It's me again.....
1995 855 turbo is fluctuating in temperature, so I am trying to replace thermostat. The front screw came out okay, the back screw didn't and I stripped the head on the torx screw. Since this is the rear one, it will be difficult to remove.
Any tips on how to do this? What should I remove and how? I suppose the fuel rail needs to be removed, what is the correct way to do this?

I have a screw extractor, so hopefully that will work.

 

You can remove the fuel rail 2 screws. You can usually turn it out of the way.
WHAT EVER YOU DO DON'T HIT THE SCREW WITH A HAMMER. The thermostat housing will snap off the head.

 

Measure the bolt you got outs diameter and get a drill that size. Drill in until the head comes off and then remove the housing/outlet. Just plain old WD-40 and a pair of Vise Grips after that.

BTW,
I think a 5/16" drill should work OK.

 

Cool, I will try these tips out and report back.
Thanks!

Oh, were can I get some new bolts online>??? Dealer is over an hour away...

 

Drilling it out is most likely the easiest way. As for the bolts, take the good one to the hardware store and get a stainless steel one the same size and thread, and replace BOTH. Hex heads will be a lot easier to take out then Torx ones next time.

 

Well, I got the thermostat replaced, but dropped one of the fuel injector seat (the blue seat) seals below the motor! I am supposed to leave town today so I am in a hole. Would I be in danger if I put things together without one in place? Would the motor even run or would I suck air in the injector???

 

I don't think I would try it. Can you see the part you dropped, or are you able to proble around where it dropped and possibly knock it loose?

 

I looked around and found one of the two. I looked for a long time and stuck my hands and screwdriver to see if I could nock it loose.... No luck. Of course it was dark, so I was using lights... I am gona try soon this AM to see if daylight will help me. My fear is that it fell behind the PVC Trap and I'd have to remove the intake to see there.

 

AH, found this on the forum here
https://volvoforums.com/m_19692/tm.htm
and also on volvospeed
http://volvospeed.com/vs_forum/index...0202&st=20

Looks like i nee the seat seal... Dang.

$4.80 from dealer that is 4 hrs from me. hah!

I am gona look to see if i can find it.

 

Okay, I got the one and only seal they had in stock at the Athens, GA volvo dealer.
Bought a new colbalt drill bit set, wow, it drilled that screw/bolt out in 30 seconds! Some anti-seize coating, 2 new hex bolts, M7*30, and a new thermostat [87 degree].
FWIW, the thermostat was broken on the top [just like my 93 945t was when purchased, never seen this on other makes]. Replaced it and back in business, for now.

Some photos...
http://i221.photobucket.com/albums/d...t/DSCN4314.jpg
http://i221.photobucket.com/albums/d...t/DSCN4315.jpg
http://i221.photobucket.com/albums/d...t/DSCN4316.jpg
http://i221.photobucket.com/albums/d...t/DSCN4317.jpg
http://i221.photobucket.com/albums/d...t/DSCN4320.jpg
http://i221.photobucket.com/albums/d...t/DSCN4321.jpg


Thanks for all the tips.

 

Glad all is well now.