Difficulty

Moderate

Steps

6

Time Required

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Sections

1

  • Thermostat
  • 6 steps

Flags

2

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  • Back1995–2004 Volvo S40

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Introduction

What you need

Step 1

              Thermostat
  • MAKE SURE ENGINE IS COLD Locate the upper radiator hose and follow it to the location where the hose connects to the engine block. The hose clamps to a metal housing called the “water inlet.” Loosen the band clamp that secures the hose to the water inlet with a screwdriver. Pull the hose off the inlet.

MAKE SURE ENGINE IS COLD Locate the upper radiator hose and follow it to the location where the hose connects to the engine block. The hose clamps to a metal housing called the “water inlet.” Loosen the band clamp that secures the hose to the water inlet with a screwdriver. Pull the hose off the inlet.

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Step 2

  • Locate the two bolts that secure the inlet to the engine block and remove them. Use a 12 mm socket and ratchet. Pull the water inlet off the engine block. Due to age, the inlet may stick to the block. Place pressure on the side of the inlet to break the seal, if needed.

Locate the two bolts that secure the inlet to the engine block and remove them. Use a 12 mm socket and ratchet. Pull the water inlet off the engine block. Due to age, the inlet may stick to the block. Place pressure on the side of the inlet to break the seal, if needed.

Step 3

  • Scrape the base of the engine and the bottom of the inlet to remove the old gasket material and to clean the mating surfaces.

Scrape the base of the engine and the bottom of the inlet to remove the old gasket material and to clean the mating surfaces.

Step 4

  • Pull the old thermostat out of the engine and place the new one into the engine. One end of the thermostat has a large spring. The spring sits inside of the engine.

Pull the old thermostat out of the engine and place the new one into the engine. One end of the thermostat has a large spring. The spring sits inside of the engine.

Step 5

  • Place a bead of RTV gasket maker around the bottom edge of the water inlet. Place the water inlet over the thermostat and bolt it into place. Using RTV gasket maker instead of a gasket compensates for pitting that occurs in cast iron. It helps to promote a better seal between the engine and the inlet.

Place a bead of RTV gasket maker around the bottom edge of the water inlet. Place the water inlet over the thermostat and bolt it into place. Using RTV gasket maker instead of a gasket compensates for pitting that occurs in cast iron. It helps to promote a better seal between the engine and the inlet.

Step 6

  • Slide the radiator hose onto the inlet and secure it with the band clamp.

Slide the radiator hose onto the inlet and secure it with the band clamp.

To reassemble your device, follow these instructions in reverse order.

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                    Josef

Member since: 08/06/2012

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