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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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Fun, wasn’t it?
I think the photos are great. Lots of new Volvo owners here that you just helped out. The fasteners you call hex is actually a torx head fastener. Want to have more fun? Bust out the tranny cooler located in the plastic side tank. It looks line a mini radiator.
Where can I find the heater control valve to replace?
There are two hoses connected to the heater core coming through the firewall, just left of the center of the car. Follow the two hoses and you will find the heater control valve with a vacuum hose to actuate the valve on one of them. Sketch the orientation of the valve for correct replacement. Because it is tight there I think it is harder than the radiator.
What is the correct thermostat PN from IPD (1995 940 nonturbo sedan)?
The correct part number is… the same part used on all 940s. Why is IPD having part problems?
What are the 3 prongs on the bottom left of my radiator screen?
I lost you there.
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?
I cannot stand working in a dirty engine compartment. Depending on how dirty it is you can do a spot touchup with your favorite cleaner, a paint brush and a low pressure warm or cold water spray. Some of the cars I have bought were so nasty, I carefully sprayed the bad spots with degreaser, other spots with simple green or 409 drove three miles to the high pressure wand type car wash and went medieval on it. I did cover the alternator, dist cap, injectors with plastic bags. Use a little common sense about what your spraying.
I’ll use the car wash wand before I work under the car, like exhaust system, pinion seal replacement, struts or other front end work.
Prior to a brake job, a day or two in advance, to get rid of the dust and road grime, I’ll spray a cleaner on the caliper area and the inside of the wheel and blast with a hose.
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You're right! Torx head fastener... For some reason "hex" was the first thing to come to mind.
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Heater control valve is 'behind' the engine close to the bulkhead. Look down between the brake booster and the intake manifold for a device inline in the heater hose, with a 5mm vacuum line going into it.
I can't believe IPD sent you the wrong stat, as they are all the same for all the B21/23/230 engines, just two or three different temperature ratings. But, I have never seen anything remotely like that middle thing they sent, for a Red Block. Your Kragen "Stant" is probably a repackaged Wahler or Calorstat. Your dealer will sell you a Wahler in the blue Volvo box for about what Kragen charged you.
The three "prongs" are pressure switches in your A/C system...they signal the compressor to turn on or off, tell the fan to run at high or low speed, etc.
I use Gunk engine degreaser, let it sit, then spray off with a pressure washer (or the sprayer at a DIY carwash. Protect electrical stuff when doing such.
--
Bob (son's 81-244GL B21F/M46, dtr's 83-244DL B23F/M46, my 94-944 B230FD and 89 745 (LT-1 V8); hobbycar 77 MGB, and a few old motorcycles)
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Just got thru putting in my new NIssens in my 740. The radiator was a piece of cake. The heater hoses were a pain in the butt. Lucky for me I have very small hands. Good luck
--
93' 240 Classic Wagon 220K & 92' 740 Wagon Regina/Rex 90K
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