thanks guys. I'll update later to see if it still overheats.

I've read that the KA likes to hold air pockets in the cooling system so that could be another problem, right?

 

Couldn't help you there. Volvo thermostats bleed air automatically. Refer to a Haynes manual or something to bleed air out of the cooling system.

 

There should be an aftermarket cap that'll bleed off extra air and the overflow tank should suck up any coolant that it needs to fill the pockets.
Most systems can use a small boost in pressure without worrying. It's standard practice on all the tuner cars I seen in Japan.

 

this crap is still happening. now I can smell the radiator fluid when it starts to overheat, it stays up near the max for about 30 seconds, then goes back down to the normal range. It's almost predictable when it goes up and down. I'm getting a higher pressure cap and flushing it ONCE AGAIN...
anyone else have suggestions?

 

get a new car...