Coolant leak around heater hoses in firewall

GotaGetMeloYall · Post by **GotaGetMeloYall** » 09 Dec 2012, 20:57

2002 C70 Convertible , 2.3 Liter, auto

I had my radiator recently replaced and not too long after my top heater hose sprang a leak, so I replaced it and the bottom one too with Volvo OE hoses. I also bought the Volvo OE replacement o-rings, spacers and quick connects. After getting the hoses on, I started my car and it appears that around the top hose where it connects to the firewall is leaking. I don't think my bottom hose is leaking, but since the top hose is right on top of it and leaking on it it's very hard to tell. I went as far as ordering a whole new o-ring kit and still the same thing. What is going on here? What could be causing it to leak? Any help will be appreciated.

Post by **rspi** » 09 Dec 2012, 21:19

It's likely that the coupler is leaking. The 850's and other FWD older Volvo's have a coupler that goes through the fireway. So, see if that part is sold. It will likely be a assembly.

GotaGetMeloYall · Post by **GotaGetMeloYall** » 09 Dec 2012, 21:29

rspi wrote:It's likely that the coupler is leaking. The 850's and other FWD older Volvo's have a coupler that goes through the fireway. So, see if that part is sold. It will likely be a assembly.

I take it that it's this part you're talking about?

http://www.ipdusa.com/uploads/images_pr ... e_1417.jpg

Can I take it off at the firewall or do I have to take it off under the dash too? Is there any o-rings or anything else that I need to get with that?

Thanks for the quick response

Post by **rspi** » 09 Dec 2012, 21:50

Bingo!!! That part has everything you'll need. I would drain the block, take loose the hoses under the hood, loosen the heater core box so it moves a little when you take the lines loose under the dash, take the plate off the coupler under the hood and it will come out under the dash.

: Volvo 850 Heater core lines coupler bracket; PICT5963.JPG (120.59 KiB) Viewed 4951 times

You are welcome and glad you found the site.

Post by **erikv11** » 10 Dec 2012, 07:17

Where the hose is leaking, it is more probably just bad o-ring(s). I would first try new o-rings for the cabin side only from the Volvo dealer. Unless you have a visual that the coupler is cracked or something. And then, personally I would not replace a broken coupler, I would bypass it with heater hoses. IMHO the coupler is an over-engineered PITA.

Post by **cn90** » 10 Dec 2012, 08:19

You may want to bypass this whole thing altogether.
Search forum for DIY that connects heater hose directly to the metal pipes in the cockpit, through the firewall ---> engine.
You basically get rid of this troublesome plastic coupling.

GotaGetMeloYall · Post by **GotaGetMeloYall** » 10 Dec 2012, 12:22

erikv11 wrote:Where the hose is leaking, it is more probably just bad o-ring(s). I would first try new o-rings for the cabin side only from the Volvo dealer. Unless you have a visual that the coupler is cracked or something. And then, personally I would not replace a broken coupler, I would bypass it with heater hoses. IMHO the coupler is an over-engineered PITA.

The coupler doesn't appear cracked just seeping where the hose connects, I was wondering if there was o-rings on the cabin side. I can't bypass them I already bought the factory hoses, I would have if I knew it was going to be like this.

When I change out the rings on the inside can I get to them like this?
http://volvospeed.com/vs_forum/index.ph ... e-install/

Also what are these o-rings called and where can I get them? I ordered the ones on the firewall side from parts geek.

Thanks alot guys this is my first time posting,but I have lurked here for several years. I have saved a ton of money by coming here. Thanks for the site.

Post by **erikv11** » 10 Dec 2012, 12:37

Hey a couple things:

- Your car is a 2002, I didn't realize that. Likely all of the general tips are the same, but I have never worked on one of those.

- Is the leak on the cabin side or on the engine side? I thought it was the cabin but now I re-read your original post and I can't tell.

If the leak is on the engine side of the coupler, I would guess you just didn't get all of the spacers and o-rings in correctly, and the sealing on the cabin side is fine. I'll try to hunt down a diagram for the 850, yours is probably similar. Would be as simple as unplugging the hoses, fixing the rings, then plugging back in.

Post by **erikv11** » 10 Dec 2012, 12:39

Here ya go, give this a look:

http://volvospeed.com/vs_forum/topic/35 ... ring-kits/

I am wondering if you have the proper number/arrangement of o-rings/sealers in there on the engine side.

GotaGetMeloYall · Post by **GotaGetMeloYall** » 10 Dec 2012, 19:36

erikv11 wrote:Here ya go, give this a look:

http://volvospeed.com/vs_forum/topic/35 ... ring-kits/

I am wondering if you have the proper number/arrangement of o-rings/sealers in there on the engine side.

Yes it is leaking on the engine side, I will post a pic as soon as I possible. I ordered that same o-ring kit. The original o-rings were 2 black rings, 1 thin yellow spacer, and 1 thick yellow spacer. The kit I ordered had 2 black rings, 1 yellow spacer, but the connector had a longer end tha. the original. I figured the factory started making the connectors longer on one end to make up for the thick yellow spacer, maybe to save money from making the yellow spacer?

erikv11 wrote:Hey a couple things:

- Your car is a 2002, I didn't realize that. Likely all of the general tips are the same, but I have never worked on one of those.

- Is the leak on the cabin side or on the engine side? I thought it was the cabin but now I re-read your original post and I can't tell.

If the leak is on the engine side of the coupler, I would guess you just didn't get all of the spacers and o-rings in correctly, and the sealing on the cabin side is fine. I'll try to hunt down a diagram for the 850, yours is probably similar. Would be as simple as unplugging the hoses, fixing the rings, then plugging back in.

I thought the same thing that I didn't put them in right,but I ordered another kit thinking I messed up an o-ring and got the same result. I will try again tomorrow even if I get the time.