Replace Thermostat Housing - 2002 S60

anolds60 · Post by **anolds60** » 30 Dec 2011, 13:07

Hell all. I am new to the forum. And frankly, working on cars. Anyway.

I have to replace the entire thermostat housing on a 2002 s60. I am obstructed by other parts when trying to get at the Torx on the bottom portion of the housing. Any tips or suggestions on how I can get to this thing would be greatly appreciated.

Happy New Year!

Post by **JRL** » 30 Dec 2011, 13:47

Unfortunately you need to remove a couple of those parts that are in the way first
Make SURE you put the housing gasket on the right way and use anti seize on the threads, these things have a habit of rusting

anolds60 · Post by **anolds60** » 30 Dec 2011, 14:12

Thank you JRL. Re the anti seize, that is for reassembly? I have some PB Blaster for removal. On the parts removal, are you willing to be more specific? It seems like alternator or belt tensioner (maybe) are in the way. Heck, maybe I just need a special tool?

I don't want to take this to the shop. They want $542 (they would have gotten the part w/ that quote) to do this repair. Ugh.

J5T · Post by **J5T** » 30 Dec 2011, 18:09

I did this not too long ago and I believe I had to remove the PS pump. I used a 1/4'' u joint with a torx to get the bottom bolt out. Try not to drop any of the bolts when replacing the T-stat. Glück.

johngasstation · Post by **johngasstation** » 01 Jan 2012, 10:23

Hi, I replaced mine recently.
I found a torque screwdriver bit bent to 30 degrees 1 inch from the end did the trick for the bottom one.
To get to the next one back, use a quarter drive ratchet with 3 inch extension.
A little bit fiddley, but can be done without removing p/s pump and other parts.
I have done this myself!
Hope this helps

anolds60 · Post by **anolds60** » 01 Jan 2012, 11:25

Thank you John and JST. I am going to take a shot next week. Fingers crossed. Happy New Year!

Ao60

orbya · Post by **orbya** » 05 Jan 2014, 10:27

Any pictures for the removal process? I just tried to remove and all I've read is removing belt and ps assembly. Before I take it in to Volvo I wanted to try and get the right tools for DIY

Post by **oragex** » 05 Jan 2014, 18:45

anolds60 wrote: I don't want to take this to the shop. They want $542 (they would have gotten the part w/ that quote) to do this repair. Ugh.

That's the reason Volvo will only be memories one day. Everything done at the dealer comes in numbers of several hundreds. They don't realize they are chasing customers away.