The Nissens radiators for the 940 (non-turbo) have a hole in the upper right corner for a sensor to run the electric fan. The hole is unthreaded and has only a short and relatively thin inner neck. In the later 940's with Bosch FI, there is no sensor and the original Volvo rads do not have a hole there (although you can see the mold marks where they would be). Nissens only has the one generic replacement rad for all base 940's. It also has plastic side tanks that have the fittings and holes (all-metal rads are no longer being produced).

There is apparently a friction fit bushing and plug available from Nissens as extra orderable items to fill this hole. You'd think they'd include these small items with the rad, but they don't. I don't know exactly what the bushing looks like, but apparently it's a very tight fit and can be rather difficult to install. Unfortunately for me, apparently there are none currently in stock in the Canadian supply chain. Even if I could find ones in the U.S. they would take up to a week or more to get here and the on-line prices get ridiculuous when you add shipping and brokerage fees. I want to get this car back on the road ASAP.

Anybody run into this and come up with a good solution?

One thought I saw was to use an expandable rubber stopper from a marine supply house -the kind where you tighten a center brass bolt to expand it, but I haven't seen one of the appropriate size.

Another thought I saw was to get a sensor and bushing out of a wrecked 740 or 940, but I'm not sure if the bushings are removable or re-usable.

The hole is too thin to thread even if I could find some kind of plastic or metal threaded plug at a plumbing supplier.

If I could find a snug fitting plastic plug I thought of using ABS cement to glue it in place. I'll be checking out local supply houses later today.

Of course, whatever plug I put in mustn't be able to blow out, especially if the rad pressure rose above normal due to a bad pressure cap or blocked hose. The results could be catastophic for the engine not to mention my blood pressure. There's also the issue of voiding the warranty with a DIY solution.

Thanks in advance.
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Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now