I need information regarding the radiator for a '93 940. there is a plug at the top of the radiator above the lower radiator hose. My 940 overheated and blew the plug out. Is there a replacement plug available anywhere or do I have to replace the entire radiator?

Dear MadDogKY,

Hope you're well. You do not need to replace the radiator. The plug is Volvo Part #1274052 (cost is about $1.50); the rubber bushing is #1378869 (cost about $3.50).

Your car may not have over-heated. The plug may simply have worked loose.

When this occurred, I replaced the plug and bushing. I used heavy brass wire to secure the plug.

To ease insertion of bushing and plug, lubricate both with dishwashing liquid. Insert the bushing into the radiator opening. Then, press the plug into the bushing. It will take a lot of finger power to do this. You may want to use a large water pump pliers to press the plug into place. Make sure that the teeth on the pliers do not damage the radiator.

Hope this helps.

Yours faithfully,

Spook

Thanks Spook. I will check on these parts tomorrow. If my local Volvo dealer does not have them I might try a radiator repair shop to see if they might have the needed parts.

Dear MadDogKY,

Hope you're well. You're welcome. A Volvo dealer should be able to get these "next day". Alternatively, a shop that supplies Nissens products should have these. Nissen A/S, a Danish outfit, made the factory-original radiators. A plug and bushing made by Nissens will work perfectly.

Hope this helps.

Yours faithfully,

Spook

Thanks Spook. I ordered the parts this morning from the local Volvo dealer. Cost is less than $6.00. I should have them tomorrow morning. Any special instructions for installing them. I figure it shouldn't take more than about 10 minutes to do the work.

Dear MadDogKY,

Hope you're well and glad to learn that a local Volvo dealer had the parts.

After the plug has been seated, I'd use some heavy brass wire to secure it. Loop the wire around a fin on the radiator (that closest to the front of the engine). Put the wire across the notch in the plug and then under the transmission fluid line. Bring the wire back up toward the fin, and twist three times, to close the loop. This wire will keep the plug from backing-out. I'd use brass wire, as it won't create corrosion, where it contacts the brass fitting, to which the transmission cooling line attaches.

Hope this helps.

Yours faithfully,

Spook

I got the parts installed yesterday with no problem. Instead of using brass wire I used tie wraps instead to hold the plug in place.

Dear MadDogKY,

Hope you're well. Glad to know new plug went in smoothly. Plastic cable ties will work: they do not present corrosion risk. I used brass wire, because it will not corrode and will not stretch much. I'd guess that cable ties won't stretch enough to allow the plug to come out. That's what count.

Thanks for posting back.

Yours faithfully,

Spook