Volvo 940 radiator leaking - what are my options?

[Eyebrows123]

My Volvo 940 (Manual WITHOUT AC) has just sprung a leak on the side of the radiator plastic meets the metal. It's 25 years old, I guess that's probably the lifespan of these mixed material rads?

I wish I could solder it but you can't with these modern plastic things! So what are my options?

If I replace it with the same plastic and metal one, who makes a good one, are Nissen any good? I suppose I should see if Volvo themselves make them and if they're affordable?

Or should I upgrade it to the AC version which I believe is larger? If I do that, what else needs changing, I'm guessing top radiator hose but intercooler as well?

I see do88 make what looks like a nice all aluminium radiator, quite expensive but I do like the idea of getting rid of the plastic and having a larger radiator, it would future proof it as well when I get round to a larger turbo (although I'm sure the stock ones are fine).

What would you all suggest?

[capt jack]

Why not try some proprietary pour-in radiator sealant first? Our S70 was losing coolant from the rad core, and having just spent significantly on new tyres, brakes and shocks I didn't really want to start hauling out the radiator too.

That was three or four months ago, and a leak that would see the expansion tank empty in a day had remained totally fixed, with absolutely no loss of coolant since.

Cheers

Jack

[Eyebrows123]

Could do, didn't really want to bung up any other part of the system though or make it worse in the long run. I thought might as well sort it properly rather than delaying the inevitable, but maybe I'm just overthinking it?

[Noddy299]

Don't use leak sealers unless you are desperate. They may stop a leak but they also block water jackets, thermostats, hoses and anywhere else water goes. They are a good get you home fix if stranded but they are not designed for a long term fix. Its like putting a bucket under a leak and calling it fixed.

If you can afford to fix it properly, do that, unless you can afford to upgrade it in which case, do that. I can't help on price or performance unfortunately but I would say that putting a DO88 full cooling system on, chuck a new stat in, replace all pipework with silicone, flush through fully and fill with evans waterless coolant. That way you will hopefully never really have to worry about that system for a long time It is my eventual plan for the 940 minus the performance rad as I don't really care for the performance. I do however believe in investing in long term piece of mind and reliability.

[Eyebrows123]

I'd rather invest in long term with this otherwise knowing my luck the leak will spring much worse when I really don't need it to, this is my daily car so could do with it being sorted.

I can afford to fix it, but the top end radiators are pushing the budget, if it's worth it, i'll do it, if not I'd rather spend the money elsewhere on the car. Just know of stories of replacement plastic end radiators just bursting leaks and I kind of dislike them so would really rather an all aluminium one.

At which point, if I'm spending money to replace it, is it worth getting the larger size, or would that just lead to a load more large costs like larger intercooler etc?

[volvo always]

I would stick to the original size rad.

When I bought my 940 the rad hose stub was weeping a bit.

The top rad stub had cracked.

4 years ago fitted a Nissens make. Bought exact replacement. Fitted perfectly and no issues since. My 240 also had a Nissens rad.

Also installed a Nissens AC condenser. Again fitted perfectly.

Mine is an auto with AC.

James

[griston64]

Just fit a new Nissens rad for a hundred odd quid

[Noddy299]

If you get a stock radiator of high quality (without plastic if you think it will play on your mind) and silicone hoses, new jubilee clips. You will know youre safe for a while. If I was doing it I would spend my money on replacing things which could fail like the stat rather than a larger rad. Especially on a daily driver.

If you get to so much performance you need a larger radiator, you will already be many thousands deep so upgrading just the radiator alone won't hurt you so bad.

[martin calva]

Originally Posted by Eyebrows123

My Volvo 940 (Manual WITHOUT AC) has just sprung a leak on the side of the radiator plastic meets the metal. It's 25 years old, I guess that's probably the lifespan of these mixed material rads?

I wish I could solder it but you can't with these modern plastic things! So what are my options?

If I replace it with the same plastic and metal one, who makes a good one, are Nissen any good? I suppose I should see if Volvo themselves make them and if they're affordable?

Or should I upgrade it to the AC version which I believe is larger? If I do that, what else needs changing, I'm guessing top radiator hose but intercooler as well?

I see do88 make what looks like a nice all aluminium radiator, quite expensive but I do like the idea of getting rid of the plastic and having a larger radiator, it would future proof it as well when I get round to a larger turbo (although I'm sure the stock ones are fine).

What would you all suggest?

Twenty years is probably the lifetime for a Volvo radiator. I replaced the radiator in my 1998 V90 a couple of years ago on the basis that a faulty radiator can put engine coolant into the automatic gearbox which could well be terminal for the car. Once the radiator was out of the car, it was clear that, although it was not leaking, it was definitely corroded and looked very much due for replacement. I think my replacement for the V90 came from Skandix.

But it is possible to repair a 940 radiator. Years ago, I drove my 940 onto what appeared to be the grass verge by the side of a French country lane. In fact it was a ditch full of long grass and leading into a concrete culvert. So an aluminium wheel with a bent rim (corrected with some blows from a lump hammer), a bent track rod, and coolant leaking from the radiator, which had made contact with the concrete.

I removed the radiator and freed the plastic part at the side by opening the aluminium fingers that held it in place. After doing my best to straighten the aluminium, I got it all clean and dry and then coated the face liberally with silicone gasket sealant. Then I put the plastic part back in its place and bent the aluminium fingers back to hold it correctly.

A bit to my surprise, and my relief, there was no leakage of coolant. A couple of years later I bought a replacement radiator. Eventually, when I had the timing belt and water pump replaced by the local garage, I asked him to fit the new radiator at the same time.

The garage owner gave me the bill, which did not mention the replacement of the radiator. He said that they remove the radiator to replace the cam belt so the replacement of the old radiator by the new one was included in the price and involved no extra charge. That was in about 2009. The replacement radiator, which I think was Nissens, has given no problems.

Skandix list the radiator for manual transmission 940 at about 200€ but there are plenty of suppliers on Ebay offering 940 radiators for less than £100.

cheers
Martin