Thermostat, Replacing

REMOVING THE THERMOSTAT

Fig 1: Identifying Expansion Tank

Courtesy of VOLVO CARS CORPORATION

Remove

the clamp holding the return hose for the power steering
the screw holding the engine stabilizer brace to the bracket on the engine
the screws holding the engine stabilizer brace to the suspension turrets
the engine stabilizer brace
the expansion tank cap.

Raise the car. Remove the lower splashguard.

Position a container under the engine drain cock. Drain the coolant.

Close the cock.

Install the lower splash guard.

Lower the car.

Fig 2: Identifying Plastic Hoses Between Turbocharger, Charge Air Cooler & Air Cleaner/Turbocharger

Courtesy of VOLVO CARS CORPORATION

the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC). Applies only to B6xx4T engines .

Fig 3: Front Timing Belt Cover

Courtesy of VOLVO CARS CORPORATION

Lift up the servo reservoir and place it on top of the engine.

WARNING:

Seal the cover for the servo reservoir. Check that no oil leaks out.

Servo oil is highly inflammable.

NOTE:

Ensure that the timing belt cover has cleared the nipple on the thermostat housing before the cover is pulled up.

Remove:

the screw for the front timing belt cover. Applies only to B6xx4T Cars with chassis number 203779- see TIMING COVER FRONT, REPLACING .
the timing belt cover. Use a weatherstrip tool.

Fig 4: Identifying Thermostat Housing & Cable Duct

Courtesy of VOLVO CARS CORPORATION

the thermostat housing cover
the thermostat.

INSTALLING THE THERMOSTAT

Fig 5: Front Timing Belt Cover

Courtesy of VOLVO CARS CORPORATION

NOTE:

Clean all mating surfaces. Ensure that no dirt enters the fluid ducts.

NOTE:

Ensure that the timing belt cover is in position before the cover is pressed in against the rear timing belt cover to prevent damage to the nipple on the thermostat housing.

Install

the new thermostat
the cover of the thermostat housing with a new gasket . Tighten to 17 Nm
the front timing belt cover. The mudguard over the right drive shaft boot may come loose. If this happens, secure it from underneath
the screw for the front timing belt cover. Tighten to 12 Nm . Applies only to B6xx4T Cars with chassis number 203779- see INSTALLING THE FRONT TIMING COVER .

Fig 6: Identifying Plastic Hoses Between Turbocharger, Charge Air Cooler & Air Cleaner/Turbocharger

Courtesy of VOLVO CARS CORPORATION

the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC). Applies only to B6xx4T engines .

Fig 7: Identifying Expansion Tank

Courtesy of VOLVO CARS CORPORATION

the servo reservoir. Check that the hoses are correctly positioned
the engine stabilizer brace
the screws holding the engine stabilizer brace to the suspension turrets. Tighten to 50 Nm
the screw holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm
the clamp holding the return hose for the power steering.

Carry out a function test

Fill with coolant.

Install the cap on the expansion tank.

Test drive the engine until the thermostat has opened.

Top up the coolant if necessary.