IPD sale XeMODeX - Experts in Volvo Electronics Free shipping all USA - Experts in Brakes
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy your stuff using this and it helps MVS!

2005 S60 2.5T AWD: Radiator replacement

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

MarcM
Posts: 183
Joined: Wed Sep 23, 2015 6:52 pm
Year and Model: 2005 S60 2.5T AWD
Location: Monadnock Region, New Hampshire
Has thanked: 1 time
Been thanked: 3 times
United States of America
MarcM

2005 S60 2.5T AWD: Radiator replacement

Post by MarcM » Sat Feb 06, 2016 1:14 pm

I jumped on this afternoon and started the radiator replacement for a leaking radiator that developed last week by replacing it and both hoses with new. Didn't do my usual "research 'til death", otherwise this would've been at a Volvo shop. Being one to admit my mistakes for others to learn from, I'm posting it here while I warm up and stew over my screw up. Don't do this unless you have an AC recharge/evacuation unit and certainly do NOT remove the (4) ~3" long bolts. They hold the 3 units together, you'll have 3 different units hanging from the nose of your car, not that I'm in that situation ( :oops: ), okay.... I am in that situation. Now I have to make some phone calls to see if can get someone to possibly swing by to properly drain the AC system as two pressure lines have to be removed. It is NOT a driveway repair/replace, especially on ramps.
I wish there was an actual paper manual available. Web info is non-existent for the most part.
2005 S60 2.5T AWD
IPD mods:
IPD HD PVC intercooler coupler/upper, HD Subframe poly inserts
ProPartsSweden HD top mount square mount, PPS lower torque rod & control arms.

User avatar
phils94850
Posts: 1156
Joined: Tue Jul 11, 2006 6:14 am
Year and Model: 2009 s60 turbo
Location: Indiana
Has thanked: 0
Been thanked: 0
United States of America
phils94850

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by phils94850 » Sat Feb 06, 2016 3:05 pm

we all been there and learn from mistakes..
1996 Platinum Edition

MarcM
Posts: 183
Joined: Wed Sep 23, 2015 6:52 pm
Year and Model: 2005 S60 2.5T AWD
Location: Monadnock Region, New Hampshire
Has thanked: 1 time
Been thanked: 3 times
United States of America
MarcM

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by MarcM » Sat Feb 06, 2016 3:20 pm

I publish them for others to learn. ;)
2005 S60 2.5T AWD
IPD mods:
IPD HD PVC intercooler coupler/upper, HD Subframe poly inserts
ProPartsSweden HD top mount square mount, PPS lower torque rod & control arms.

User avatar
abscate
MVS Moderator
Posts: 20035
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
Location: NYC, ALBANY NY
Has thanked: 273 times
Been thanked: 852 times
Trinidad & Tobago
abscate

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by abscate » Sat Feb 06, 2016 5:00 pm

It's listed as a 3 hour job on the V70 and indeed, AC evacuation and recharge is required for replacing the radiator
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
Link to Maintenance record thread
Link To Volvo Glossary

MarcM
Posts: 183
Joined: Wed Sep 23, 2015 6:52 pm
Year and Model: 2005 S60 2.5T AWD
Location: Monadnock Region, New Hampshire
Has thanked: 1 time
Been thanked: 3 times
United States of America
MarcM

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by MarcM » Sat Feb 06, 2016 5:31 pm

Pulled some strings and got someone over to recover the R132a and drain it down. Tomorrow I finish the mess.
2005 S60 2.5T AWD
IPD mods:
IPD HD PVC intercooler coupler/upper, HD Subframe poly inserts
ProPartsSweden HD top mount square mount, PPS lower torque rod & control arms.

User avatar
abscate
MVS Moderator
Posts: 20035
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
Location: NYC, ALBANY NY
Has thanked: 273 times
Been thanked: 852 times
Trinidad & Tobago
abscate

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by abscate » Sat Feb 06, 2016 6:34 pm

My local Jiffy will recover AC charge for free, and I have the pump and manifold to recharge myself. It's paid fir itself about 3x now
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
Link to Maintenance record thread
Link To Volvo Glossary

MarcM
Posts: 183
Joined: Wed Sep 23, 2015 6:52 pm
Year and Model: 2005 S60 2.5T AWD
Location: Monadnock Region, New Hampshire
Has thanked: 1 time
Been thanked: 3 times
United States of America
MarcM

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by MarcM » Sun Feb 07, 2016 10:09 am

Good times. Finally got the condenser free. It's been slammed with stones on the bottom half and full of little pieces of sand (Image taken upside down). Just going to replace it. Luckily mine uses the cheaper one.
The original radiator was the Premair from Valeo. Putting in a Behr that is straight aluminum. I did notice that the hose necks on the Valeo one have metal inserts on the inside of the necks, reinforcing them. My 1 day job is now going into a week having to wait for parts. Ugh.
Anyone know the part # of the 4 long bolts that sandwich everything together (pic below)? Threads are 6mm x 1 pitch. Unit was missing the top one on the driver side. Can't locate them in Volvo's online parts diagrams and the condenser didn't have the threaded clip.
IMG_20160207_115840823[1]Condenser.jpg
IMG_20160207_115939656[1]bolt.jpg
You do not have the required permissions to view the files attached to this post.
2005 S60 2.5T AWD
IPD mods:
IPD HD PVC intercooler coupler/upper, HD Subframe poly inserts
ProPartsSweden HD top mount square mount, PPS lower torque rod & control arms.

User avatar
abscate
MVS Moderator
Posts: 20035
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
Location: NYC, ALBANY NY
Has thanked: 273 times
Been thanked: 852 times
Trinidad & Tobago
abscate

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by abscate » Sun Feb 07, 2016 3:22 pm

Just replace with a stainless steel M6x1 bolt of the right length. If you can't find it, buy one a bit too long, spin a nut onto it, cut off the excess length with a hacksaw (thanking yourself for buying stainless) and then spin the nut off to chase the threads straight.
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
Link to Maintenance record thread
Link To Volvo Glossary

MarcM
Posts: 183
Joined: Wed Sep 23, 2015 6:52 pm
Year and Model: 2005 S60 2.5T AWD
Location: Monadnock Region, New Hampshire
Has thanked: 1 time
Been thanked: 3 times
United States of America
MarcM

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by MarcM » Sun Feb 07, 2016 4:44 pm

My issue is that the Behr radiator is now junk. The taper where the bottom of the cooling fan slides into is incorrect. The stock one starts thick and steps down to a smaller slot. The Behr one has the thin slot all the way up. Broke the tabs right off.

What the tabs are SUPPOSED to look like:
open-uri20141023-6157-1vgnqne.jpg
(Yes, I stole FCP's image)

Awaiting return decision and buying the Volvo one mid-week. The Behr one has ANOTHER bad molding at the bottom mounting slot by lower radiator hose. It's WAY too narrow to get the 6mm bolt through.... more like 4mm. Used a collett and a drill bit to ream it out. Seriously considering dumping the car and going back to Dodge / Hondas / GM. Withholding substantial trucker talk over this, out of my mind PO'd.
You do not have the required permissions to view the files attached to this post.
2005 S60 2.5T AWD
IPD mods:
IPD HD PVC intercooler coupler/upper, HD Subframe poly inserts
ProPartsSweden HD top mount square mount, PPS lower torque rod & control arms.

User avatar
abscate
MVS Moderator
Posts: 20035
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
Location: NYC, ALBANY NY
Has thanked: 273 times
Been thanked: 852 times
Trinidad & Tobago
abscate

Re: 2005 S60 2.5T AWD: Radiator replacement

Post by abscate » Mon Feb 08, 2016 4:22 am

I'm hearing the Behr part is a no-go? That's important to know.

An Alldata subscription for your car is about 15 bucks or 5 years for 30 bucks. It's about 90% of VIDA
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
Link to Maintenance record thread
Link To Volvo Glossary

Post Reply
  • Similar Topics
    Replies
    Views
    Last post