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I'm amazed that no one else on this forum can help this guy through some manner of response. I'm some years out on futzing with Turbos, intercoolers, oil coolers, and the sort of stupid setup of combining the transmission fluid and engine oil coolant in one. (Don't forget to change the coolant to protect the welds and other less noble metals from corrosive deterioration.
... soapbox ...
Why I drive manual transmission. Or, in Old Duke speak, from whom we should derive some manner of documented lexicon or dictionary, "three pedals". Yet what 940 with or without Turbos in North America are usually without.
Blackish water came out of ... ?
- radiator / automatic transmission fluid cooler
- engine oil cooler
With some oily residue, yes?
Use water under pressure for oil cooler leaks? Why?
The heat exchangers (coolant / transmission fluid, engine oil cooler, and possibly the intercooler) can all be tested, I guess at a radiator chop. Useing a hose with city water pressure without a seal at the ends is an inconclusive take on it.
It would have helped to have performed a compression or leakdown test of the cylinders.
A radiator shop (find an honest one) can pressure test these for you. I would consider maybe looking at the heater core for accumulated schmaltz, yet the 700-900-90 series dash so utterly sucks to get into, maybe not as bad as 240. Or leave it and let any hydrocarbons and oily residues peculate to the top of the expansion tank when you have it back together and running.
As you state earlier in this thread the engine oil is black, well, black would some out of the engine oil cooler. You'd need to use some manner of industrial cleanser. And blow out remaining water, if this is how you want to do it.
The heat exchangers (coolant / transmission fluid, engine oil cooler, and possibly the intercooler). It would have helped to have performed a compression or leakdown test of the cylinders. You indicate some manner of movement of the radiator supports. On this forum (use search) and also check here ...:
http://forums.turbobricks.com/
(You can search, yet posting requires an account.)
... so if left to rattle around, the rather brittle radiator and intercooler may flex in such ways as to lose seal. They can fracture. The coolant / radiator mix occurs in the radiator when the two separate chambers internally lose seal and mix.
However, the collected black hydrocarbon mix that coast the underside of the expansion tank seal suggests that this mixing of engine coolant / transmission fluid, and what may be very likely engine oil have been mixing for some time to coat it like that. That would appear to be engine combustion products coating the expansion tank cap.
I dunno. I'm not there. I'd scrape the coated bits and under sunlight with a magnifying lens have a close look. I can also smell the stuff and tell you what coats it. The sweet smell of the coolant, the phenolic odor of the transmission fluid, and the smell of old (I'll guess you use mineral dino oil, not synthetic, though that does not matter) engine oil in need of change some time ago.
With these items apart, I'd suggest you resolve what items have failed and whether they can be repaired or should be replaced.
Yet you've done this before, so you know the prep, parts, and assemble, and part and tools to torque, yes?
Have the heat exchangers tested for leaks and structural integrity. If at fault, either repair or replace as you wish or can.
Get new or bend and weld reinforcing steel matter to the radiator brackets. They suck and are weak. This is a known, so I've read, yet not too often.
Find machine shops through these resources in your area:
- https://www.brickboard.com/SHOPS/
- https://www.volvomechanics.com/
- http://www.cartalk.com/mechanics-files
On facebook, Try the Volvo 240 fan club for suggestions.
Again try http://forums.turbobricks.com/
No obvious signs of cylinder head seal loss and leaking there? Images may help of the cylinder head under side, the gasket, and the engine block top.
Does that help?
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