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Adding a Coolant Level Sensor!!

Help, Advice, Owners' Discussion and DIY Tutorials devoted to the second generation C70, S40 and V50 Volvos -- awkwardly model year 2004 ½ onwards -- plus where to go for advice and discussion on Volvo's sporty C30 Coupe powered by Volvo's ubiquitous inline 5-cylinder power plant.
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Krons
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Re: Adding a Coolant Level Sensor!!

Post by Krons »

Richard99 wrote: 17 Jan 2023, 23:26 There is a video by Robert DIY on how to do this
Thanks a bunch! Found the video and Robert links to this kit. For $200 cheap insurance vs a catastrophic coolant loss and losing an engine. Seems a major gap in design that the coolant temp doesn’t warn nearly quick enough.

https://swedishcarparts.com/parts/1820
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
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Krons
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Post by Krons »

Update on this. Installed the sensor yesterday on my 08 C70 T5. With long nose pliers was able to pull the connector and install the jumper harness without full air box removed. Had to free it from the mounting pegs and slide to driver side.

Overall build quality of the piece is ok, not great but not bad by any means. For $200 a lot of time saved over making your own. Hopefully it’ll hold up. Main challenge is not twisting up wires when tightening the cap. It does work well, my coolant was between max and low and on hard acceleration got engine temp hot warning. Topped off coolant to just a tad above max to not get unnecessary warnings.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

nelaco
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Post by nelaco »

Searching in youtube sucks! Here is the link...

2020 S60 T5
2013 C30 R-Design
2005 XC90 2.5T AWD

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Krons
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Post by Krons »

Krons wrote: 12 Feb 2023, 06:37 Update on this. Installed the sensor yesterday on my 08 C70 T5. With long nose pliers was able to pull the connector and install the jumper harness without full air box removed. Had to free it from the mounting pegs and slide to driver side.

Overall build quality of the piece is ok, not great but not bad by any means. For $200 a lot of time saved over making your own. Hopefully it’ll hold up. Main challenge is not twisting up wires when tightening the cap. It does work well, my coolant was between max and low and on hard acceleration got engine temp hot warning. Topped off coolant to just a tad above max to not get unnecessary warnings.
False positive warnings this week and sensor eventually failed. Will see if Swedish Auto Parts will provide a replacement. Glad I saved the old cap.

UPDATE: Swedish Auto Parts wouldn’t return calls so their $200 sensor went in the trash, great concept but would not recommend.
Last edited by Krons on 10 Oct 2023, 14:49, edited 1 time in total.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

S40T5AWDM66
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Year and Model: 2010 S40
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Post by S40T5AWDM66 »

Krons wrote: 11 Jul 2023, 21:23
Krons wrote: 12 Feb 2023, 06:37 Update on this. Installed the sensor yesterday on my 08 C70 T5. With long nose pliers was able to pull the connector and install the jumper harness without full air box removed. Had to free it from the mounting pegs and slide to driver side.

Overall build quality of the piece is ok, not great but not bad by any means. For $200 a lot of time saved over making your own. Hopefully it’ll hold up. Main challenge is not twisting up wires when tightening the cap. It does work well, my coolant was between max and low and on hard acceleration got engine temp hot warning. Topped off coolant to just a tad above max to not get unnecessary warnings.
False positive warnings this week and sensor eventually failed. Will see if Swedish Auto Parts will provide a replacement. Glad I saved the old cap.
How did it go with the replacement?

I'm thinking about buying one to install when I replace the radiator hoses and thermostat housing.

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Krons
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Post by Krons »

Swedish Auto Parts wouldn’t answer my calls. So $200 and 1500 miles later and it went in the trash. Would NOT recommend.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

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Post by crazycat »

Ouch!
Sorry to hear that. Swedish Auto Parts really should have better customer service. It is a great idea tho.

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Krons
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Post by Krons »

crazycat wrote: 29 Oct 2023, 20:44 Ouch!
Sorry to hear that. Swedish Auto Parts really should have better customer service. It is a great idea tho.
It is a great idea. Just sold my C70 so “fixed” the problem lol.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

precisionguesswork
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Post by precisionguesswork »

MadeInJapan wrote: 06 Aug 2016, 12:23 I'm sorry- no write-up yet, but I'm going to be working on this- it's a new project of mine.
Why???

Well, because our cars don't have a sensor in the expansion tank (reservoir) to tell you when your coolant is low. This is a huge Volvo over-sight, or is it? Is it just another way to make more money from us??? This should be the first defense against loosing your coolant and overheating and rendering your Volvo as pretty much toast!! Ask the many members on the different forums whose lower radiator hoses broke and immediately shot their engine temps through the ceiling, toasting their aluminum engines. I had a close call yesterday. it wasn't a hose but after getting to work, I looked out my window and saw coolant all over the ground under my car. My expansion tank had cracked and spewed my coolant out. Fortunately for me, that was the extent of my loss! I got some fluid from the local auto parts store and although I looked for a replacement reservoir, I could not find any from our local parts stores so went to the dealer for full retail price. Still, better than a blown engine.

So, I wonder, why is there a windshield washer fluid level sensor but not one for the coolant?
I'm working on a, I hope easy solution, to add a level sensor to our expansion tanks, tie into the wires from the window washer tank so that you will get a warning on your dash if either of these tanks are low. When the message comes up on your dash, at least this way, you know to get out and check your coolant level.

I'll keep you posted in regards to this. In the meantime, if anyone here has any ideas on this, please let me know. As things are progressing, I'm thinking that this is going to require a placement of a float in the reservoir, hopefully from the top with a locking washer on top so the tank will still hold pressure.

-MIJ
I know this is an old thread, but, there is a fix for this issue. Swedish car parts offers a really nice expansion tank with molded in place low level sensor that plugs in in line with the thermostat wiring and triggers the temp light on the dash for low coolant. I've installed this unit on my c30 with their aluminum thermostat housing.

The new unit does not use the cap sensor.
Swedish Car Parts New Expansion Tank
Swedish Car Parts New Expansion Tank
acbb171f-61e2-4ce0-8a3c-53500051219e.jpeg (73.81 KiB) Viewed 790 times
Non-contact sensor location
Non-contact sensor location
78cf166b-3a1b-4633-91d4-92bc2088ff74.jpeg (78.63 KiB) Viewed 790 times
Low level Sensor
Low level Sensor
Aluminum T-Stat Housing
Aluminum T-Stat Housing
3698d33f-fb76-4236-b2ef-874930e2433c.jpeg (100.66 KiB) Viewed 790 times
Aluminum T-Stat Housing Inside
Aluminum T-Stat Housing Inside
975318ac-8809-43f1-bd65-bd37ec599ca7.jpeg (125.6 KiB) Viewed 790 times
Aluminum T-Stat Housing w/ do88 Silicone Coolant Hose Upgrade
Aluminum T-Stat Housing w/ do88 Silicone Coolant Hose Upgrade
All parts are of high quality manufacture. Tank assembled and welded in Italy and tank is
not made in China. Nor is the T-stat housing. The casting is quality as well as the machining on the T-Stat housing.
The sensor snaps into the molding in the bottom of the tank. Very easy install.

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Krons
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Post by Krons »

Way better solution for the money, huge improvement.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

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