Cooling System - Gurgling Noise From Front of Engine
S80/XC902003-
Section
2
Group
25
No.
0038
Year
04
Month
02
Vehicles involved: B6294T
Replacing the hose under the intake manifold
Background
A gurgling or groaning type of sound from the front of the engine could be caused by the hose under the intake manifold or the hollow screw that attaches the banjo fitting to the manifold. To prevent having to replace the entire hose assembly, a new hose kit is available as a replacement part. There is also an improved hollow screw. This Service Bulletin describes how to replace the hose.
Competence requirement
Volvo Level 1 Technician
Material
Description Quantity P/N
Hose kit (nipple) 1 30677801
Clamp 3 978170
Clamp 1 978401
Gasket 1 9458535
Gasket 2 947282
Screw 2 946934
Washer 2 960139
Hollow screw 1 30651591
General
Hose under the intake manifold, replacing
Information 1
The illustration displays the new replacement part with pipe screw and copper washers.
Removing the intake manifold 2
Intake manifold removal, see VADIS:
Repairing and installing
Function group 25
Intake manifold/-gasket replacing
Removing the vacuum nipple 3
Wet the outside of the insulation using soap solution.
Fold in both ends of the insulation.
Removing the vacuum nipple, continued 4
Place paper under the vacuum nipple to absorb any coolant leakage.
Install hose clips on the engine coolant hoses.
Remove the hose clamps on the engine coolant hoses.
Disconnect the engine coolant hoses from the nipple.
Removing the vacuum nipple, continued 5
Remove the hose clamp from the plastic hose nipple on the oil trap.
Pull the plastic hose out from the insulation.
Note!
If the white plastic nipple comes off and remains in the rubber hose it must be removed. See the following step.
Removing the vacuum nipple, continued 6
If the nipple breaks, it must be removed. It must not be pressed into the hose.
Hint:
Secure the hose above the clamp. Use pliers.
Carefully screw a self-tapping screw into the nipple. The inner diameter of the nipple is 2.7 mm.
Remove the clamp.
Pull out the broken nipple.
Installing the vacuum nipple 7
Wet the plastic hose on the new nipple. Use a soap solution.
Press the hose through the insulation following the previous routing.
Install the hose and nipple on the oil trap. Use a new clamp.
Installing the vacuum nipple, continued 8
Install the engine coolant hoses on the vacuum nipple. Use new clamps.
Remove the hose clips.
Installing the vacuum nipple, continue 9
Fold the insulation back into place.
If the insulation breaks, apply tape over the crack.
Installing the intake manifold 10
Intake manifold installing, see VADIS:
Repairing and installing
Function group 25
Intake manifold/-gasket replacing
Note!
Install new hollow screw.
Test drive the car.
Check the cooling system for leakage.
Check the coolant level.
WARRANTY STATEMENT:
Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.