Coolant return line busted

T_Bone · Post by **T_Bone** » 25 Mar 2011, 17:47

2002 S80 T6. Was replacing motor mounts.

The coolant line that runs out of the timing cover snapped off!!! I barely touched it but it snapped off at the elbow where it runs into the top of the pump...

What should I do?? I don't even know how to get to it.

Any ideas?

Post by **JDS60R** » 25 Mar 2011, 18:03

It is part 19 in the digram and part of the thermostat housing under the cover .

It does not have a part number so contact Volvo or Volvo parts retailer for which part you have to buy. Make sure to clean all mating surfaces and seal the new unit properly.

T_Bone · Post by **T_Bone** » 25 Mar 2011, 18:18

that nipple has an elbow right?
Here's two pictures of what I'm looking at. I was just tightening a piece down and heard a sizzling sound and saw the coolant leaking. Coolant literally flushed completely out from the small hole in the second picture. Oh and that piece is stuck in there of course.. Do I have to take the whole pump/thermostat apart or is this a piece that simply fits in?
That's number 19 in your diagram though?

T_Bone · Post by **T_Bone** » 25 Mar 2011, 18:42

can I just plug this damn thing? I think its part of a bleeder system.. i think its bleeder hose part..

Pops · Post by **Pops** » 25 Mar 2011, 19:40

Can you post pics not zoomed in so tight so I can get a better idea of what I'm looking at in relation to the rest of the car?

tshor13 · Post by **tshor13** » 25 Mar 2011, 20:04

That nipple is part of the thermostat housing. You should also replace the hose between the reservoir and thermostat housing.
A bit tough to do but not too bad. You need to move the PS and Coolant reservoirs out of the way for access. Good luck! Tim.

T_Bone · Post by **T_Bone** » 25 Mar 2011, 20:20

Here is a drawing I did of the basics. I can't get a clear picture. The "shield" behind the nipple (broken part) is actually just a dust shield it leads back to a smallllllllll .07 or so hole that then runs into the sensor whose wiring runs up from there. It's still fine.

This component is the thermostat then? If so, can I just plug this bleeder line? Or does it continuously flow? Its also really gunked up inside (the broken nipple).

I've got the car jacked up because I'm doing the lower torque mount right now which completely broke (not just the bushings the actual mount snapped off at the head)..

thanks.

Pops · Post by **Pops** » 25 Mar 2011, 20:24

Tshor - Can he just plug the orifice at the thermostat housing for a short term fix so he can drive the car? He won't be able to pick up parts until Monday. This is the soldier's Dad trying to help from about 1400 miles away.

Post by **jimmy57** » 25 Mar 2011, 23:20

plug it, cap the fitting on tank. Drive it and check coolant level a few times until all air has settled out.
The earlier 6's were a bear to get bled and ended up going to customers after repairs involving coolant drain n fill and the low coolant light would come on the next day.

Post by **JDS60R** » 27 Mar 2011, 10:04

I think the snow man broke it ??