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Hello,
My [1995 Volvo 940 non-turbo sedan] radiator broke last week and found the 700/900 FAQ - Cooling System most helpful! I performed an emergency patch. I initially called the dealer and they told me they would have to special order the part (~$400) and that the labor would be (~$300). Instead, I decided to save some money and do it myself. I ordered the following parts from IPD: - Nissen Radiator - 8601002 740/940 92-95($195)
- Heater Control Valve - 1259327 ($25)
- Thermostat ($10)
The Radiator Replacement Guide in the FAQ is nice, but since I am only an occasional weekend mechanic I was hoping for a bit more detail. I spent most of my time trying to figure out what size tools I would need (hoping I had all the tools I need). After completing the job, I inventoried what tools I used:- Hose clamps (7mm socket)
- ATF lines (15mm open wrench)
- Various screws (10mm & 12mm sockets)
- Straight slot screwdriver (flathead)
- Hex screwdriver
- Thermostat housing screws (10mm socket)
- Replacement coolant (about 2 gallons)
I couldn't figure out how to remove the radiator drain plug in the original Volvo radiator on the car, so I ended up pulling the lower hose to drain the coolant. After the coolant drained, I removed all the trim. Rather than disconnect the fan, I slid it out and set it behind the shroud leaning against the engine. I removed the shroud, disconnected all the lines and hoses from the radiator and just lifted it out.
Original Volvo radiator (The red caps were taken from the new replacement radiator to stop the ATF fluid from running all over the place):
Replacement Nissen aluminum radiator:
My original radiator didn't have a temperature sensor in the upper right corner. I had a hard time pushing in the plastic stopper and rubber gasket to plug the hole. I ended up using combination wrench to save my fingers/palm:
Just before replacing the Nissen, I took a hose and washed out my radiator screen (from the engine side). An amazing number of bees, dirt, and rocks came out.
What are the three connectors on the bottom left of my radiator screen?
After sliding the new radiator in place and putting back the fan and trim, I searched all over for something that looked like the heater control valve replacement I received, but I couldn't find it! Where exactly can I find it (next time I flush the coolant)? I decided to skip this for next time and move on to the thermostat.
The only hitch in the whole process was replacing the thermostat. After flushing the system, I popped out the old thermostat and went to put the new one sent by IPD (part 2G0158) and discovered that it wouldn't fit! I ended up going to Kragen to buy a Stant ($27 - part 29918) and gasket ($2 - part 810) so that I could finish the job! The left is the original thermostat, middle IPD 2G0158, right Stant 29918:
I did spend a little time wiping off all the dirt/dust from all the hoses, reservoirs, and even engine since most were wet anyway due to the flush. Some of the dirt was really caked in, any suggestions for cleaning those up?
Replaced the coolant (about 10 quarts) and ran the car. Found no leaks, yay! It was a relatively straightforward repair and felt very rewarding afterwards. The additional cost savings of doing it myself was a bonus too!
Question summary:
Where can I find the heater control valve to replace?
What is the correct thermostat PN from IPD (1995 940 nonturbo sedan)?
What are the 3 prongs on the bottom left of my radiator screen?
What is the best way to clean the grime under the hood? Can I just take a hose and spray indiscriminately? Maybe just cover the alternator and distributor cap?
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Radiator Replacement Project (with pictures) [900][1995]