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2004 8.1 Gi Thermostat Housing, Unavailable. HELP

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btt5060

New member
I have an 2004 Cobalt with a 8.1 Gi. I need to replace the thermostat but the housing is like welded together, I looked up a new housing (3819500) and I cannot buy it. Has anyone had this issue? How do I replace the thermostat or how do I buy the housing?????? Volvo says the housing is unavailable and I cannot buy it anywhere

Thanks so much!!!!
 
Tapped it with a 3 or 5 pound sand hammer?

While sort of doubtful, it may still be worth a call to see if Raylar marine can help such as looking at old engine parts in the back shop area, etc..

496 MAG / 496 MAG HO Mercruiser Performance Parts - 496cid Marine Performance Packages - Raylar Engineering

Mercury marine mercruiser 496 MAG / 496 MAG HO performance parts. Raylar Vortec 8100 8.1L mercruiser marine performance kits and performance packages.
www.raylarengineering.com
 
Fun Times said:
Tapped it with a 3 or 5 pound sand hammer?

While sort of doubtful, it may still be worth a call to see if Raylar marine can help such as looking at old engine parts in the back shop area, etc..

496 MAG / 496 MAG HO Mercruiser Performance Parts - 496cid Marine Performance Packages - Raylar Engineering

Mercury marine mercruiser 496 MAG / 496 MAG HO performance parts. Raylar Vortec 8100 8.1L mercruiser marine performance kits and performance packages.
www.raylarengineering.com
Click to expand...
btt5060 said:
I have an 2004 Cobalt with a 8.1 Gi. I need to replace the thermostat but the housing is like welded together, I looked up a new housing (3819500) and I cannot buy it. Has anyone had this issue? How do I replace the thermostat or how do I buy the housing?????? Volvo says the housing is unavailable and I cannot buy it anywhere

Thanks so much!!!!
Click to expand...
You can see where the old thermostat sat in there but unable to access due to the welding (factory?)
 

Volvo Penta SX-A Operator's Manual (Page 122 of 156) | ManualsLib

www.manualslib.com www.manualslib.com


8.1 Liter Engines (Raw Water Cooled)
1. Loosen and remove long bolt 1, washer 2, and
short bolt 3; save for reuse.
2. Remove thermostat housing 4.
3. Remove thermostat 5, small O-ring 6, and large
O-ring 7, from cross-over pipe housing 8. Discard
thermostat. Inspect O-rings and, if damaged,
replace.
4. Place new thermostat and O-rings into the groove
in the cross-over pipe housing.
5. Replace upper thermostat housing.
6. Install bolts and washer and torque to
18–30 ft. lb. (25–41 Nm
 
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