The 1994 ones are pretty decent. Is this one with the 'new' bodyshape?
Problem areas:
- Not too hot on fuel economy and power for a 2.0L
- Sometimes electronics are a bit shoddy. Keep those contacts clean! Make sure all ground-points are OK.
- Coolant expansion tank/cap sometimes crack.
- Bulb-out detection can have a hair-trigger.. Make sure all bulbs are the right wattage too! It will signal a failed bulb if an incorrect wattage is used.
- Rear springs tend to sag pretty quickly. Volvo sells load-carrier additional springs which help.
- Struts for rear door can wear quickly, especially if spoiler is mounted on door. Volvo has higher-strength struts for rear doors with spoilers.
- Probably no problem on yours yet, but most engines need new front and rear seals when they get about 10 years old. Rear is especially labour-intensive on a FWD car (difficult to reach).
- Make sure timing belt has been changed at right times. Engine on these cars is an interference design, so broken belt == severely damaged engine!
- Seat cushion on front seat can get 'tired' and sag a bit.
- Check lower front suspension arm rubber bushings. If they crack you need a whole new arm (not replacable)
- Rust can develop underneath plastic covering under sides of car and in rear wheel arches. Keep an eye out.
- Handbrake cables can get stuck with dirt. May cause accelerated pad/disc wear on one rear wheel and/or bad handbrake 'grip'. Usually caused by disintegrating rubber boots at end of cable.
- Not enough tuning parts :-)
I'm not aware of any real major design flaws which cause problems. There are 2 1989 460's in my family. Both have done over 150K km's (one even with a ZF-autobox) and no real big problems, just wear-and-tear stuff (clutch, brakes, etc.) and regular maintenance.
Bye, Arno.
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