960 24vBlock water leak

After main dealer failed to find a water leak and them fitting new hoses and
thermostat housing I decided to look for it myself. 10mins. later I found
the leak, it is coming from a crack in the cylinder block about 1/2 way up
behind the exhaust manifold where there is some "light webs"in the "Ali"
casting, upon giving it a blast with the pressure wash I found two more!.
With the pressure cap loose and not using Sport mode it is not leaking. The
car has done 130k, main dealer serviced, not been treated unfairly,
has anyone any ideas, (please not radweld and sell) I would contemplate a
new or recon engine, but from where?.
The car is a K 93 plate.
Cheers

 

I haven't come across this, and it doesn't seem to be an experience of
many posters to this group; however, very early models of the B6304
reportedly had a porous block problem due to improper casting.

If you get a reconditioned engine, make sure it is a B6304F2 ('95 and
later).

I don't know about the UK, but in the US a used engine is between
$1200 - $3000, and there are several places that sell them.

Beverly

 

<snipped>

I've never seen this either, but from what I've heard there's no fix.
Welding up the cracks cause them to reappear right beside the weld.

--
Mike F.
Thornhill (near Toronto), Ont.

Replace tt with t (twice!) and remove parentheses to email me directly.
(But I check the newsgroup more often than this email address.)

 

Are you sure its cracks or what seem like cracks as a year ago my 940
was leaking like hell what seemed from the water pump but it was the
head gasgit ....when i saw the gasgit there was nothing left of the
corner part of it as it had been eaten away. Volvo say they sell a lot
of head gasgit kits for mine and i assume its a very close engine on
the 960.it took me a while to convince myself it was not the block as it
sure looked like it.

regards to all....Steve Beds UK voc 17953

 

you might want to investigate cold repair: metalock, metalace, metal
stitching, casting repair etc

 

960 and 940 have very different engines (in the US). The 940 has a
traditional red-block 4-cyl engine (B230 or B234), while the 960 was the
first Volvo to have one of the new modular engines (B6304). In the UK
market there was a 960 sold with a turbocharged B230, but it doesn't
appear the original poster has one of these.

Beverly

 

Sounds like it may have frozen at some point in the past through lack of
antifreeze? Or a bad casting?

Probably best cost effective therapy is a 2nd hand motor? Or if you cant
find a low enough mileage one- strip your existing and have it ally welded?

Both options probably carry the same risk..

Tim..

 

A 940 4 cylinder and 960 6 cylinder are completely a different motor. No
connection at all.

Tim..

 

Thanks for all your imputs, I will keep you informed of what the main dealer
has to say tomorrow.