Hi guys - our '94 945T (110k) overheated on my wife (six months pregnant!) last week on her way home from work. Thankfully, she was talking to her dad at the time and he told her to "pull over NOW!". When I got there to pick her up, the electric fan was running and the temp gauge was still pegged. I could see where the dirty coolant/water in the cooling system had spewed out of the fill bottle and spewed all over my clean engine compartment.

Anyway, as I didn't have any water tools, we went home and I loaded up our other 940 with five gallons of water - we only had about 5 miles to go to get home. Got back to the 945 and put about two gallons in. The car started up fine and seemed to have no issues - other than the 'check engine' light was on. There was no water in the oil, and the oil level was a tad low. Anyway, we made it home with her following me in the 940. As soon as we pulled in the driveway, I checked (by touch) the operating temp - by grabbing the upper/lower radiator hoses on both running 940s - and the wagon was definitely hotter. I then stuck a candy thermometer in both radiator fill bottles. The 940 was about 150 degrees - the 945 - somewhat higher. So I shut the cars off for the night.

The next morning, I got up before work and pulled the radiator on the 945T - and the thermostat housing. I had a working, original volvo thermostat to compare to the 'autozone' thermostat I had in my 945T - the one I thought was at fault. It seemed to me that the autozone piece - not more than 18 months old - was opening much later than the original volvo thermostat.

So I went ahead and bought an 'o'reilley's thermostat as a replacement, and installed it in the 945. I also washed out the backside of the intercooler with water/air - as I read about doing this in the 900/700 FAQ (thanks FAQ!) - and bolted everything back together. After adding coolant, I let the car idle in the driveway for about 20 minutes (95 degree Texas heat) with no problems. I also drove the car to church sunday (about 5 miles) and back with no loss of coolant. BTW - I pulled the positive on the battery for about 30 minutes - and that cleared the 'check engine' light indicator. Hope this was OK. I also changed the oil/filer as a precautionary measure.

MY QUESTION: I drove the car to work this morning. Left about 5:30 a.m. (80 degrees) and about 25 miles. Went to the gym. When I came out, the radiator fill bottle was empty. I put about 40 ounces of water in the fill bottle, and it brought it up to the minimum. I then drove on to work (another 10 miles through 45mph city streets and stoplights). When I pulled up in my parking lot, the level was sitting on 'max' on the fill bottle. And the coolant in the fill bottle seemed a bit 'active' - or bubbly. And it started to creep/spew out a tad when I loosened the fill cap. What do you guys think???

I'm thinking (hoping/praying! :) that all is well. I do have two gallons of water with me, but a 30 mile drive home tonight (100 degree temps). Let me also say that less than 12 months ago, I replaced EVERYTHING in the cooling system (other than the heater core). I mean all belts, hoses, water pump, radiator fill bottle and cap, heater hoses, heater control valve, turbo cooling/oil hoses. Everthing.

FINALLY - Funny, but I had planned on working on the 945T the weekend it crapped out. As I had noticed the coolant in the radiator fill bottle had developed into this hideous color of brownish yellow. I was just a few days too late I guess. I would've assumed the thermostat was faulty and had allowed the engine operating temp to rise lately, thus the discolored coolant. What do think this was a sign of?

And did I miss anything? I'd greatly appreciate your advice guys. Kind regards, Chris.