PI-072 6/00 Dedicated to improving vehicle fun, safety & performance

ipd Heavy-Duty Radiator

Hose Connectors:
Old hoses get hard and transfer engine shake to the radiator. This can cause cracks in the soldering and joints, leading to premature failure.

Installation Instructions
Coolant Temperature Sensor Port:
For Volvos equipped with original equipment electric cooling fan. Install new switch provided here. If your car does not have an electric fan, youll still need to install switch to block this opening.

We recommend installing your new radiator with NEW HOSES.

Automatic Transmission Cooler Connections:

These are made of brass for optimal seal and a long, rust-free life. Dont worry if your car has a manual transmission. The cooling tube is sealed from the water and wont leak You dont need to cap them.

Reservoir Connection:
It may appear that the tube is not drilled through. What you see when you look in is the transmission cooler pipe.

Shroud Slots:
NOTE: Some solder may be left in the tanks, this is Plastic fan shroud has tabs that insert into a normal part of the manufacturing process. you may also these slots. notice what appears to be coolant or corrosion. This is residual leftover from pressure testing by the manufacturer. All components are acid etched before assembly for optimum solder adhesion. Brace and copper construction WILL NOT rust. The paint is for appearance only and is very thin to aid in heat rejection.

SUGGESTED TOOLS
Blade and Phillips screwdrivers Ratchet wrench Various metric sockets Open-ended wrenches 1/2 hose (3ft. long)

SAFETY WARNINGS

Anti-freeze is a dangerous chemical. Treat it with respect. It will often have a sweet smelling odor that may attract children and animals. It can be fatal if swallowed. Please take the time to properly contain and recycle your anti-freeze. Youll feel better and may avoid fines. Do not perform this job when the coolant is hot. Wait until you can hold you hand on the cam cover for at least 30 seconds (usually 30-60 minutes after shutdown). Be aware that removing the overflow reservoir cap on a hot or running engine may allow scalding hot coolant to violently gush out!

Attention
Please inspect your new radiator for any damage that may have occurred during shipment. If any damage is found, please contact your local UPS office to arrange for an inspection as soon as possible. We use UPS certified packaging so any damage from shipment is generally covered by the carrier, and they will contact us right away to arrange for a replacement to be shipped.

11744 NE Ainsworth Circle, Portland, OR 97220 (503) 257-7500 Fax (503) 257-7596

INSTALLATION
1
We recommend draining and flushing the entire cooling system when installing your new radiator to lessen the chance of contamination from the old system. Locate the drain valve at the rear of the engine on the passenger side. Attach a 3ft. long 1/2 i.d. hose to the drain valve and direct it into a catch pan beneath the car. Use a 12mm wrench too open valve (counter clockwise). About a gallon of coolant should drain from the block. move the pan under the lower radiator hose and remove the plastic belly pan so the coolant will drain directly into the pan. About a gallon will drain from the radiator and hoses. Remove the upper radiator hose from radiator and push a garden hose into it a few inches. Turn on the hose for about one minute and let it flush the block through the drain valve. When the water looks clear, stop flushing and tighten drain valve. After youve removed both radiator hoses, disconnect the expansion reservoir hose from the radiator. On automatic transmission models, carefully disconnect the transmission cooler lines. Use two wrenches to prevent the lines from being damaged. One wrench holds the brass adapter while the other loosens the fitting. Have a shop rag ready as a little fluid will drip. If your Volvo has an electric fan switch installed in the radiator tank, carefully remove wires from switch. Remove the two Phillips head screws at the top of the plastic fan shroud (engine side). Gently lift up on the shroud until the lower plastic tabs are loose. Move shroud back toward the engine and let it rest on the fan out of the way. Use a 10mm wrench or socket to remove the two upper radiator brackets. Gently lift radiator out of the car. Some automatic transmission models might have an extension adapter for the transmission lines, be sure to remove this from your old radiator and install it on your new radiator if this is the case with your car.

Carefully install your new radiator making sure it seats properly into the lower mounts. attach the upper mounts and the fan shroud. Make sure the lower shroud tabs engage the lower lip of the radiator. Install the lower hose, connect the transmission lines (auto transmission only) using two wrenches as described in step 3. Re-attach the reservoir hose and electric fan wires if equipped. Double check all connections before proceeding. If you old coolant is clean, re-use it. If not, Volvo recommends a 50/50 mix*. Fill the engine through the upper radiator hose as much as possible (did you close the drain valve?) Connect the hose and fill the system to the Max mark on the plastic reservoir. Start the car and run it for several minutes at different speeds. If necessary add more coolant to bring back to Max level. Recheck after 50 miles of driving.

2 Heavy Duty Radiator

1-800-444-6473