Howto replace bottom half of thermostat housing 1996 volvo850

Drill a hole down the center of the bolt and use a bolt extractor

Hello rev7, this is an easy job on the 4.3 litre engine.

Drain some of the engine coolant by placing a bucket under the radiator and open the petcock (the plastic bolt facing the engine) located on the bottom of the radiator. Empty the coolant from the radiator until the radiator is about half full.

Remove the air intake, hose and the coolant neck (outlet) bolts using a ratchet and & 13 mm socket. Remove the outlet from the intake manifold. Take note of the direction the thermostat is seated and then remove the thermostat from the housing.
Clean the remains of the old gasket or sealer from the housing and outlet. Install the thermostat and gasket to the intake manifold in the same direction it was seated before removal. Put a thin layer of silicone on the water outlet surface. Install the outlet before the silicone dries

Install the water outlet bolts. Tighten the bolts to 18 foot pounds
Filll the radiator completely and check for any leaks. Install the radiator cap. Install the air cleaner inlet hose. Start the engine and turn the heater on with the blower on high & run the engine until the thermostat opens. The top radiator hose will be hot when the thermostat opens.

Turn off the vehicle and allow the engine to cool. Check fluid level and add more antifreeze if needed.....Good luck & hope this helps.

Locate the Thermostat

• Find the hoses that leave your radiator.
  
• Trace the top hose back to your engine.
  
• Locate the thermostat housing attached at the end of that hose. Verify the location in your owner's manual, as some manufacturers house the thermostat at the bottom of the radiator rather than the top. This makes removal far more difficult.
  

Replace the Thermostat Locate the clamp that secures the thermostat to the radiator hose. Unscrew this clamp and gently remove it from the engine. You might see radiator fluid or coolant come out of the hose at this stage, in which case you can catch it in a drip pan and dispose of it later on. Unscrew the bolts that secure the thermostat to its housing. Wipe out the inside of the hose with a rag to ensure it is free of debris. If anything falls into your radiator, it can result in expensive repairs. Replace the gasket. Install the new engine thermostat. Make sure the power unit faces the engine. Replace the bolts to secure the thermostat housing to the radiator hose. Reconnect the hose and tighten the screws in the clamp

On 1996 VW JETTA,The thermostat is located at the engine end of the lower radiator hose (passenger side). If the car has power-steering, then power steering pump and mounting bracket are to be removed to get to the thermostat housing. The thermostat is at the end of the bottom hose, in the water pump housing. Follow the lower radiator hose to the water pump housing. There are three bolts that are very difficult to navigate around. The thermostat is located behind those bolts.
----------------- Thank you.

2.2L (VIN 4) Engine

1. Drain the cooling system.
2. Remove the lower radiator hose from thermostat outlet.
   
   
   Fig. Remove the thermostat outlet bolts and outlet
   
3. Remove the thermostat outlet bolts and outlet.
   
   
   Fig. Remove the thermostat
   

2.2L (VIN F) Engine

1. Remove the thermostat housing to water pump feed pipe bolts.
2. Remove the thermostat housing to water pump feed pipe.

Fig. Remove the thermostat


Hope helps (remember rated this),

Follow the radiator hose to the drivers side of the engine. The thermostat housing (this is what the hose is connected to) is below the coil and air intake tube and the thermostat in located inside the housing. The housing held on with 3 bolts. Be very carefull removing the bolts because the the bolts and housing have a tendency to get corroded and could break off.
If the bolts or housing show signs of corrosion they should be replaced.
You'll have to drain the engine coolant before removing the housing.

buy the correct thermostat and thermostat gasket for your car, then locate the upper radiator hose. Where the upper hose connects to the engine there should be a two bolt hose connection/ thermostat housing ( could be 3 or 4 bolt, but most are 2) these bolts should be removed and then gently lift the hose and hose connection/thermostat housing exposing the old thermostat. note the position then replace the new thermostat just as the old was installed.

THE THERMOSTAT IS BELOW THE DISTRIBUTOR AT THE END OF THE UPOPER RADIATOR HOSE

drain half of the coolant.follow top hose to the thermmostat housing .loosen hose clamp then loosen the thermostat bolts.remove the thermostat housing and thermostat.remove traces of all the old gasket from housing and the intake where thermostat goes.becareful dont scratch the surfaces while removing all the old gasket.this info is for the 4.9 models.now for the 4.6 engines. you have to remove radiator support cover .remove the air filter housing.loosen hose clamps .remove your thermostat housing bolts then thermostat.remove traces of all old gasket.on thermostat housing and intake. then put in new thermostat in. put on housing .torque bolts 18 to 20 ft lbs.

Follow the bottom hose around the back of the engine and over to the passenger side. This hose ends up almost directly behind the front/top hose (where the thermostat should be...but that would be too easy). Unbolt 3 bolts holding the housing on, pop off the housing, and the thermostat should just pop right out.