions around on this but I copy and pasted this out of VIDA. That part you broke off is a pain in the rear, they ALWAYS break. The part number you need is 8642047 (tstat housing) and 9142697 (gasket).

-Remove
-the clamp holding the return hose for the power steering
-the screw holding the engine stabiliser brace to the bracket on the engine
-the screws holding the engine stabiliser brace to the suspension turrets
-the engine stabiliser brace
-the expansion tank cap.

Raise the car. Remove the lower splashguard.
Position a container under the engine drain cock. Drain the coolant.
Close the cock.
Install the lower splash guard.
Lower the car.

Lift up the servo reservoir and place it on top of the engine.
Warning! Seal the cover for the servo reservoir. Check that no oil leaks out. Servo oil is highly inflammable.
Note! Ensure that the timing belt cover has cleared the nipple on the thermostat housing before the cover is pulled up.

Remove:
the screw for the front timing belt cover. Applies only to B6xx4T Cars with chassis number 203779- see Timing cover front, replacing
the timing belt cover. Use a weatherstrip tool.
-----------------------------------------------------------------------------
Installing the thermostat

Note! Clean all mating surfaces. Ensure that no dirt enters the fluid ducts.
Note! Ensure that the timing belt cover is in position before the cover is pressed in against the rear timing belt cover to prevent damage to the nipple on the thermostat housing.

Install
-the new thermostat
-the cover of the thermostat housing with a new gasket. Tighten to 17 Nm
-the front timing belt cover. The mudguard over the right drive shaft boot may come loose. If this happens, secure it from underneath
-the screw for the front timing belt cover. Tighten to 12 Nm. Applies only to B6xx4T Cars with chassis number 203779- see Timing cover front, replacing:Installing the front timing cover .

-the servo reservoir. Check that the hoses are correctly positioned
-the engine stabiliser brace
-the screws holding the engine stabiliser brace to the suspension turrets. Tighten to 50 Nm
-the screw holding the engine stabiliser brace to the bracket on the engine. Tighten to 80 Nm the clamp holding the return hose for the power steering.

Carry out a function test
Fill with coolant.
Install the cap on the expansion tank.
Test drive the engine until the thermostat has opened.
Top up the coolant if necessary

Post by **dcarlson12** » 26 Oct 2009, 16:44

Some VADIS pages for you to augment the reply already posted

way01 · Post by **way01** » 26 Oct 2009, 21:43

You guys rock!!

That is exactly the info that I needed. It looks like replacing the water pump while I am that close would be a good idea. I have over 150,000 miles so it is overdue. Also maybe the timing belt. Does the tensioner pulley need replacing at the same time or is it just according to its condition?

The water pump instructions were already included on one of the pdf files from dcarlson. Would one of you kindly provide the timing belt replacement instructions, I am thinking that the idler pulley will be included with that also.

By the way I was quoted $1050 for the water pump and timing belt replacement at my local dealer today. Even an independent local shop quoted me 800-1000 but said I should go ahead and figure on the $1000. I think I can save some money by doing it myself. Neither of those estimates includes the thermostat housing. I can get all I need, thermostat and gasket, housing and gasket, water pump and gasket, and the timing belt for 316.11 plus shipping off myvolvopartsonline.

Is there any way for me to get the VADIS or VIDA software? I have seen it mentioned in other posts and it was mentioned that you could get vadis on ebay but I could not find it.

Thanks again for the help. Without instructions I would have been forced to tow it to the shop.

Post by **OEMVolvoParts** » 27 Oct 2009, 09:04

You can get free shipping on your parts if you just mention this page in the notes when you place the order. (Look at the banner on top of this page)

The timing belt is a big deal. The interval for your car is every ten years or 105k, whichever comes first. If you have 150k on your first timing belt, you are in dangerous territory. If it's been changed before then you have until 210k or another ten years. The tensioner and idler pulley are up to you if you want to change. You can inspect them and see how they feel to you, but no way really to predict if they will last another 105k. The water pump is another one that is up to you, if you are already in there, may as well change it for peace of mind.

Changing the timing belt will require some special tools, most importantly being the one to lock the cams in place. If you can get your hands on something that will work, then dive in.

Here are some part numbers you might consider:
30758268-timing belt kit for your year, includes belt, tensioner, idler
274184-timing belt only for your year
9440904-tension pulley
8692561-idler pulley (also need 982795)
8694627-water pump kit

way01 · Post by **way01** » 27 Oct 2009, 21:42

Thanks for the tip on free shipping. I will go ahead and replace all of the mentioned items so I don't have to worry about them later. I know I am on borrowed time for the timing belt.

I went ahead and added the 8694627-water pump kit to my cart but I could not find the 30758268-timing belt kit.
If I buy the kit then I assume I dont need any of the following:
274184-timing belt (obviously)
9440904-tension pulley
8692561-idler pulley (also need 982795) does kit come with both parts?

I just need to make sure I get all the correct parts and then I need to find a way to lock the cams and I am set. Can you send me the instructions for the timing belt replacement? I have looked in the repair database and it appears that it may not be super easy but thats ok. As long as I have general directions then I should be fine.

Thanks again for all your help.

Post by **OEMVolvoParts** » 28 Oct 2009, 11:33

30758268 was just released from Volvo as a brand new part number and kit. Our page is being updated right now with the new numbers. Way to go Volvo the car is almost 10 years old and finally made the kit!

Buying the parts individually will end up costing almost $70 more. The kit is $127.52, a very good price, it includes belt, tensioner and idler. If you want the parts by friday, it will make it, just update your order today with the new kit part number and it leaves today. Any questions please email!

Post by **dcarlson12** » 28 Oct 2009, 16:36

Here are three files re: timing belt replacement including special tools which I am sure others have gotten along without. I remember one guy on this or another forum who made some alignment tools out of wood, so.....

anthonyhicks · Post by **anthonyhicks** » 26 Jan 2012, 02:31

I bought water pump, timing belt and tensioner. But no new idler pulley. Is this a problem?