I got this 940 Regina a year ago and did some repairs/improvements. One was coolant level warning light. I have replaced the coolant bottle with the one equipped with floating device that I took from a junkyard along with the cap that came with it. Unfortunately the pressure relieve mechanism was stuck so the engine developed a small leak from head gasket between cylinder #1 and water pump. It is not spraying the coolant but rather it sweat down there. The compression in all cylinders is “by the book”. So what now? Is it more likely just head gasket replacement or did I messed up with cylinder head? For me it is kind of scary job.
One day I was watching “Wheeler Dealers” and the mechanic says to the other guy:”It could be the head gasket”, and the guy replies: “Don’t dare to swear in my presence”.
I feel kind of same about the job.
The car is 940 Regina 1994 with 300K km on it.

--
'91 740 turbo SW, '92 940 turbo, '94 940 Regina SW (PL)

DO NOT BELIEVE those turkeys on the 'whiner dealers', they love to impress the newbies with their amazing 'knowledge'. Replacing the head gasket on a B230 is just a piece of cake, really. Straightforward with very little chance to go wrong, if you follow instructions. I have done at least 8 head replacements and I am just a fellow BBer. Of course, it will pay for you to invest in some high quality tools. Snap-on is the best, but Craftsman from Sears will serve you well.
Follow the Bentley manual for the 240's or the FAQ for the 740, both have the same B230 red-block as your 940.
Buena Suerte!!
el Raidman

O.K. will get my hands dirty on this, there always has to be the first time.
My question is: if the head is not warped do I still have to send it to machine shop or just good cleaning will do?
--
'91 740 turbo SW, '92 940 turbo, '94 940 Regina SW (PL)

As noted, get a new rubber donut gasket for about $3 and re-install it above the water pump. Get a new coolant reservoir cap while you are at it. Your head gasket is probably fine.
--
See the 700/900 "FAQ" at the menu bar top screen left side.

It doesn't look like the water pump leak. See the pictures:

http://www.brickboard.com/GALLERY/index.htm?pix_type=TECHNICAL&

in the techical gallery.
--
'91 740 turbo SW, '92 940 turbo, '94 940 Regina SW (PL)

<< cylinder head? For me it is kind of scary job. >>

So there may be a head gasket job in your future. As others have remarked, it's not that hard. Find a spare weekend and order the parts ahead. If you work methodically and clean, you can complete the job. Print out the FAQs, get acquainted with the job and take pictures during disassembly. Many shops shun the job because it's more labor than parts. I've done two head gasket jobs on red blocks with simple hand tools. Remove the head, take it to a good machine shop for measurement and shave as the shop recommends. Re-install and complete job.

Chris in VT, '94 945 w/ 177K

The head gasket on my 1994 944T was doing this a year and a half ago.

...and another one here, where you can see that the water pump is in a distance. It is leaking between head and block.
--
'91 740 turbo SW, '92 940 turbo, '94 940 Regina SW (PL)

Yep, HG leaking. Mine has leaked at the same place(and about the same amount as yours) for the last 15,000 miles or so when my Heater control Valve crapped out and engine overheated. I have waited so long(procrastinated) that I am now going to wait for it to fail(or get worse).
Just curious how long it will remain status quo....resist the temptation to use stop leak crap, it just mucks things up!

<< a small leak from head gasket between cylinder #1 and water pump >>

The junction where the water pump meets the cylinder head will show coolant seepage when the rubber "donut" that seals the pump to the head starts to fail. That may be your problem. See FAQ about how to get a better seal at that joint when replacing the water pump.

Chris in VT, '94 945 w/ 177K