How to Replace Radiator 2003-12 Volvo XC90

Hey, friends! It's Len, here at 1A Auto. Today, we're working on our 2004 Volvo XC90 all-wheel drive, and I'm going to be replacing the radiator. It's going to be a very simple job. I can do it, and you can do it too.

If you need this or any other part, you can always check us out at 1AAuto.com. Thanks.

Okay, so now what we're going to do, now that the hood is up, we're just going to open up this right here. This is your coolant reservoir. You want to make sure that your coolant is not hot. This vehicle has been sitting for a while, so I'm not worried about it. We'll set the cap aside, and we can move along.

Okay, so now that we're underneath the vehicle, what we're going to do is we're going to try to get this out of here so we can get to the radiator that's located right here. It's going to be very easy. We're going to use a 14 millimeter. We're going to take out this bolt, this bolt, there's one hiding up in here, and then the same thing for the other side of the vehicle. All 14s.

I've got my airgun. 14 millimeter. You can use a ratchet if you want.

Here's what my bolts look like. There's two long ones, and then the other four look the same. The two long ones were, of course, the two that were hiding. So, we'll set this stuff aside, and we can move along to the next step.

Okay, so I grabbed a rubber mallet just in case I need it, because what we need to do, these arms right here, they kind of have like a ... Almost like this that goes right up here. Okay? So, what we need to do is get this to go forward, and then come undone, and then come out. So, I'm just going to be using my rubber mallet. Just give it a couple bonks. Let me try to lift up.

Okay. Just getting it to move is the hard part here because of the way that these hooks are. There it is. Okay. Almost. Come on, baby.

There we are. We got this out of here. Let's move ahead to the next step.

Okay, so we've got our recycling receptacle here. It's ready to catch the coolant that's going to come out. Now what we need to do is drain the coolant. We're going to come right up here. We've got a little petcock area. We're going to turn this counterclockwise, that's to the left, with our 13 millimeter socket, and we should have coolant getting ready to come out of this.

Getting close here. Probably going to make a mess. Safety glasses, hand protection. Here we go. There we are. Cool. We'll just let this do its thing, and we'll move along.

So, now that we have the coolant drained, we're going to move along. We're going to take out this bolt right here, and this one right here. So, we'll grab our 10 millimeter. That's what our bolt looks like. This bolt right here just goes down through this plate and it goes in, and this shaft right here kind of goes into a slot on the radiator. It keeps it from moving around.

There's those two bolts. They're both the exact same. We can set these aside and move along.

So, now we're going to take the clamp off of the upper radiator hose to the radiator. To do that I'm going to use a seven millimeter socket and my quarter inch ratchet. If you think you can do it with a screwdriver, you can also try with a flat-head screwdriver.

With these clamps, you don't have to loosen them up all the way, to the point that they come apart. You just loosen them up enough so you can slide them up the hose a little bit, and you can get the hose off of the radiator.

That feels pretty loose. Let's grab the hose, give it a wiggle. There we are. There's our clamp. This one looks like it's reusable. If you don't think it is, then you'd want to replace it. This one looks decent. I'll set it aside. On to the next step.

Okay, so we're going to remove this 10 millimeter headed bolt, and this 10 millimeter headed bolt. That's going to make it so we can move this out of our way. Both are the exact same. We'll set these aside, and we'll reuse them later.

So, we'll grab this. Give it a little wiggle. It's just got this end right here, which slides into the box. The air comes up through here into your airbox, it goes through the air filter, and into the intake. We'll set this aside.

Okay, so now that we've got that out of the way, we're just going to come over here. We're going to take off whatever we can off of our fan shroud unit here. Let's get that unclipped. There's another clip down lower. That looks like it's a little harder to get to. Just going to use this forky tool, and it's going to essentially go around the clip, and then I'm going to pop it up.

There it is. Okay, that's loose. Get that out of the way.

We've got some wiring here. Looks like we're just going to grab right here, give it a squeeze, lift it straight up. We always take a look at our electrical connectors. Make sure there's no funny colors in there. Anything besides metal color is not so great, in which case you'd want to get a terminal cleaning kit. This one looks fine, so we'll just set that aside for now.

Now come across the top up here. Get this clip off of here. Keep coming across this clip. Should be able to get this under there. There we go.

This one. Come on. Oh, yeah! We are cruising!

This one. Yeah! Cool.

So, we've got this right here. We've got a little push-tab. We're going to squeeze it, separate these two. There we are. Take a look at our connector. Looks great. Looks great. Set this stuff aside.

Following this one down, it looks like it goes down and away. So, it's not connected to the radiator shroud at all. Or fan shroud, I should say.

Okay, so let's take a look at our new radiator here, and just go over what we're looking at in the vehicle. Since we can't see all this, we'll look at this.

You've got your upper radiator hose here, right? That's already off. You're going to have a mounting bolt up here, one right up here, and that's for your fan shroud. Once you take out those two bolts, the fan shroud just slides right into these hooks right here. There's one right there, and there's one located over there. So, essentially the fan shroud will just go up and out, and then it will be off of the radiator, once you take out the two bolts up top. You can't get to these because they're up and behind this thing. So, we'll get to those after we take out these bolts right here, which is what holds the radiator in. Okay? There's going to be a big bolt right here, and one over on this side. This area right here, a bolt is going to come through from the forward end. And this is very visible from down on the bottom, from the front of the vehicle. It's going to come through right here. And then this one right here, the bolt comes through from the inside of the engine compartment this way, and then screws into a Nutsert right over here. And it will be about the same on this side.

You've got your lower hose. You've got the other hoses right here that we're going to disconnect. You've got your little hooky-doo there for the fan shroud. That's right here. No, this one right here. Sorry. Right there. That's where the bolt is going to come through. And then this one right here has the bolt that comes through this way.

So, that's pretty much the basics of it. Just so you have an idea of what we're looking at inside the vehicle, which you can't really see very well. We'll set this aside, and we'll continue.

Okay, so now we're just going to spray down the lines. This area right here, where the line goes in. And then the same on the lower side. Just a little bit of penetrant goes a long way here. It's going to help us out down the line. We'll let that do its job, and we'll continue with ours.

So, I'm going to go for my 10 millimeter bolt. Get my tool on there. So, unscrewing it from right back here. There we are. Get my tool out of here.

There's our bolt. Very long. I'll probably clean this up before I go ahead and put it back in there. We'll set this aside. We'll do the other side of the vehicle. It's right down in here. It's the same thing: 10 millimeter. Bolt number two. Looks the same as the first, in exception of, well, it's just not rusted up. No big deal. We'll set this aside with the other one, and we can move along to the next step.

So, we've got our line that goes into the radiator. There's a little green clip here. The way these work is you squeeze the tabs. Something like that. And then you should be able to grab the line at the same time as those tabs being squeezed, wiggle, and pull at the same time, and it should want to slide out of the radiator. So, let's give that a try.

Get this stuff out of the way. Let's see about grabbing that. There we are. We'll set that aside. We'll do the same to the other hose.

All right, so I'm grabbing this lower hose here. I'm giving it a twist. It moves around fairly easily, so that's always nice. If it doesn't, just spray it again, and keep trying to wiggle it.

Put my flashlight down there. I'm going to squeeze those two green clips, or ears on the clip, and I'm going to try to pull this out. There we are. It came right out. A little bit of oil comes out; it goes right into our collection bucket there.

Okay, so we're going to take off this lower clamp right here. And that's for the lower radiator hose to the radiator. I'm just going to use my flat-head. I'm going to get this fairly loose. I don't want to keep going till the clamp comes completely apart. It's not about that. It's just getting it loose from the hose so I can move it, and I can get the hose off of the radiator. That's all I need to do.

There we are. Slide that up and out of the way. We know we've got plenty of room there. Let's go like this. We might have coolant coming out even though we drained it. You never really know. So, of course, hand protection, eye protection. Super important. And keep your mouth closed while you do this. There it is. Got that clamp off of there.

We're going to use a T27 to remove this bolt right here. That's what the tool looks like. It's a little star. Get that right up on there.

This is the bracket that holds this line still. Get that bolt out of there. We'll set it aside. Just give this thing a little wiggle. Okay.

So, now we have a 10 millimeter over here; we have another 10 millimeter over here; and then, of course, the ones over on the other side. So, let's grab a 10, and we'll continue.

Using my 10 up here. It doesn't give me very much room for a ratchet with a socket. If you have a ratcheting wrench, it might come in handy. Or even just a regular wrench, I guess. But that would take quite awhile probably.

So, this line right here, it's just in a little clamp that goes like this. The line comes up through. I'm going to try to pop that out of there. There we are. That's going to give us a little bit more room to get in here with our 10 millimeter. We're just going to continue till we get this bolt all the way out. This bolt is almost ready to come out. There we are.

So, we're actually going to take that bolt, and I'm just going to put it in a thread or two here. And that's just to hold this from moving around, so I can take the other bolt out on the other side there.

So, there's another 10 millimeter bolt here. The reason why I put the bolt in on the other side is just so this thing isn't flopping around. It makes this a little bit easier for me.

This bolt is out. Once we take this out, this is going to be able to flop down. This is going to be able to flop down, so watch your face. Make sure you're wearing your eye protection. Safety first is a number one concern here at 1A Auto.

Bolt number two. We'll let these down, nice and easy here. There we are. There's our two bolts. They're the exact same. We'll set these aside, and we'll continue.

Okay, so you've got this plastic thing right here on the passenger side of the radiator. Directly above it there's another 10 millimeter head bolt that holds your AC condenser to the radiator. I'm just going to remove that bolt using a 10 millimeter. There we go. Just get this bolt out of here. It should just slide right through. There's our bolt.

So, we've made our way over to the driver's side now. We're going to do the same thing: remove the 10 millimeter bolt that goes through the condenser.

You want to be careful for any dripping fluids. This side would have oil and coolant dripping down. So, wear your eye protection and your hand protection.

Get this bolt out of here. I'm assuming it should look like the first. Just wiggle stuff around.

All right, so here's the bolt from the left side. It looks the same as the passenger. So, we'll just set it aside with the other one.

So, we've got one bolt right here, and then one over on the driver's side. And those are going to be the last two bolts that are holding this radiator in. Aside from that, there might be a little bit of finagling that's going to go on to try to get the ears on the radiator to maneuver around other things.

So, I'm going to use my 12 millimeter socket. And I've just got it on an airgun, but you can use a ratchet if you need to. That's what our bolt looks like. We'll set this aside. Driver's side, same thing.

Okay, so everything is working its way down here. So, I'm going to leave this in. I'm going to grab something to support this real quick.

Okay, so I went and grabbed a pole jack here. You can use whatever you've got. But essentially, all I'm doing is applying very light pressure to the AC condenser over here and to the turbo intercooler. Literally no pressure. I'm not crushing it or anything. I'm just kind of holding it up so when I take out this last bolt for the radiator, the radiator is going to want to come down, and the intercooler and the AC condenser will want to stay up.

Going back to using my 12 millimeter here. Oops! Throw that there.

There's our bolt. It looks the exact same as the one on the passenger side. So, we'll put them together as a pair.

We're just going to wiggle it around. I'm going to drain out the rest of this coolant real quick into our recycling receptacle. We'll wait for that to finish up, and then we'll continue.

Okay, so here we go. I'm just going to continue wiggling this thing around. We're going to move this out of the way.

Okay. Oops! We've got some more coolant coming down. That's nice. That's special. You can think you have all the coolant out ...

Let me see if I can get this out of the way.

So, let's let this down a little bit here. That's going to give us a little bit of wiggle room for everything that's going to be happening here.

We're going to get our safety glasses on. Make sure we're safe. Safety is a number one concern here at 1A Auto. And we're just going to see if we can wiggle the radiator down past the inntercooler.

This relentless amount of coolant that's coming out of this!

Okay. All right.

So, now that we've got the radiator down a little bit, and the fan shroud, we can see up here we've got our hose. This is an overflow hose. It comes all the way up here and connects into your reservoir. So, we want to make sure that we have this separated, so when we lower the radiator down further it won't be hanging from this, essentially. And it can be easy to forget this because, while the radiator is mounted in, this is underneath this right here, and it's impossible to see and get to.

Okay. Pull that up like that. Work on it in my terms here, which is up where I'm comfortable. Slide that all the way up there, out of the way. Get my flashlight out of your way. I'm just going to twist the two hoses, separate them. There we are. Take a look at the hose. It doesn't look cracked. I'd say it's reusable. I'll set this aside, and put it right up where we can find it, and make sure that we put it back together. We've got the other end of the hose. That can just do whatever it wants to do.

All right, now what we're going to do ... We're going to remove this bolt right here, and then the other one on the other side of the fan shroud. All the way over here. And that's going to make it so we can lift the fan shroud up and away from the radiator, and get that out of the way.

So, we're just going to get our light over here. I've got my 10 millimeter.

Okay. There's our bolt. Nothing too special about it. We'll set it aside. Now we're going to do the same to this side over here.

So, we've got all of this stuff right here. Just try to push it out of your way. You don't want it to get caught on anything. Now we're just going to grab the fan shroud, and try to pull it up, maybe about half an inch to an inch. Slide it away.

On the bottom of the radiator, or the lower end of the radiator, you've got like these little hooky-doos that go like this, and then your fan shroud just goes ... Sits in there. Just like that, okay? So, it's kind of latched in down here, just by sitting there. And then up top is where those two bolts were that we just took out. Now that we took those out, we'll slide the radiator, I mean the fan shroud, up and then slide it away from the radiator. And then we can take it out of there and ...

So, we'll just lift it up. There we are.

If it's easier, you could try to go back underneath now. Because what we need to do is lift it up, and then also move it away from the radiator. There it is. That just slid down quite a bit. This side slid down quite a bit as well. Cool beans.

All right, let's go back underneath, and we'll get it out of there.

Okay, we're back underneath. As you can tell, the fan shroud is making its way down, like we were hoping that it would. There's a little catch on the radiator on this side. So, I'm just going to go like that, and I'm going to help the fan shroud come down by pressing the radiator towards the front of the vehicle, and pulling the cooling fan down.

We've got this hose holding us up. Okay.

There's our fan. We'll set this aside.

Here we go. So, we're going to come over here, grab onto our radiator again, and just try to finagle it out of here. We're going to do whatever we can to make magic happen.

We've got more coolant coming out of this thing. It's unbelievable how much coolant is coming out of it.

So, this up here ... If we can just get it to work its way ... What's holding it up is these hoses for the intercooler. And what I'm hoping to do, which is not going to happen, as I'm looking at it closer, is weasel it down past them. Past the hoses for the intercooler. So, what it looks like is we're going to have to take off the clamps for the hose for the intercooler. We'll just do one side, and take that off of there. We'll just have to make sure we have it cleaned up nice, and the clamp is nice and tight when we go to reconnect it, because that's going to be your boost pressure and everything going through there.

Okay, so we have our hose for our intercooler. It comes right over to here. Down here is the clamp that I was talking about. I'm just going to use a flat-head. I'll probably use a socket to tighten it back up, so I can make sure I have it nice and snug. I'm just going to loosen up this clamp. I'm not going to take it completely apart or anything.

Boy, this screwdriver is going to aggravate me!

You can use your socket. It's a seven millimeter. Just get it on there. Turn it to the left so it's nice and loose. You don't want to take it completely apart. It's kind of a pain in the butt to put back together once you get it all the way apart. We just want it loose enough that the hose can come off.

There shouldn't be any fluid in here. You might see a little bit of oil. Theoretically, it would be best if there was no fluid at all in there. If there was oil, you would have a problem with your turbo.

Get this socket off of here. Daggone thing!

Okay. Let's just get this off of here. All right, so that doesn't look too bad. Now, hopefully, I'll be able to take my radiator, pull it further over there.

Okay. Cooking now. Get this hose out here. Okay.

All right. Let's go back down bottom.

All right. I'm just going to keep on working this down here. More coolant is coming out, of course. There we are. Let's just get the rest of this coolant out of here. And there's our radiator.

Okay, so we're going to take off this clamp right here. This is a non-reusable clamp. So, we're just going to go ahead and use some cutters. Snip that off of there. Get my radiator to stay still. There we are. Get that clamp off of there. Pull our hose off. We'll set this aside, and we can move along.

So, here we are, friends. A quick product comparison for you.

Over here, we have our radiator out of our 2004 Volvo XC90 all-wheel drive version. We just took it out. It was not so simple, but whatever. Over here is our brand new quality 1A Auto part. Both of these parts are created equally. They've got the same shapes and dimensions, which is super important. You want to make sure you have the same width and length. All right? Want to also make sure you have the same connection ports. You've got your oil cooler line areas right here. These plastic things just pop right out of there. You've got your hooky-doos for your cooling fan right there. Up here is where we're going to mount those screws into. We've got the hardware that came with it as well. You've got your coolant hose area there, and a lower hose area here. Aside from that, you've got a couple of little ears here. Those are the mounting ears to hold it up to the body of the vehicle.

It's got everything you need to install into the vehicle. With all of that said, I don't see any reason why this wouldn't be a quality part to install into the vehicle. So, I'm going to go ahead and do it.

If you need this or any other part, you can always check us out at 1AAuto.com.

Thanks.

All right, so before we go ahead and install our brand new quality 1A Auto radiator, I just want to show you something on the original one.

You see how nasty and dirty this is? All these right here are little cooling fins where air is supposed be able to get rushed through. They're supposed to cool down the engine coolant basically by letting air get blown through. It cools down all these little fins, which in turns cools down all these little tubes that run from this channel over to that channel, back and forth. All of these are supposed to let air go through. When they get all clogged up with dirt and debris, like this one is ... As you can tell, this one is really nasty. It limits the amount of air getting rushed through it, so it's going to limit the ability for your vehicle to be able to cool down the cooling system, which in turn is going to mean that your engine is going to run hotter. You'll probably get a little bit worse fuel economy.

If we turn this over, which would be the forward side of the radiator, you can tell it's even worse. This is just absolutely nasty. This radiator is hurting, for sure. And I think it's ready to be recycled at this point. So, I'm going to go ahead and install our brand new quality 1A Auto radiator. I just wanted to show you the difference on this: old to new.

So, we're going to take this off. This just slides. Easy-peasy. It's just a little rubber air damper. And we're going to put it onto our new radiator. We'll get this one out of the way.

Okay, so we're just going to take our rubber. We're going to go right along this lip right here. And essentially, it just rides right inside this groove. Okay? There really isn't anything to it. Not much to explain, so I'm not going to over-explain it. Just put it on there, and try to get it to stay.

Okay, so we've got our radiator. We're going to bring it up, and just try to weasel it all up in there. This is going to be interesting. Probably about as much fun as taking it out. So, prepare yourself. If you haven't eaten anything, have a little snack, and just take your time on it, because it's going to test you.

We've got wiring that's got to get out of the way.

As we're pushing up, you need to be careful not to grab onto these fins. If you happen to peen a couple of them over, it's really not a big, big deal. But I mean, if you go ahead and write some initials in there, you know, "I love Len", or whatever you're into, it's going to restrict airflow. So, I wouldn't do it on the radiator if you're going to do it. You can put it on your license plate.

I'm just going to see if I can get this up in here. I love it. I love the fight. There we are. Cool. All right. Cool. Just keep wiggling it and working it until it goes up to where you need it.

I'm going to leave that just like this for now. And then I'm going to grab my mounting bolts that go through the radiator and up. We'll get those started. We're not going to tighten them up yet.

We're going to grab our fan shroud. We're going to do the bolt side up. And then, of course, these areas right here, that's going to go into the hooks on the radiator once we get it up in there.

All right.

There we are. Okay. Cool.

So, there's that piece. That needs to go right down inside here. So, it's not completely set in there yet. So, I'm just going to kind of try to wiggle it around, and see if I can get it so it's lined up. It needs to be lined up on both sides to slide in right. So, this side just slid in, and this side has to be close at this point. There it is. That's in. We'll double-check this side. Yep, it's in. It feels good. Cool.

All right, let's bring the vehicle down. We're going to put in the mounting bolts for the top of the fan to the radiator, and then we'll go ahead and put this up.

Okay, so our brand new quality 1A Auto radiator came with some mounting hardware. This stuff isn't trash. You need this.

What we're going to do, we're going to bring it right over to the radiator. And on the ear, where the fan shroud connects onto ... Let's see if I can lift it up. Hopefully we can see it. There you are. Okay. See the ear right here? I'm going to take this piece, I'm going to slide it from the outside facing in. I'm also going to have this little nub facing towards the inside of this hole right here. So, it's flat on the fan mounting area.

So, it's going to go just like that. All right? We'll do the same over on the driver's side.

Okay, so now we're going to take our bolts. We have one that looks just like it for the driver's side as well. It's going to go right through the fan assembly there, and then into the little clip we just put in there. Let me get that started. Do the same thing to the driver's side.

Both of these are started in, so now we're just going to go ahead and snug these right up. I'm using my 10 millimeter. That's bottomed out. Just give it a teeny bit more, and off to the driver's side. Same thing: snug it, a teeny bit more, on to the next step. There we are. Bottomed, a teeny bit, get that off of there. Very nice.

Okay, so we remember taking this hose off the radiator. We removed the clamp. The clamp was a one time use only. So, I'm going to go with something as basic as this. We're going to use this. I'm just going to go right around the hose. Get it to approximately the same size. That's pretty great. We'll cut off some of the excess here. We're going to run this inside there, up along the top of the radiator. We're going to slide the hose right onto this little piton right there. Okay? There we are. Looks good. I'm just going to twist it so it's facing towards me. Slide it on there the best I can.

Now we want to make sure we get this as tight as possible without breaking the ear off the radiator. So, I'm just going to us these needle-nose pliers, or long-nose pliers, whatever you want to call them. Once I know I've got it tight, trim off the excess, and we'll continue by connecting the rest of that hose.

Okay, so we've got this. That's just going to go right on here. We'll grab our clamp. It's made its way all the way down over there. Bring it up here. We're going to get it settled back in, right to where it belonged. You can see where it was before. That's where I'm going to line it up with now.

So, I'm going to use this right here. Squeeze on my clamp. Watch your fingers, of course, because these clamps are spring clamps, and they like to snap on you. Give you a little pinch. That will wake you up for sure.

Looks like I can turn it a little bit. There we are. That looks pretty great. Very nice.

This is going to come right along here. It's going to sit inside this right here on your fan housing. You can see where the marks are on the hose. So, just slide it in there. This one, just slide it in. There we are. It can't go anywhere now. We can move along to the next step.

I've got my mounting bolts here. I'm just going to start lifting everything up, and try to get it up to where it's going to go. I'll actually grab my pole jack ... Well, let's try it by hand first real quick. Let's see if we can get it to play nice. And if not, we'll grab a jack of some sort. I'll probably grab my pole jack. But if you're working on the ground, which would be pretty much impossible for this job, you can just use whatever you've got. Maybe a regular jack, or something.

I need to get my bolt lined up with my hole there.

So, I'm just going to use my pole jack here. Slowly bring this up. If it feels like it's binding on anything, of course, I'll slow down. It feels like I've still got plenty to go here. So, I'm not worried about that. This is just going to make it easier for me to get my bolts up in there. Let the pole jack do all the hard work here. A little wiggle. Okay. It's getting a little stiffer now. So, we'll just figure out what's holding this up, because that looks like it's pretty close to wanting to go in. This needs to come down.

Okay, let's see. So, these two pieces stay exactly like that. We just need the radiator to be able to go up a little bit higher. There it is. Cool.

I'll just get the holes lined up. That feels pretty good. We'll grab the other bolt for the other side. Looks pretty good over here too. That's nice. There we are.

We'll get these up in there a little bit more. And we won't tighten them down yet, until we get everything else situated, and then we'll go about tightening everything up at once.

Okay, that one is still loose. But up there, this one ... Get my socket on there. Okay. Get this down. We'll just set this aside, and we can move along.

So, we've got these. They're just going to go down here now. We've got one for the passenger side, right there; and then one for the driver's side, all the way over on the other side.

So, the way that I'm putting these, you'll have the little piton coming out. That goes into the center area, and the flat edge is facing outward, where this is all going to connect into.

All right, so we've got those in there. Now we can start lining everything up, and get some bolts started. And then we'll start tightening everything up.

Okay, so we've got our bolt. I'm going to try to bring it through this hole, through the hole that's through here, and then into the nutted end that's on the AC condenser. You might have to wiggle everything around a little bit. Just see if we can get it to work for us.

All right, get that bolt started in good. We're just going to do the same to the other side, and then we'll snug them up.

All right, that's getting pretty snug here. There it is. It's bottomed out. Just give it a teeny bit more. That one is tight. We'll do the same to the driver's side.

Okay, that's snug. Just give it a teeny bit more. That's that. Let's move along to the next step.

We're going to go ahead and snug up this bolt right here. It's a 12 millimeter. Do the same to the passenger side. Tight. Let's move along.

All right, so we're just going to line this up. Make sure it lines up with the Nutserts there that we put in. Looks like if I line that one up this one is too far in, and vice versa. So, we're just going to try to get them lined up. If they don't line up, you can just use a screwdriver, give it a nice little bonk. Just push them a little bit so they're wherever they need to be to line up. And once you have these lined up, which it looks like they are pretty well, grab the power steering cooler here. This is going to go up as well. That goes on the outside. The hose is up inside the bumper there.

I've got one of my bolts. You can pick whichever side you want to start with. You do you, boo-boo. I'm just going to go with this one. Get that started. We're going to do the same to this side. There.

All right, now that we have both of those started, we can go ahead and snug them up. We're going to use our 10 millimeter. You can use a ratchet, or whatever you've got. But it's a 10 millimeter.

Okay, it's bottomed out. A teeny bit. On to the next side. Do the same thing over here. Okay, it's bottomed out. Just give it a little bit more. Both of those bolts are tight. We can move on to the next step.

So, now we're going to install this bolt right here. It's the Torx one. You're going to use your T27. It just goes right in the side of the radiator, right here, and holds these lines secure.

So, get that lined up. Start it in there. Use my T27. Okay, that's bottomed out. There we are. That's tight.

All right, so we're just going to clean up our oil cooler line here. We'll get it so these gaskets are nice and clean. There we are. It looks pretty good. Try to clean up this green locking clip here, just for good practice.

This line right here is going to go right inside this, which is right above where the lower hose goes into. Okay? It's going to be very easy. Bring it around, line it up with your hole, give it a little wiggle. Now what I'm doing is I'm trying to squeeze it and push it in, and I'm going to try to get it so that little ear of this is bottomed out against this end of the plastic, and these little clippy-doos are inside there.

There we are. Just to make sure I'm going to give it a little wiggle here. Now I'm going to give it a tug. Oh, yeah! Tight.

All right, so we've got this cooler line from up top now, just like the lower one. We're going to clean it off so it looks nice. Check the gaskets. Those still look great. The radiator has still got its little plug in it. I'm just going to take this, same as the lower part. Just going to work it in there. Give it a little wiggle. Make sure it's rotating nice. Give it a nice tug, make sure it's locked in there. Very nice.

We've got our electrical connector here. We've got our two locking ends. Just going to clip it in. It's going to go right here. We're going to take this one. It's going to go right up in here. It's kind of hiding. You might forget that it's there. We've got our electrical connectors. Bring this around, and put it there.

This right here, here, it's going to go right down there. You can see you've got the big widely separated prongs, and then the smaller ones. It's going to match up inside here. The smaller ones basically face towards the engine, and the bigger, wider separated ones are towards the front of the vehicle. This just tucks right in here, just like that. That's very nice.

We have our intercooler hose. Try to make sure we get any crud out that might have went inside the intercooler there. I'm just going to slide it right on.

We're going to snug up this clamp now. I'm using my seven millimeter socket on a quarter inch ratchet. And the reason why I'm using a socket and a ratchet over the screwdriver is just so I can get a better grip on this.

This doesn't give you much room to get in here. I'm going to try taking off that extension. Oh, yeah! Lenny likes.

Make sure that hose is on there as far as it can go, of course. You want to make sure you have great contact with the hose to the intercooler. Just double-check. It looks like if I could push it up like that ... Just like that.

Okay, it looks like it's definitely on there. I just want to make sure before I continue to tighten. It feels like it's getting snug. When I'm tightening, I'm only tightening with one finger here, just to make sure that I don't over-tighten. It's very easy to do with these clamps. And once you do, they're garbage.

That feels pretty good. Give my hose a little wiggle. That's going nowhere. The clamp is nice and tight. We can move ahead to the next step.

Okay, so we're going to grab our hose. We'll grab our hose clamp. We want to take a look and see which way is going to be the best way to put this clamp. So, when we get the hose on there, we'll be able to tighten it up. There's lots of different ways you can put it. Some of them are going to be worse than the original way Volvo had them on there. So, I'll probably just put it just like this, and I'll see if I can get my ratchet in there.

Just going to put this under here. Get this on there just like that. I'm just going to put it right up onto the hose. Put my hose onto the radiator. It should just work its way on. I like to wiggle it. There we are.

Just take a look. I need a light. All right, looks like it's all the way on, all the way around the neck of the radiator there. That's super important. You want to make sure that it's all the way on. We'll get our clamp, bring it on over. All right.

Once you get it so it's getting pretty snug and it's not wobbling around crazy, you just want to make sure that you have it parallel to the end of the hose. That looks pretty great. We'll continue snugging it up with our seven millimeter. Okay, it's bottomed out. Let's give it a teeny bit more. Tight. Give it a little wiggle. That feels great. Awesome.

All right, I'm just going to get my hose clamp started on here so it's close to where it needs to be. We'll bring our lower hose up. I'm going to get it onto the lower portion of the radiator there. It slides right on. All right. Just slide right over that.

Once again, you want to make sure it's flush. Make sure your hose is all the way up against the radiator, as far as it can go. And make sure, when you put your clamp on, you don't have it very close to the edge, and you also don't have it past the edge of the tubing that comes out of the radiator. That looks pretty good right about there. I'm just going to snug this right up. Tight.

Just putting a little bit of copper never-seize on there. It's going to help it come off down the line.

So, on the skid plate you've got these little pitons that come down into ... Right in between here. And so, this part right here sits up on the subframe area. Right up here. So, that piton is going to come up and then sit down into its groove right up along the top up there. So, if you're struggling, you're getting it over, but it's just not doing its thing, it's because that thing needs to slide down in right there.

All right, so let's get this up here. I'm going to go at an angle. I'm going to try to do one side at a time. Onto there, up over that. Bring this around. Up this way. Give that a little push. Bonk! There we are. Those little pitons came right down into the subframe, like what we wanted them to do. All of our bolt holes are lined up. Let's grab some bolts, and get it in.

All right, so we've got our bolts. We've got four of these, two of these. These two are the same. They're the same as those two over there. Just get those started in. Just going to start all of these in. We're not going to tighten anything down until they're all started.

I'm going to use a 14 with my extension, just so I can get up in here.

Now that they're all started, we'll go ahead and tighten them down.

All right, all six are tight. Easy-peasy.

All right, so we have our air dam. This is where the air gets pulled in, right up through here, into the airbox, filtered, metered, drawn into the engine, burnt. This is super important. You need to make sure you put it back in. There's a slot where this square connects into in the bottom of the box. Same place we took it out of. That's where it's going to go in. It slides right in, just like that.

Take your two bolts. Now that we have them both started, we'll go ahead and snug them up. There we are. Easy-peasy.

Okay, so when we're filling the coolant, generally speaking, you'd want to apply a vacuum. Add coolant that way, because that will make it so it draws coolant into all of the areas inside the cooling system. If you don't have access to a vacuum system to be able to fill the coolant, you're just going to have to slowly top it off. It's going to work its way in. Once it gets up so it looks like it's full, run the vehicle for a little bit. It's going to draw it down. Just keep adding. Make sure you're wearing safety glasses as you're doing it. Once it gets hot, anything can happen in there.

You're going to want to run it for a little while because it's going to burp out a lot of air through this system. There is the heater core, you've got all of your coolant hoses, you've got the inside of the engine, all sorts of areas where this coolant is going to need to go.

Once you get it so it's running, and it's burped out all its air, you just make sure it's at its topped-off level. Take your cap, screw it right on there, and down the road you go. Easy-peasy.

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