Saving Kiloran's 940

[kiloran]

Tracked down the ABS issue - the fuse on top of the surge protector is really loose in the holder, which probably explains why it comes and goes whilst driving. A bump is going to be enough to jiggle it, and eventually it will jiggle enough to lose contact. Such an odd design - rather than fitting snug in a conventional fuse holder it's effective pushed down on top of the relay with the red plastic cover. Time to deploy some electricians tape I think.

[360beast]

Great news! Electrical tape is very useful for these little issues.

[Laird Scooby]

Originally Posted by kiloran

Tracked down the ABS issue - the fuse on top of the surge protector is really loose in the holder, which probably explains why it comes and goes whilst driving. A bump is going to be enough to jiggle it, and eventually it will jiggle enough to lose contact. Such an odd design - rather than fitting snug in a conventional fuse holder it's effective pushed down on top of the relay with the red plastic cover. Time to deploy some electricians tape I think.

Slide the ABS relay up the ABS ECU bracket so you can drop it down and get access to the fuse connectors. Squeeze them gently with a pair of pliers to tighten the contacts and then refit the fuse - no insulting tape needs be harmed!

[stephend]

Originally Posted by Laird Scooby

insulting tape

PMSL!! "Your fuse box was a hamster and your wiring smelled of elderberries!"

[kiloran]

Well, shakedowns never go entirely to plan do they - which is why we have shakedowns.

Popped out yesterday morning to a pool of coolant on the drive. "Oh bother, what now?" was a close approximation of my response.

Now, it had been fine all the way back from Luke's via Bristol and sitting in traffic for a couple of hours. Initially I couldn't find where it was coming from but then the leak got much, much worse. As in a stream of coolant ****ing off the back of the engine.

All fine on the exhaust side, no leaks from rad or expansion tank. Heater hoses dry on the bulkhead. Heater working. Puzzling. So it was time to dig out the phone camera and try and track it down.

Exhibit A:

PXL_20211114_151805079.jpg

Now, initially I thought that this was HG - as did Luke. But on further inspection Luke spotted moisture right at the top of the photo above the HG, and as the car is sitting on its wheels rather than its roof and gravity exists this actually points to the heater outlet union or hose being the culprit.

So now it's hopefully just a question of ordering the right hose and fitting it. And replacing the lost coolant with the right stuff in the right mix. Phew!

Looks like this is the hose required:

https://www.partsmonster.co.uk/genui...13-24719-p.asp

Volvo p/no 3507413 - note that it says this is for 740/940 92-95 only though. Access looks tight and here's hoping it's the hose rather than the union. At least I have a spare block and head out of the car so I can practice working blind on it.

[kiloran]

Also should add that this is a huge benefit of the work Luke puts in to install a clean engine and ancillaries. It's made it really easy to track the leak down because moisture shows up immediately.

[360beast]

Naturally it couldn't possibly have happened when I was road testing it, it had to wait until it was back with you and full of nice new coolant!

[kiloran]

It's fine - all a good learning experience for the nipper! I got to explain what head gaskets do, why engines need oil and coolant, and teach the "water runs downhill" diagnostic skill.

Here's a pic of the offending beastie (dry, without the engine running because I really don't want to spray my phone with coolant)

Thanks for orienting the hose clamp so it's easy to access through the intake manifold.

PXL_20211114_150507388_2.jpg

[kiloran]

Hmm, not sure that p/no I quoted (3507413) is right.

I'm thinking that this is the right one - https://www.partsmonster.co.uk/volvo...hd-19032-p.asp

Volvo p/no 3514629. Thoughts? PartsMonster also list the following which is for the exhaust/water pump side of the engine - "connects the long metal pipe to the upper connection at the bulkhead"

https://www.partsmonster.co.uk/volvo...hd-14683-p.asp

I've had a look at D088 direct and they only make LHD ones. Been a while since I've messed around with silicone hoses and I've never worked with narrow bore ones like these hoses, if I just get a length of hose will I need bends, t-pieces and the like to run it cleanly without kinking it?

[kiloran]

Hmm. More parts weirdness. That hose is basically a flat S-bend, runs straight across the back of the engine, above the metal water pipe, to the lower heater inlet pipe. So it bears no resemblance to any of the parts catalog images I've seen.

Does anyone have access to the official Volvo UK catalog?

I know the hose is NLA from Volvo but the correct RHD, non-a/c, non-turbo p/no would be handy for future reference. It'll be the same as an RHD non-a/c non-turbo 740 I think.