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Any tips to get lower oil line off the radiator?

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
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Re: Any tips to get lower oil line off the radiator?

Post by scot850 » Mon Mar 16, 2020 12:27 pm

You do not have to remove the AC radiator/intercooler. You do have to separate them and support the cooler so as to not break any lines.

To separate than you will need to access the bolts from the front of the car and they are fiddly to access, but you will need to remove the radiator mounts and tilt the radiator and AC cooler back to access them.

The 2 radiator mounting bolts are usually the biggest bitch as they will normally rust solid. Soaking with penetrating oil regularly for a few days is the ideal way to go because of the welded retaining nuts break off it is a challenge to then get the bolt out without shearing it and using 2 people, one below the car and one above

Before removing separating the radiator for the cooler, take pictures of the 2 rails attached to the side of the radiator, as everyone I have removed the rails have separated from the radiator. You can re-attach them as they are only held in place with double sided tape stupidly.
They have little pointed tangs usually on the radiator which I have used to bend through the rails and used metal glue to hold them all together for the future.

As for the thermostat, as mentioned they are now NA. So do not break it! If I recall the hardest part is removing the Torx screw holding the oil cooler pipes into the thermostat. Access is a little tricky as the bolt is between the 2 pipes. I think the thermostat is also held in place with Torx screws, but my recollection is dim as it has been a while. There is a 'rubber?' shaped seal between the thermostat and the engine which you will need to get from Volvo as not sure it is supplied aftermarket.

While you are in there and have the thermostat out, check where the 2 x cooler pipes to the radiator sit. Over time the 'moon' shaped plate that holds the pipes into the thermostat bends allowing them to pull out slightly and build up crusty oil in the pipe seats. This in turn will rip any new 'O' ring seals being installed as I found out. Also flatten the holding moon plate or re-verse it when you re-install.

The oil pipes are a pain as they have a hidden bolt and plate holding the 2 pipes to the front of the engine. This bolt is a pain to get to as you cannot see it. The bolt is tilted slightly downward if I recall. Re-install the pipes before re-fitting the radiator as you will have better visibility.

Hope this helps,

Neil.
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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Mon Mar 16, 2020 12:29 pm

Thanks guys!!!

I'll start hitting everything with PB Blaster.
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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Tue Mar 17, 2020 9:14 am

Fan is out.

Thanks to RobertDIY. LOL
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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Tue Mar 17, 2020 10:45 am

Radiator shelf thing circle nuts are broken and seized. [email protected] this thing!!!
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Re: Any tips to get lower oil line off the radiator?

Post by volvolugnut » Tue Mar 17, 2020 10:59 am

All plastic fasteners are sounding better. At least until it gets cold.
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2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Tue Mar 17, 2020 11:27 am

Off to buy a hack saw.
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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Tue Mar 17, 2020 12:46 pm

This was NOT fun...

Putting it back in is going to be worse...
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Re: Any tips to get lower oil line off the radiator?

Post by abscate » Tue Mar 17, 2020 2:47 pm

Yank that dipstick before you bump it with something and snap it off.

I have three headless ones to show for that trick.
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Re: Any tips to get lower oil line off the radiator?

Post by abscate » Tue Mar 17, 2020 2:49 pm

TheOtherside wrote:
Tue Mar 17, 2020 10:45 am
Radiator shelf thing circle nuts are broken and seized. [email protected] this thing!!!
Yeah, and you can't heat unless you are really careful not to melt/set afire the rad.

Go SS on those - even cheap Lowes SS will work
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Re: Any tips to get lower oil line off the radiator?

Post by TheOtherside » Tue Mar 17, 2020 3:08 pm

Haha. Thanks for the tips man!

Was the intercooler supposed to fall out also? Lol.
Last edited by TheOtherside on Tue Mar 17, 2020 3:09 pm, edited 1 time in total.
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