How to Remove & Replace a Thermostat on a 2002 Volvo V-40
- 1). Trace the top radiator hose to find the location where it is connected to the engine. The metal cover that the radiator hose connects to is called the thermostat housing and is bolted to the intake manifold. The thermostat is located inside of the intake manifold, under the thermostat housing. Remove the thermostat housing cover by removing the bolts that hold it onto the V-40 intake manifold. Place the thermostat housing cover off to the side. The thermostat housing cover will still be connected to the radiator hose. Pull the hose vertically to push the coolant back into the radiator.
- 2). Pull the thermostat out of the engine and remove the thermostat gasket that was pressed between the thermostat housing cover and the intake manifold. Both can be removed by hand without any special tools. However, with age the gasket might stick. A small metal scraper or razor blade can be used to peel the gasket off of the intake manifold.
- 3). Place a thin bead of RTV silicone sealant around the hole in the intake manifold and around the bolt holes for the housing. A consistent unbroken line of RTV silicone should be placed on the surface of the manifold so when the thermostat housing is placed back on to the manifold a seal is created. Refer to the instructions of the RTV manufacturer for drying times.
- 4). Place the new thermostat back into the intake manifold. The thermostat sits on a machined flange located just inside of the intake manifold. The end marked "top" should protrude out of the intake manifold. Place the thermostat housing cover on top of the RTV silicone bead and then bolt the cover into place.
