Removing the Old Radiator

• 1). Park your Volvo on a level surface. Set the heater control to MAX and shift the transmission to Neutral.
  
  
• 2). Open the hood. Wait for the engine to cool and disconnect the negative (black) battery cable with a wrench.
  
  
• 3). Raise the front of your Volvo with a floor jack and place a jack stand on each side for support. Apply the parking brake and block the rear wheels with chocks.
  
  
• 4). Remove the cap from the coolant reservoir tank and slide a large drain pan under the drain valve of the radiator, on the passenger's side. Install a vinyl hose on the drain valve. Aim the other end toward the drain pan and open the valve. Let the coolant drain completely and cover the drain pan to keep the coolant clean.
  
  
• 5). Unfasten the two bolts located on each side of the relay module holder, above the engine fan, with a ratchet and deep socket. Remove the air hoses from the air intake immediately in front of the relay module with a Phillips screwdriver and move the relay holder toward the engine.
  
  
• 6). Unfasten the four engine fan mounting bolts with a ratchet and deep socket. Unplug the fan's electrical connectors and pull the fan out of the engine compartment.
  
  
• 7). Detach the engine fan shroud with the ratchet and deep socket and disconnect the upper and lower radiator hoses, at the radiator, with a standard screwdriver.
  
  
• 8). Place a small catch pan under the cooler lines connected to the radiator. Disconnect the two lines from the radiator with a pair or retaining ring pliers. Immediately plug the lines with clean plastic sheets and rubber bands to keep dirt and grease from entering the system.
  
  
• 9). Unplug the sensor electrical connector on the upper driver's side of the radiator and unfasten the two upper radiator mounting bolts with a ratchet and deep socket.
  
  
• 10
  
  Unfasten the remaining mounting bolts and bracket bolts from the lower section of the unit, working from under the vehicle. Remove your Volvo 850 radiator through the bottom of the engine compartment.
  
  

Installing the New Radiator

• 1). Position the new radiator through the bottom of the engine compartment and ask an assistant to hold it firmly. Fasten the lower and bracket mounting bolts with the ratchet and deep socket.
  
  
• 2). Fasten the two upper radiator mounting bolts with the ratchet and deep socket and plug in the sensor electrical connector.
  
  
• 3). Connect the two cooler lines to the radiator with the retaining ring pliers.
  
  
• 4). Connect the lower and upper radiator hoses with the standard screwdriver and replace the engine fan shroud with the ratchet and deep socket.
  
  
• 5). Replace the engine fan with the ratchet and deep socket and plug in the fan's electrical connectors.
  
  
• 6). Reinstall the relay module and air hoses with the ratchet, deep socket and Phillips screwdriver.
  
  
• 7). Lower your Volvo off the jack stands and remove the chocks from behind the rear wheels.
  
  
• 8). Replace the coolant through the coolant reservoir tank using a small funnel, and connect the negative (black) battery cable with the wrench.
  
  
• 9). Start the engine and let it idle for 20 minutes so that it reaches operating temperature as the cooling system purges itself of air. Turn off the engine, tighten the coolant reservoir cap and check for coolant leaks at the radiator.