Inserting radiator plug in 1998 V90

yav969 · Post by **yav969** » 24 Nov 2011, 13:10

The old plug leaked due to the grommet deteriorating. I purchased a new grommet and plug. I can't get the plug in. I assume the grommet goes in first. I've tried pushing, rotating and even hammering the plug in. Right now the plug is in the freezer. I hate to lubricate it with something that will hurt the rudder or get into the coolant. Has anyone done this? Have any tips?

Here is a link to the image:
http://a6.sphotos.ak.fbcdn.net/hphotos- ... 7772_n.jpg

I put the old one back and strapped it in so I can operate the car. It's a loose fit and it leaks slowly.

Post by **JDS60R** » 24 Nov 2011, 13:43

Any chance you can upload a picture?

I am not sure if you are referring to the drain plug, the upper side plug used to block of the sometimes not used sensor, or aplug for a trans or oil cooler line not being used.

Because you said "grommet" I am going to assume the plug on the top of the rad. Rubber plugs and grommets slip together better with lubricants that do not contain petroleum (ie dishwater soap "Dawn" or ru-glyde vegatble oil based rubber mounting lubricant).
Stay away from motor oil as that grommet may not be petroleum resistant. If you know that it is then vasoline etc will be fine.

yav969 · Post by **yav969** » 24 Nov 2011, 15:42

Yes , it is the white plug near the top. Has a rubber grommet and a (phenolic?) plug. I tried freezing the plug and lubing with dish soap. Still no go. It's possible this radiator is from another model as the Volvo parts guy said he had to look under a different model. Maybe it's the wrong size?

Post by **JDS60R** » 24 Nov 2011, 15:45

Anything is possible.

Are you installing the grommet first and then trying to insert the plug? We usually hear that the problem is keeping them in.

yav969 · Post by **yav969** » 24 Nov 2011, 16:05

Yes grommet first. Tried installing with the plug already in the grommet but that does not seem possible. Grommet fits nice. I just cannot get the plug in after.

Post by **JDS60R** » 24 Nov 2011, 17:14

I guess posting a pic might help get more ideas but it sounds like someone owes you the right plug.

You can always lathe/sand it down to the right size but in my experience its not worth the time to just get the right one.

yav969 · Post by **yav969** » 25 Nov 2011, 09:36

Thanks for all the help so far.
The old and new plug are the same size, neither will fit into the grommet once it is installed without more force that I have been willing to apply. The # on the grommet is:1378869 642 Fo 6857-11.
Here is a link to a pic of the new grommet and plug.

Post by **JDS60R** » 25 Nov 2011, 12:12

Does the small part of the plug fit?

yav969 · Post by **yav969** » 25 Nov 2011, 12:27

No. I am trying to insert it with the smaller diameter first. The other side (with the castling) is way too big.

Post by **JDS60R** » 25 Nov 2011, 14:26

Ok - just checking as I have had others with the issue of trying to insert the entire plug by mistake.

I'm sure the new plug will go in right.