960 24vBlock water leak

Discussion in 'Volvo 960' started by J.R.Alsop, May 30, 2005.

  1. J.R.Alsop

    J.R.Alsop Guest

    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.
    J.R.Alsop, May 30, 2005
  2. J.R.Alsop

    Bev A. Kupf Guest

    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
    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.

    Bev A. Kupf, May 30, 2005
  3. J.R.Alsop

    Mike F Guest


    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.)
    Mike F, May 30, 2005
  4. J.R.Alsop

    xntrick Guest

    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
    xntrick, May 30, 2005
  5. J.R.Alsop

    m-gineering Guest

    you might want to investigate cold repair: metalock, metalace, metal
    stitching, casting repair etc
    m-gineering, May 30, 2005
  6. J.R.Alsop

    Bev A. Kupf Guest

    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.

    Bev A. Kupf, May 30, 2005
  7. J.R.Alsop

    Tim.. Guest

    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.., May 30, 2005
  8. J.R.Alsop

    Tim.. Guest

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

    Tim.., May 30, 2005
  9. J.R.Alsop

    J.R.Alsop Guest

    Thanks for all your imputs, I will keep you informed of what the main dealer
    has to say tomorrow.
    J.R.Alsop, May 30, 2005
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