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I have not heard of this problem on 940s. Overheating is more of an issue in 240s, some due just to the thermal compensation board, some real.
I have switched over to the 75 kilopascal cap on the family fleet, the turbos, NA, the 1993 plus the 240. No problems. I believe that relates to about 11 PSI. I think Volvo Dad, if I have that name correct, one of the more experienced "Dads", had a brief and convincing argument for the lower pressure cap. Something like let the cap blow off the excess pressure rather than a cooling system component. And the system pressure should never exceed 7 PSI.
I have experienced a red line hot only once in the 1992 240 and it has a good thermal compensation board. 100F and going 25MPH could not cool the engine. Heater on and shortly after a faster speed corrected the overheating. No thermostat replacement yet.
Clean out the radiator fins, replace the thermostat, I think you use the hotter T stat. Now I question the condition of the radiator installed thermostat although I have not heard of failures but a carbon build up in the contacts due to the higher amp fan motor is possible, just not common.
Tom
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