2002 S80 Broken connector on Coolant Line To Thermostat in T

Wichitas80 · Post by **Wichitas80** » 02 Nov 2015, 10:42

Can I trim this plastic piece on the back of the back timing cover without creating a new problem?

Volvo.pdf: (1.83 MiB) Downloaded 282 times

Kick_it provides an EXCELLENT Tutorial to repair the small plastic coupling inside the timing belt housing here:
https://www.matthewsvolvosite.com/forums ... 10&t=61343

He includes the following “Note.”

Note: there is a plastic piece on the back timing cover that will need to be modified. The easiest and best looking would be to use a dremmel or something similar. I did not have one on hand and opted for some pliers and just "snapped" the plastic. This is required or the housing will not sit flush.

The same issue is discussed here and there’s a good photo (better than mine) of the plastic piece that needs to be trimmed: https://www.matthewsvolvosite.com/forums ... 11&t=37644

So my options are to trim the plastic piece or buy a new thermostat housing. My concern is that the plastic piece is there for a reason.

Cees Klumper · Post by **Cees Klumper** » 02 Nov 2015, 14:26

i went through all this and my advice is to get a new thermostat housing ($110 or so including new thermostat and I think also the coolant temp sensor) and install that, rather than trying to fix the old one with the poorly designed Uro metal nipple. It's just not worth the hassle and risk, this is an essential system on your engine and you don't want to take chances. Plus the amount of work involved in getting in and out of this very tight spot means you want to do it once and do it right. Good luck and keep us posted.

Wichitas80 · Post by **Wichitas80** » 04 Nov 2015, 19:58

Good advice. It's really a tight space and I can't seem to get it put together right after two tries. This reminds me of the reasons I quit working on cars years ago. I'm taking it to a professional tomorrow.

Centex Swede · Post by **Centex Swede** » 10 Jan 2016, 17:54

These are some very helpful comments and links about the pesky and weak T on the thermostat housing. I want to add my experience in case it might help someone out. Here's the link I created:
https://onedrive.live.com/embed?cid=EF5 ... OhP7Q&em=2"