96 850 GLT Nonturbo radiator replacement

Systek · Post by **Systek** » 05 Mar 2008, 11:09

OK, ive been looking around and can't seem to find any how to's on replacing the radiator. The repair database here doesnt include one and the downloadable volvo manual doesn't either. Can anyone help or will I be forced to buy a manual/wing it?

Post by **billofdurham** » 05 Mar 2008, 12:02

It's quite straightforward on the non-turbo.

Disconnect the battery negative lead. Radio code required.

Detach the air cleaner inlet duct and ECU module box air duct from the fan shroud.

Cars with Exhaust Gas Recirculation disconnect the two hoses at the EGR controller. Make a note of their locations.

Undo the bolts on each side that secure the fan shroud and relay carrier to the front body panel.

Lift up the relay carrier and disconnect the fan wiring connections. Lay the carrier to one side clear of the fan shroud.

Lift the shroud upwards to release the two lower locating pegs and lift the shroud and fan clear of the car.

Drain the cooling system.

Undo the retaining bolt each side, release the clips and remove the splash guard under the radiator.

Disconnect the top and bottom hoses from the radiator.

Undo the air conditioning condenser upper mounting bolt on each side. Secure the condenser to the upper body panel with string or wire to keep it in position then undo the two lower bolts.

On auto box models disconnect the fluid cooler lines from the side tank. There will be some fluid spillage. Plug or cap the lines to keep dirt out.

If an engine oil cooler is fitted undo the pipe unions from the side tank.
Plug or cap them.

Support the radiator, undo the lower mounting bolt on each side and lift the radiator out of the engine compartment.

Bill.

Systek · Post by **Systek** » 05 Mar 2008, 12:37

i was told it comes out the bottom alot easier, is that true? i am looking for the easiest way possible to replace. oh yeh, i have access to a lift and shop

Post by **billofdurham** » 05 Mar 2008, 15:42

On the turbo model it can only come out the bottom. On the non-turbo there is no reason for it to go that way. I took mine out through the top.

Bill.

Systek · Post by **Systek** » 06 Mar 2008, 14:28

billofdurham wrote:On the turbo model it can only come out the bottom. On the non-turbo there is no reason for it to go that way. I took mine out through the top.

Bill.

thanks bill, i appreciate the input!

Post by **akitawagon** » 06 Mar 2008, 18:01

Here's a link to the VS page for a radiator replacement (with pictures) that you can use with Bill's steps: http://volvospeed.com/Repair/Radiator850turbo.php

For my non-turbo 850, I removed the radiator from the top.

Systek · Post by **Systek** » 07 Mar 2008, 06:42

thanks for the link, printed in color and added to my favorites! After reviewing everything, I guess my last question is, are there any bleeder valves that need to be opened to ensure all the air is out of the system when i refill it the 50/50 mix?

Post by **billofdurham** » 07 Mar 2008, 11:07

No bleed valves.

Ensure the heater control is at its hottest setting.

Lower the car to ground level.

Pour new coolant through the expansion tank as it is the highest point in the system.

Pour it very slowly as air must escape through the expansion tank.

Occasionally massage the two large hoses whilst pouring to help move the air.

Bill.