1994 940 Volvo, with 213,000 miles. I've owned this car since 1998. I have replaced, or had replaced, a ton of stuff. I am interested in maintaining a sort of "cross the country" standard of reliability, in other words, a state of maintenance that will allow me to take off tomorrow on a long trip with my 5 year old son and expect reliable passage to and from our destination.

To ensure this, what parts should be replaced? I am speaking mostly of parts that can fail with no warning and leave one stranded, not those that will fail slowly with warning, such as say, a water pump.

A few items on my car are still original, such as the coil, the alternator, the starter. Should these start the list?

What is your "Replace for Reliability" list?

Thanks.

1. Heater valve. No more than a seven year life.

2. If turbo, replace the two hoses to the oil cooler.

3. The radiator. I just replaced the original radiator in my 1994 944T (325,xxx miles). It cracked. Check all the hoses, replace as necessary.

4. If you haven't already installed a Coolant Loss warning light, do it. Check to make sure it works. I've repaired about five 1993-94 instrument clusters (broken foil track) which didn't power the Coolant Loss light.

5. Alternator. Mine is original (325,xxx miles), but the one on my wife's 1993 944T failed at about 200,000 miles. Nippondenso appears to have a better service life than Bosch.

6. Water pump.

7. Accesory belts. Carry a spare for the one which drives the water pump and alternator. You can keep driving if the power steering or AC belts fail.

8. Battery. Check the terminals for corrosion. Replace the cables if they are swollen near the battery terminals.
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john

My list: voltage regulator, expansion tank, heater valve.

I had to replace the brushes /voltage regulator in my alternator are about 300K miles. (1992 945T)

Check the condition of the coolant expansion tank. I had the bottom nipple break off at about 285K mile (1992 945T) resulting in a stranding loss of coolant incident. I replaced with an aftermarket part.

Lost a 1994 940 due to fracture of the heater valve at speed on I-81 leading to a very rapid head gasket failure.

I second the tip about the alternator - In our 740s, we had two alternators fail within a thousand miles of 215K - one had its brushes wear out, but the other seized up.

We got another 100K+ out of a used one with 110K on it.

If the alternator really is original, then I suggest changing it ASAP. It could fail without warning (I have had this happen). The alternator idiot light does not always give a heads up warning.

Be sure to do the gauge cluster solder repair too. The charging circuit goes through the gauge cluster. Also, I have added a voltmeter to both of my 94 940s to keep an eye on the power.

Battery age?

Replace any old coolant hoses with new genuine Volvo hoses. They can fail without warning. Radiator OK? Original? If so, consider changing it too.

Belts OK. Carry spares.

Exhaust solid? Exhaust holes can give warning... Or a rusted joint could just drop.

Keep back up ECUs in the car.

CPS original? If so, I'd consider swapping that. If it fails you will be dead in the water.

There are a few other relays that if they fail will stop the car (no ignition)... I have to look up my repair paperwork to check. I'd replace them or carry backups.

How old is the fuel filter?

Thanks, Mr. Nabisco. Yes,the main fuel pump and filter has been done, but not the in tank pump. Battery is recent, and I will shortly be renewing the cooling system. Exhaust is good on this California car.

Is the gauge cluster solder repair in the FAQ?

Also, what is the ECU and CPS? Thanks.

Gauge cluster repair info.

http://www.turbobricks.com/maint.php?content=art0031

ECU = Electronic Control Unit
CPS = Crank Position Sensor