Changing Thermostat (2.4 petrol)

[reggit]

Had to change a stat on my old 2.4 petrol S60 when it failed open on holiday (in winter). Did it at the side of the road in about 10 minutes, it’s just a 3 bolt jobbie to pop the housing apart.

Unlike my current P3 car which looks like a 2 day job grrr

[VOLVOBOY]

Likewise,
Forget what i said before. The early stat is a simple fix.
Sorry for the bum steer.

[oragex]

Originally Posted by reggit

Had to change a stat on my old 2.4 petrol S60 when it failed open on holiday (in winter). Did it at the side of the road in about 10 minutes, it’s just a 3 bolt jobbie to pop the housing apart.

Unlike my current P3 car which looks like a 2 day job grrr

On 2003-up P2 it's atrocious as well and expensive as the entire housing with CTS must be ordered because the actual thermostat is a special design and Volvo doesn't sell the thermostat part alone. But there is a trick to make the replacement faster, and as mentioned we should be able to replace the actual thermostat piece alone with the one for the D5 engine which appears to be of similar design - so no need to order the entire housing

https://youtu.be/6daL0qzlj6k
.

[stuart bowes]

Originally Posted by VOLVOBOY

Likewise,
Forget what i said before. The early stat is a simple fix.
Sorry for the bum steer.

no worries it's the thought that counts, you were trying to help

was under the bonnet today replacing steering reservoir and putting the correct green stuff in instead of the red that was in there. that was a pretty easy job tbh, hardest bit was getting the bottom pipe off the old tub, welded on with age I guess

anyway the thermostat housing is indeed the 'old' 3 bolt jobby, although why they couldnt have put a cutout in the pulley cover to allow removal of the rear bolt is beyond me. i might cut a notch myself when it's off just in case of (unlikely) future issues

[Georgeandkira]

Years ago when the combined housings (a needless design change) came out they were <$60. Was the purpose to force you to change the CTS with the thermostat? Whatever Volvo's thinking was, I figured I could live with it.

When I read the new housing was much more difficult to change, I concluded it was something designed by the evil dwarves at Ford.

My '07 has this design obviously.

When the time comes to change mine I am not going to open my housing to replace it with a diesel stat. It'd likely be a hassle to get a diesel stat in No. America. I assume the whole thing unbolts from the engine and I won't have to open the housing for bolt access.

To stuart, oragex and VOLVOBOY: Click me a "thanks" if you can. Maybe they'll let me back into the UK if I get enough of them.

[oragex]

What happened with traveling ? As for the thermostat, like others European cars Volvo has no choice but to go with the parts market which is owned by big European companies such as Bosch, Behr and others. These are big corporations and car makers better get well along with them. Other european car brands also went with full tstat housing at same moment Volvo did. I also remember P3 Volvo platforms had major troubles with new PCV systems which had a faulty design that was taking the engine down - at same time BMW, Audi and perhaps other had the same issue. They just have no choice to go with the big corporations and I image it can be quite frustrating for a car maker (and the owners)

[GedW]

Half-way down this page, I was convinced that it would entail a trip to the local Volvo specialist, until the 2001 model comment, which mine is, 2.4T petrol. Hope mine is as easy as that one sounds.. not looked yet. At the weekend it took 30 miles to get the gauge to 1/4 point, so assume my stat is stuck too. 76,000 on my clock.

[stuart bowes]

green box = easy to change type (my engine bay)

ignore the red arrow that was me asking a different question

yours will have a big turbo pipe over the top which shouldn't make any difference because you only need to remove the left side part of the plastic cover (over the pulleys)

be careful with the drain plug because it's plastic so don't use a ratchet just have a socket on an extension and turn by hand

[GedW]

Ok, Thanks Stuart. I did the job this afternoon. After much deliberation of around 10 makes of thermostat, I decided to order an original Volvo one from PFS, which, with post, came to £30.42. A direct non-Volvo match may have saved a tenner, but I bit the bullet.
Most went to plan. The drain plug was NOT a socket operated one. I couldn't figure why a 10mm, 12mm, 13mm socket gave no purchase, so took a pic with my phone, and discovered a hex in the middle, which required an Allen key. A perfect tool to use to loosen and not over-tighten.
Top cover came off no probs. 2 Torx on stat housing was not so easy. A bit tight, broke the ratchet on my manual screwdriver handle. Broke the plastic handle on my T-bar. Decided that damaging the Torx heads was a distinct possibility without the proper tool and leverage. I whizzed out and got a £17 1/4 drive socket drive from the local S****fix. Perfect.. with all the right Torx sockets as well as may others. 10 minute job then. Topped back up, of course with drained anti-freeze, with a filter funnel.
A short test run got the gauge to exact centre, with no waver. Very happy.
My only issue is the level is now max, rather than 3/4, so I MUST have an air lock. How do I bleed it?

[Georgeandkira]

Squeezing the upper radiator hose after warm up with the engine running is the method I've read. I didn't need to.
I've also read our setup is good at debubbling itself. Have you taken it out for a long run?

I do remember those tight torx screws. Nothing wrong with an OE thermostat. Avoiding cheap thermostats is "parts lesson" #1.
Sources here offered Wahler, the OE manufacturer for many. Saved me a fiver.

FUTURE NOTE: If / when your upstream O2 sensor goes out you'll read of our cars' sensitive emissions systems, cheap replacement sensors brands and the dread "universals".
Take heart, Denso makes 'em for Volvo et al. I've been party to 3 trouble free replacements with substantial savings.