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non-LBC (Volvo) question: Why does a bad thermostat = new engine?

To: "'mgs@autox.team.net'" <mgs@autox.team.net>
Subject: non-LBC (Volvo) question: Why does a bad thermostat = new engine?
From: Steve Shoyer <Steve@shoyer.com>
Date: Tue, 14 Mar 2000 22:53:56 -0500
After spending a couple of years working on my 1980 MGB, I thought I had
picked up a little knowledge about engines.  However, we have a 1997 Volvo
850 GLT sedan.  Every once in a while, the "low coolant" light would go on,
so I'd top it off (with the "special" Volvo coolant, of course).  It started
happening more frequently, and when we took the car in with 49,500 miles (it
has a 50K warranty), we had them take a look at it.  They said a hose was
loose, tightened a clamp, topped off the coolant, and told up it was fixed.
Soon after, the coolant light was back on, and the "Check Engine" light was
going on, too.  The only other symptom was that the car would run pretty
rough after a cold start, but it would be OK after a minute or two.  Anyway,
they said replaced the upper radiator hose and thermostat, and checked the
head gasket for leaks.  For the "check engine" light and rough running, they
found gas washed cylinders which they cleaned, and they replaced the spark
plugs, oil, and filter.

A few weeks later the "low coolant" light was back, as was the "check
engine" light.  The coolant leak was becoming more pronounced.  We took the
car back, and it's been at the shop for almost two weeks while they ran more
compression tests and waited for the Volvo regional service person to get
back to them about something.  Today we got a message that they recommend
that the engine should be replaced, which should cost about $6500.  It's out
of warranty, but Volvo is willing to pick up $4500 of the cost, leaving us
to pay $2000.  From what I've picked up from my wife's translation of what
the service person told her, the bad thermostat caused a crack in the head.
They said that we could try to just replace the head gasket for about $1000,
but only if we were about to trade the car in.

The car never overheated, and the temp gauge never showed that the engine
was getting hot.  I still don't understand why there should be any
interaction between the cooling system and the "check engine" light (which,
according to the owner's manual, relates to the emissions system).  I don't
know how a bad thermostat could crack the head, especially without any
external signs other than a low coolant level.

We like the car, so we'll probably get it fixed, but can anyone tell me why
this might have happened?  Is it something we should have to pay for, and if
not, what would be our argument for getting the dealer to pick up the whole
cost?  I'm not trying to weasel out of paying if it is my responsibility,
but the car was in a few times for the same problem, and each time the
dealer said that they had fixed it.  The $2000 would be better spent fixing
my rusted sills (although my wife might not agree).

Sorry for the use of the bandwidth, but if anyone has any suggestions, I'd
like to know.  Thanks.

--Steve Shoyer (1980 MGB)

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