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Replacing thermostat D5 163hp tips

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Old Mar 21st, 2018, 14:15   #11
R-P
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I was going to write about karma and me being a good person, but meh.

When I remove the steeringpump, the bracket holding the alternator and AC compressor is STILL in the way. So I would have to remove that whole bracket, of which some bolts are not accessible unless you remove the alternator and/or compressor...

So either I am completely dumb, or the D5 (or my police version), is a lot harder than I thought.

[sarcasm]
Seems logical to put an item that dies on at least one in every two cars with >200,000km on the clock, in a place where you pretty much have to remove the complete engine to access it.
[/sarcasm]

Compare 1:35 in this clip with below picture. Offending hex bolt is slam in the middle of the pic. I hope you can make out that not only the pump, but also another piece of aluminium (from the bracket) is in the way.
BTW, it is a bolt from the UPPER part of the housing. I did not thoroughly investigate if removing the WHOLE housing could be possible.

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Last edited by R-P; Mar 21st, 2018 at 14:20.
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Old Mar 21st, 2018, 15:01   #12
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Ouch

How much is the space between the head of the torx screw and the bracket in front of it? I'd see if it's possible to drill a hole through the bracket just in front of the screw so as to pass a torx screwdriver if you have one. Or maybe even cut a piece of the bracket with the angle grinder if it fits.
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Old Mar 23rd, 2018, 00:01   #13
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I was indeed thinking of the hole-drilling solution. The aluminium bracket is hollow from behind, so it would only be 5mm of aluminium. And obviously have a vacuumcleaner suck out all pieces flying away so they don't wind up in the belt...

There are already two holes in it, (visible when removing the steeringpump) but they don't line up with the bolt.
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Old Mar 24th, 2018, 10:10   #14
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I have just replaced the thermostat on my V70-08 Classic 163 hp diesel.

- Remove the auxiliary belt
- Loosen bolts and move the steering pump away
- Lower the coolant level
- Remove bolts holding the thermostat housing to the cylinder head.
The lower bolt is accessible through the lower hole in the bracket. You need a long T40 wrench. Try to not lose the bolt(it is tricky)
- Lift out the complete housing.
Then you can remove bolts and split the housing and pick out the thermostat. Be careful and try to remove the gasket in one piece, because it is not avialable as spare part. I smeared a thin layer of silicon gasket on both sides of the old gasket when refitting.

Last edited by Hasse53; Mar 24th, 2018 at 10:20.
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Old Mar 24th, 2018, 21:06   #15
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google -- coolant circuit seals VOLVO V70 11(SW)2.4 D5 --
cost £5.65 -- for the thermostat seal on its own. (article no 233890) and
is available from -- buycarparts.co.uk --
Also available is the Gates thermostat (TH35991) - £10.51 (article no Th35991)
Not good at putting on links!

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Old Apr 8th, 2018, 12:24   #16
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Quote:
Originally Posted by Hasse53 View Post
I have just replaced the thermostat on my V70-08 Classic 163 hp diesel.
...
- Remove bolts holding the thermostat housing to the cylinder head.
The lower bolt is accessible through the lower hole in the bracket. You need a long T40 wrench. Try to not lose the bolt(it is tricky)
Thanks Hasse, I will have a look at that first before drilling the hole!

[offtopic] Karlstad, he? I just to have a bunch of friends in Grums [/offtopic]
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Old Apr 11th, 2018, 14:56   #17
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"just" instead of "used. What is happening to my grasp of the English language...


But Hasse, you made my day! Yes, there is a hole that gives access to the lower torx bolt!!! I will post vids later. I think it is the upper one in my case (early 2004 V70 D5)

Right now I have an issue of NOT having sealant as I have an extra gasket, but I didn't read your post carefull enough. My gasket is indeed for the assembly to the engine, not for the split parts. And that is the one that is in worst shape
Pic shows gasket with worn rubber(?) around the thermostat and the old & new (still sealed) gasket that goes between the complete housing and the engineblock.
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Old Apr 11th, 2018, 16:35   #18
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The picture is showing the split part. Is that a flat service?
If so I wonder if a liquid gasket (vloeibare pakking) will do the job?
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Old Apr 11th, 2018, 18:21   #19
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Here's the cleaned gasket. I may have flattened the ridge that is in it and tried to accentuate it a little more again with my nails. Not sure that worked
Borrowed some liquid gasket frrom father-in-law and put it all back together. Time will tell.

The old coolant was black with black specs/particles in it and an ever so slight rainbow color in it (oil?).
We'll see. I only filled 3.5 liters of coolant (which was all I had left after using half a liter last time when I aborted the thermostat swap) and the level is too high. Will check again after driving.

I called Volvo to buy from them, but they said they only have 200l cans and don't sell it separate. But "any blue fluid will do" according to the Volvo guy. So it's cheapo stuff right now (~6.50 euro for 4 liters).
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Old Apr 11th, 2018, 18:28   #20
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For anyone else watching this, you can buy the complete thermostat housing including gasket and new coolant temperature sensor and be done with this job in a couple of hours.
It's made by the genuine Volvo supplier and other than the packaging, the same as you'd buy from a main dealer.
Example

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