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Here are a few tips for starters. I'm sure others will follow.
"Cooling fan doesn't kick on, even when it overheated it didn't turn on."
• Maybe a bad temp sensor/switch in right side radiator tank.
• Or bad Fan Control relay (down low in front of battery on '92 I think.
• Open fusible link (gray insulation) leading from Battery + terminal to Fan Control relay (my son had this on his '92 940).
"Unsure of radiator age, probably should be replaced, looks a bit beaten."
• Unfasten the 3 brackets that secure the fan assembly at the top. Pull it back so you can examine the back (motor) side of the radiator. Chances are the fins will be rotting away and/or clogged with crud.
"Tried getting the crankshaft pulley off, but my impact wrench doesn't fit. so I think I'll try and get my hands on the tool for doing it."
• If you can get your hands on 3 feet of clothesline, that's the tool that I and many others use. See THIS POST . To my knowledge, this is the only "trick" holding tool method that allows tightening the bolt to book spec of 44 lb ft, then an additional 60° angle tighten (B230), or 122 ft lbs. for B21/23.
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Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.
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