1996 850 Turbo - Radiator Replacement adventure

seaninfla · Post by **seaninfla** » 19 Dec 2013, 11:25

Just completed a radiator replacement on my 96 850 Turbo.... a seemingly straight forward job that had it's challenges. I would never had been able to complete the job with out the helpful info I found in this forum, so thanks a lot for that! For the past couple of years I have been trying to do my own work on my car, not only to save money, but to make sure it gets done correctly...kinda. I don't tackle the big jobs like the timing belt...just too much for me & my skill level.

My adventure with the radiator replacement started when the mounting bolts that hold the radiator to the frame broke the bolts off the frame & both had to be cut, in tight space with limited tools. So be careful when removing these bolts...It appeared that the radiator was the original Volvo OEM radiator from 1996 and the bolts/nuts were very rusty...Is it possible that this was the original radiator?

Either way I replaced it with a genuine Volvo radiator that cost twice what the cheaper ones did, but I think it's crazy to replace it with something else when the other OEM one lasted so long. Anyway, I cut the bolts & replaced them and stumbled through the rest of the job. Attached the oil & tranny cooler lines, topped her up with Volvo coolant. A soon as I started the car, the oil cooler line mounting clip that I re-used blew off and spewed about 5 quarts of fresh Mobil 1 onto my driveway, a giant mess. After a trip to the dealership (on my bike) to get the $23 small clip, (could buy for $9 online, but time was an issue) I got it all fixed up & topped off with new Mobil 1. My lesson was when you do a job like this make sure to get the little things like clips, nuts & bolts..the video actually recommends replacing these clips, but said they can be re-used if need be and 3 of the 4 were no problem, but that 4th one was a big deal!

Just wanted to share my success story from the help provided here & say "Thanks!"

Post by **jblackburn** » 19 Dec 2013, 12:52

Most of em are still on the original rads (mine was).

I also broke the weld on one of the support nuts trying to tighten it back in.

Post by **xHeart** » 19 Dec 2013, 13:06

Good job!
I am on my third year with new Volvo radiator which I replaced with coaching from Justin. That was my first big job, soon it was PCV with Justin.
You will do fine with the timing-belt after this success.

Post by **scot850** » 19 Dec 2013, 23:22

When I replace my radiators, I have re-used the old clips, but use the advice I got on the forum and use zip-ties around the clips to ensure they aren't able to stretch open and come out like you found. Good job on tackling this challenge. It can be very addictive, be careful!

Neil.

Post by **phils94850** » 20 Dec 2013, 20:44

I kinda laughed when I read the part about riding the bike... ive worked on cars for over 20yrs and constantly get in a hurry and make a silly mistake like fill the oil back up without the drain plug installed... (huge mess) when you see the oil running down past your foot... weve all been there..

Post by **burnout8488** » 20 Dec 2013, 23:55

You did right by using a Volvo radiator. I have never heard of them prematurely failing, (yet) but you always can find someone that has had an issue with an aftermarket radiator leaking prematurely.

Worth every penny.

futureboycolin · Post by **futureboycolin** » 21 Dec 2013, 01:22

The first step in my Volvo maintenance jourrney was the radiator too! I used a Volvo radiator, an reused my clips as well. Fortunately for me they all stayed on tight.

You'll be fine doing the timing belt now! After the radiator I went on to do my front hubs, brakes, timing belt, PCV, I'm even starting to forget stuff that I've done myself! The latest job was rebuilding the cylinder head after a burnt valve, an replacing the head gasket and valve stem seals! If you'd asked me years ago if I thought I'd ever rebuild an engine, I would've told you that you were crazy. But there's no greater satisfaction than knowing you did it yourself and probably better than some hack job who won't even use OEM parts! I say go for the timing belt if you have the tools.

Neil's right though...it's super addictive! But with a resource like this, and some of the finest Volvo minds around, you can't go wrong.

Post by **xHeart** » 22 Dec 2013, 08:43

futureboycolin wrote: Neil's right though...it's super addictive!

I can't stop.
I say, things are falling apart before my eyes faster than i can fix.
Happy Holidays!

Post by **cuhfs** » 22 Dec 2013, 13:51

Cant get rad and condenser out. Any advise for the best way to "cut" with the tight space and recommended tools. Any tips before I start going crazy! Bolts are rusted and now nut broke and spins

Post by **xHeart** » 23 Dec 2013, 09:06

cuhfs wrote:Cant get rad and condenser out. Any advise for the best way to "cut" with the tight space and recommended tools. Any tips before I start going crazy! Bolts are rusted and now nut broke and spins

There is plenty of discussion on the use of penetrating oil such as PB Blaster, selective and careful use of propane torch to heat up the nut to loosen the threads.

It is likely that there are thread-locker application on bolts, probably Red. Use 1/2" breaker-bar to break the grip if you can. Dr. Lee reminds us of gentle and firm pressure when turning stuck bolt, turning and repeating clockwise and counter-clockwise to successfully draw it out.

It you must drill, use left-handed drill bit.

Use proper tools and socket size, don't get hurt please.