S80 Heater core replacement
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S80 Heater Core DIY
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jblackburn
- MVS Moderator
- Posts: 14043
- Joined: 8 June 2008
- Year and Model: 1998 S70 T5
- Location: Alexandria, VA
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s80 heater core.pdf- (206.87 KiB) Downloaded 6962 times
'98 S70 T5
2016 Chevy Cruze Premier
A learning experience is one of those things that says, "You know that thing you just did? Don't do that."
mercuic: Long live the tractor motor!
2016 Chevy Cruze Premier
A learning experience is one of those things that says, "You know that thing you just did? Don't do that."
mercuic: Long live the tractor motor!
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yuckuJackD
- Posts: 132
- Joined: 13 January 2011
- Year and Model: XC70; S80; S40
- Location: Ruse, Bulgaria
- Been thanked: 2 times
Аlways use new O-rings!
These are NOT genuine VOLVO. It was Sunday and I had no choice, so I went into a local car parts shop and choose the needed size. The new one I use are circle but the original seems to have been square. Anyway there is no leak so it's fine.
Some more pics:
mind not to break this thing (temperature control mechanism):
Bad bad bad repair. Very uncofortable place, and oh - you'll have to remove at least the brake pedal sensor and the mechanism I mentioned above to be able to pull out the heater core.
Good luck
p.s. Admins I got all the photos needed to make a tutorial for this. May I go ahead?
These are NOT genuine VOLVO. It was Sunday and I had no choice, so I went into a local car parts shop and choose the needed size. The new one I use are circle but the original seems to have been square. Anyway there is no leak so it's fine.
Some more pics:
mind not to break this thing (temperature control mechanism):
Bad bad bad repair. Very uncofortable place, and oh - you'll have to remove at least the brake pedal sensor and the mechanism I mentioned above to be able to pull out the heater core.
Good luck
p.s. Admins I got all the photos needed to make a tutorial for this. May I go ahead?
A member of VolvoClub Bulgaria
Of All The Things I've Lost,
I Miss My Mind The Most.
VOLVO 440 1.7i 89y. B18E
VOLVO 460 1.8 mono 91y. B18U
VOLVO S40 1.8 115hp 16V 97y. B4184S
VOLVO S80 2.9 200hp '00y. B6294S
VOLVO XC70 D5 185hp '06y. D5244T4
Of All The Things I've Lost,
I Miss My Mind The Most.
VOLVO 440 1.7i 89y. B18E
VOLVO 460 1.8 mono 91y. B18U
VOLVO S40 1.8 115hp 16V 97y. B4184S
VOLVO S80 2.9 200hp '00y. B6294S
VOLVO XC70 D5 185hp '06y. D5244T4
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mlanctot
- Posts: 112
- Joined: 2 July 2008
- Year and Model: 1999 S80T6
- Location: Pleasant Valley, Connecticut
OK,,,,got the brake sender out, heater core is removed. Complete sonic weld failure, the end has completely separated from the core.
Are we sure nothing else needs to be removed before putting the new one in?, very tight fit.
Are we sure nothing else needs to be removed before putting the new one in?, very tight fit.
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xjamiesonx
- Posts: 1
- Joined: 12 December 2011
- Year and Model: 2001 V70T 2.4l
- Location: Berkeley, California
After about 9 hours bent up like a circus contortionist, banging up my elbows, cutting up my hands, and badly bending and damaging the brand new unit, I have succeeded in a heater core replacement.Re: S80 Heater core replacement
Does any one have a vadis schematic of this heater control linkage?
I'm having difficulty putting this back together after taking it apart.
I am now left with this sad and broken part -- I can't figure out how to remove the rest of the arm off of the heater assembly to attempt repair. Now what?
(And thanks for the great post!)
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gsnyder
- Posts: 1
- Joined: 4 January 2013
- Year and Model: S80, 2001
- Location: United States
- Been thanked: 2 times
I have a 2001 S80 Non-Turbo (2.9) and wanted to post a comprehensive update to this after changing the heater core for myself and spending close to 1 1/2 hours searching various sites and postings for instructions. It took me about 6 hours all together but I could have done it in 2 hours if I knew some of these tricks.
Tools: Various sockets, wrenches, and Torx drivers. Flat-head screw driver(s). Towels. Small liquid container. Zip tie. Drop light.
Under the hood
1. Before starting, turn your key to the II position and turn heater to full heat and full fan. Turn the key off. This will get the linkage discussed in the forum out of the way.
2. Start by removing the Strut Brace (Long bar connecting struts at the top of the engine). It will make the hoses on the fire wall more accessible. Remove 1 bolt from the middle engine mount and 3 bolts from each side.
3. Put a small can under the 2 hoses to catch the 2-6 ounces of coolant that will come out (I used a small rectangular Tupperware bowl). Squeeze the clamp by hand and twist the bracket counter-clockwise while pulling out. You don't need any special tools for this.
4. Remove the plate behind the hoses (2 small bolts).
Inside the Car - Drivers Side Only
5.Remove the Panel under the steering wheel (2 torx bolts). Also remove the small side panel (1 flat tip plastic screw)
6. Pull the carpet away from the heater core and from under the gas pedal. You don't need too much as long as you have a full size towel and a small container. Fold it over and place the folded towel over it so that it covers the from under the core to under the brake pedal.It you fold it in half twice, it will be the right size as a rectangle.
7. Remove the brake sensor by pushing the clips at the top and the bottom in with a screwdriver or pick and push it up out of the way.
8. Remove the one torx screw holding the heater core in.
9. Remove the 2 aluminum clips slowly and gently using a screwdriver. They can bend easily so make sure you pull them out straight so that you don't bend them.
10. Put the small container under the 2 aluminum pipes and pull the pipes out (I didn't have any kind of tie at the top but you may have to cut it if you do.). You can catch about 8 - 10 ounces in the bucket and the rest on the towel.
12. Use a zip tie and pull the 2 aluminum pipes close to the bracket that the brake sensor was attached so they will be out of the way.
The steering column bracket gets in the way. This job is way easier if you move this out of the way and moving it is not very difficult.
12. Remove the lower plastic panel on the steering column (3 torx bolts). After you pull the bolts, the top snaps off first and then the bottom pulls off.
13. There are 4 hex bolts holding the column in place. You can now reach the 2 closest to the seat from the column area. Then pull the 2 closest to the engine from underneath.
14. There is one 13 mm nut holding the steering column in close to the firewall. Remove that nut. Now gently pull the column toward the seat - about 6 inches.
You will now have plenty of room to pull out the heater core and slide the new one into place. As you pull it out, some of the coolant will spill out on the towel or into your container.
When you reassemble, make sure you get the guide at the top of the column in place as you slide it back into place or you won't be able to get the column back into place. Everything else is opposite of disassemble.
Hope this is helpful!
Tools: Various sockets, wrenches, and Torx drivers. Flat-head screw driver(s). Towels. Small liquid container. Zip tie. Drop light.
Under the hood
1. Before starting, turn your key to the II position and turn heater to full heat and full fan. Turn the key off. This will get the linkage discussed in the forum out of the way.
2. Start by removing the Strut Brace (Long bar connecting struts at the top of the engine). It will make the hoses on the fire wall more accessible. Remove 1 bolt from the middle engine mount and 3 bolts from each side.
3. Put a small can under the 2 hoses to catch the 2-6 ounces of coolant that will come out (I used a small rectangular Tupperware bowl). Squeeze the clamp by hand and twist the bracket counter-clockwise while pulling out. You don't need any special tools for this.
4. Remove the plate behind the hoses (2 small bolts).
Inside the Car - Drivers Side Only
5.Remove the Panel under the steering wheel (2 torx bolts). Also remove the small side panel (1 flat tip plastic screw)
6. Pull the carpet away from the heater core and from under the gas pedal. You don't need too much as long as you have a full size towel and a small container. Fold it over and place the folded towel over it so that it covers the from under the core to under the brake pedal.It you fold it in half twice, it will be the right size as a rectangle.
7. Remove the brake sensor by pushing the clips at the top and the bottom in with a screwdriver or pick and push it up out of the way.
8. Remove the one torx screw holding the heater core in.
9. Remove the 2 aluminum clips slowly and gently using a screwdriver. They can bend easily so make sure you pull them out straight so that you don't bend them.
10. Put the small container under the 2 aluminum pipes and pull the pipes out (I didn't have any kind of tie at the top but you may have to cut it if you do.). You can catch about 8 - 10 ounces in the bucket and the rest on the towel.
12. Use a zip tie and pull the 2 aluminum pipes close to the bracket that the brake sensor was attached so they will be out of the way.
The steering column bracket gets in the way. This job is way easier if you move this out of the way and moving it is not very difficult.
12. Remove the lower plastic panel on the steering column (3 torx bolts). After you pull the bolts, the top snaps off first and then the bottom pulls off.
13. There are 4 hex bolts holding the column in place. You can now reach the 2 closest to the seat from the column area. Then pull the 2 closest to the engine from underneath.
14. There is one 13 mm nut holding the steering column in close to the firewall. Remove that nut. Now gently pull the column toward the seat - about 6 inches.
You will now have plenty of room to pull out the heater core and slide the new one into place. As you pull it out, some of the coolant will spill out on the towel or into your container.
When you reassemble, make sure you get the guide at the top of the column in place as you slide it back into place or you won't be able to get the column back into place. Everything else is opposite of disassemble.
Hope this is helpful!
Great pics guys... So I am fairly new to Volvo repair, but I have successfully replaced my heater core (exactly like the one above). however after doing so it still leaked and after looking and looking several times I finally found a small hole in the back of the "upper or back" tube leading into the heater core... I am now trying to replace these. Does anyone have any advice on getting them out? I have detached them via the quick connect in the engine compartment, and from the heater core and so far have wiggled the "lower or front" one out but the one with a hole in it is hitting the back of the climate control "box/assembly," has anyone ever had to do this particular repair... Thanks for all of the help! BTW, although I am fairly new to working on my Volvo I love this site, I have learned a lot here. Thanks again
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