2005 S60 2.5T AWD: Radiator replacement

MarcM · Post by **MarcM** » 06 Feb 2016, 13:14

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 (

), 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.

Post by **phils94850** » 06 Feb 2016, 15:05

we all been there and learn from mistakes..

MarcM · Post by **MarcM** » 06 Feb 2016, 15:20

I publish them for others to learn.

Post by **abscate** » 06 Feb 2016, 17:00

It's listed as a 3 hour job on the V70 and indeed, AC evacuation and recharge is required for replacing the radiator

MarcM · Post by **MarcM** » 06 Feb 2016, 17:31

Pulled some strings and got someone over to recover the R132a and drain it down. Tomorrow I finish the mess.

Post by **abscate** » 06 Feb 2016, 18:34

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

MarcM · Post by **MarcM** » 07 Feb 2016, 10:09

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.

Post by **abscate** » 07 Feb 2016, 15:22

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.

MarcM · Post by **MarcM** » 07 Feb 2016, 16:44

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 (59.76 KiB) Viewed 4122 times

(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.

Post by **abscate** » 08 Feb 2016, 04:22

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