Volvo Truck 2003-05

Removal & Installation

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CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

6-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect or remove:

    Clamp holding the return hose for the power steering
     
    Bolt holding the engine stabilizer brace to the bracket on the engine
     
    Bolts holding the engine stabilizer brace to the suspension turrets
     
    Engine stabilizer brace
     
    Expansion tank cap

    Click image to see an enlarged view

    Fig. Location of engine stabilizer bar-6-Cylinder Engines

    Location of engine stabilizer bar-6-Cylinder Engines
     

    1. Raise vehicle
    2.  
    3. Remove the skid plate:
      NOTE
      There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.



      Loosen the six bolts and remove
       
      Lift and slide skid plate forward
       

    4.  
    5. Position a container under the engine drain cock and drain engine coolant.
    6.  
    7. Close the cock.

      Click image to see an enlarged view

      Fig. Skid plate removal

      Skid plate removal
    8.  

  4.  
  5. Install the skid plate and tighten the six M10 bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Disconnect or remove:
    WARNING
    Seal the cover for the servo reservoir and check that no oil leaks out. Servo oil is highly flammable.


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



    Plastic hoses between the turbocharger, charge air cooler, and air cleaner
     
    Lift servo reservoir and place it on top of the engine
     



    Click image to see an enlarged view

    Fig. Location of plastic hoses for removal-6-Cylinder Engines

    Location of plastic hoses for removal-6-Cylinder Engines

    Click image to see an enlarged view

    Fig. Location of servo reservoir for removal-6-Cylinder Engines

    Location of servo reservoir for removal-6-Cylinder Engines
  10.  
  11. Remove:

    Front cover
     
    Timing belt cover. Use weatherstrip tool
     
    Thermostat housing cover
     
    Thermostat

    Click image to see an enlarged view

    Fig. Thermostat housing cover location-6-Cylinder Engines

    Thermostat housing cover location-6-Cylinder Engines
     

  12.  

To install:

  1. Install or connect:

    The hose for the water heated crankcase ventilation
     
    Thermostat housing assembly to cylinder head using new gasket and new hose clamp
     
    Tighten thermostat housing to 16 ft. lbs. (22 Nm)
     
    Upper radiator hose and hose clamp
     
    Connector for the temperature sensor
     

  2.  
  3. Refill with coolant.
  4.  
  5. Install the cap on the expansion tank.
  6.  
  7. Test drive the engine until the thermostat has opened.
  8.  
  9. Check for leaks and proper function. Fill fluid as necessary.
  10.  

5-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system:
    1. Remove cap from expansion tank
    2.  
    3. Raise vehicle
    4.  
    5. Remove the skid plate:
      NOTE
      There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.



      Loosen the six bolts and remove
       
      Lift and slide skid plate forward
       

    6.  
    7. Position a container under the engine drain cock and drain 2 quarts (2 liters) of engine coolant.
    8.  
    9. Close the cock.

      Click image to see an enlarged view

      Fig. Skid plate removal

      Skid plate removal
    10.  

  4.  
  5. Install the skid plate and tighten the six M10 bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Disconnect or remove:

    Hose clamp to the upper radiator hose
     
    Hose from the thermostat housing
     
    Connector from the temperature sensor
     
    The two bolts for the thermostat housing at the section against the cylinder head
     
    The thermostat housing from the cylinder head
     
    The hose clamp for the water hose for heating crankcase ventilation

    Click image to see an enlarged view

    Fig. Location of thermostat housing-5-Cylinder Engines

    Location of thermostat housing-5-Cylinder Engines
     

  10.  

To install:

  1. Install or connect:

    The hose for the water heated crankcase ventilation
     
    Thermostat housing assembly to cylinder head using new gasket and new hose clamp
     
    Tighten thermostat housing to 16 ft. lbs. (22 Nm)
     
    Upper radiator hose and hose clamp
     
    Connector for the temperature sensor
     

  2.  
  3. Refill with coolant.
  4.  
  5. Install the cap on the expansion tank.
  6.  
  7. Test drive the engine until the thermostat has opened.
  8.  
  9. Check for leaks and proper function. Fill fluid as necessary.
  10.  

8-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system:
    1. Remove cap from expansion tank
    2.  
    3. Raise vehicle
    4.  
    5. Remove the skid plate:
      NOTE
      There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.



      Loosen the six bolts and remove
       
      Lift and slide skid plate forward
       

    6.  
    7. Position a container under the engine drain cock and drain engine coolant.
    8.  
    9. Close the cock.

      Click image to see an enlarged view

      Fig. Skid plate removal

      Skid plate removal
    10.  

  4.  
  5. Install the skid plate and tighten the six M10 bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Remove the lower engine cover:

    Loosen and remove the six bolts
     
    Lower engine cover

    Click image to see an enlarged view

    Fig. Removing lower engine cover

    Removing lower engine cover
     

  8.  
  9. Remove the two bolts from the thermostat housing cover.
  10.  
  11. Bend aside the radiator hose.
    NOTE
    The upper bolt can be loosened more easily from above.

  12.  
  13. Remove the thermostat.

    Click image to see an enlarged view

    Fig. Thermostat housing cover location-8-Cylinder Engines

    Thermostat housing cover location-8-Cylinder Engines
  14.  

To install:

  1. Install a new thermostat with a new gasket tightening bolts of housing to 16 ft. lbs. (22 Nm).
  2.  
  3. Install lower engine cover tightening the six bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Lower the vehicle.
  6.  
  7. Refill with coolant.
  8.  
  9. Install the cap on the expansion tank.
  10.  
  11. Test drive the engine until the thermostat has opened.
  12.  
  13. Check for leaks and proper function. Fill fluid as necessary.
  14.  

 
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