Nana's 1995 960 Sedan, Regal Red Metallic 418-2

CSDentonTX · Post by **CSDentonTX** » 13 Feb 2020, 13:40

In January 2020: Replaced coolant overflow reservoir level sensor (did not turn off warning light)

Inspected under cover, to find oil leaking that appears to be leaking from oil fill cap. Replaced gasket to oil fill cap with IPD.

Replaced washer fluid cap with aftermarket from IPD.

Inspected engine mounts, found one appears squished and a little wire has come off that wraps around it. The other appears good at first glance, but as both are 25 years old, I'm thinking I'm going to replace them.

Found leak in fuel rail has come back.

To do list:
•patch fuel rail
•replace fuel injector o-rings
•motor mounts
•replace coolant overflow tank (hopefully that will make the light go off)
•replace antenna mast
•new oil dipstick
•replace struts
•figure out how to fix front passenger seat which is stuck in backmost position

CSDentonTX · Post by **CSDentonTX** » 24 Feb 2020, 11:16

Fuel rail end cap patched again with JB Weld on Feb 15. Appears to be holding.

CSDentonTX · Post by **CSDentonTX** » 28 Feb 2020, 11:25

Coolant expansion tank replaced last night with Meyle 9122997 from FPC Euro. This indeed fixed the light on the dash. Has added benefit that it is now more translucent, so I can see level more clearly. On the old one, the float is rattling around in there, but clearly wasn't doing its job.

Added to to-do list:
•Replace trunk lid shocks

CSDentonTX · Post by **CSDentonTX** » 28 Feb 2020, 12:07

Current to-do list:

•replace fuel injector o-rings (purchased)
•replace spark plugs
•replace trunk lid shocks
•motor mounts (purchased)
•replace antenna mast
•new oil dipstick (plastic broke where it holds onto the metal shaft, and who knows where the pieces went...into the oil pan?)
•replace struts
•figure out how to fix front passenger seat which is stuck in backmost position
•inspect and/or replace brake lines

Maybes
•replace knuckle bumper (9140490)
•replace thermostat (no current problems)

CSDentonTX · Post by **CSDentonTX** » 30 Mar 2020, 10:21

Done in March: Replaced dome light with used one from guy on Facebook. This proved easier than fixing the old one.
Attempted fix of door handle on driver side. This just didn't work. Need spring, and cannot see how to do this. Broke plastic screw access cover on door pull handle.

Replaced trunk lid shocks with Meyle from FCP Euro..

•replace fuel injector o-rings (purchased)
•replace spark plugs
•motor mounts (purchased)
•replace antenna mast
•new oil dipstick (plastic broke where it holds onto the metal shaft, and who knows where the pieces went...into the oil pan?)
•replace struts
•replace sway bar end links (purchased)
•figure out how to fix front passenger seat which is stuck in backmost position
•inspect and/or replace brake lines (purchased)
•re-attach plastic belly pan

Maybes
•replace knuckle bumper (9140490)
•replace thermostat (no current problems)

CSDentonTX · Post by **CSDentonTX** » 22 Apr 2020, 07:50

Done April 18, 2020:
Replaced dipstick.
Changed oil with Castrol full synthetic 5w40 and Mann filter. Found washer and plug clearly aftermarket as washer was attached to plug somehow.
Earlier in the week reattached belly pan with bolts purchased from guy on Facebook. Found I could not attach back two because the nuts that are brazed on the crossmember seem to be missing.

Started to replace spark plugs only to find out that spark plug package from IPD was pretty much mangled in shipment (or before), and one of them had crushed electrode. Contacted IPD for a replacement. He said they have loose ones available and would mail me one.
Repaired fuel rail leak for third time in six months. Started to remove, but lost front bolt down in engine somewhere.

To-do:

•replace fuel injector o-rings (purchased)
•replace spark plugs (purchased)
•motor mounts (purchased)
•replace antenna mast
•replace struts (purchased)
•replace sway bar end links (purchased)
•figure out how to fix front passenger seat which is stuck in backmost position
•inspect and/or replace brake lines (purchased)

Maybes
•replace knuckle bumper (9140490)
•replace thermostat (no current problems)

CSDentonTX · Post by **CSDentonTX** » 25 Mar 2021, 07:52

So little done.

Spark plugs were indeed replaced after replacement came from IPDUSA.
Retractable antenna replaced. IPDUSA part 236166 Volvo.
Brake fluid flushed and brake lines replaced with braided steel TechnoFit 9157386SS and 1329594SS from FCPEuro.

To-do:

•replace knuckle bumpers (9140490) (on-order from IPDUSA)
•replace fuel injector o-rings (purchased)
•motor mounts (purchased)
•replace struts (purchased)
•replace sway bar end links (purchased)
•figure out how to fix front passenger seat which is stuck in backmost position

Post by **scot850** » 03 May 2021, 19:15

For your missing belly pan nuts, have you considered rivet nuts? You can drill holes to suit and get rivet nuts to match the size you need. They come in aluminum, steel and stainless and SAE and metric

Good luck! Always wanted a 960 Executive (Long wheel base sedan).

Neil.

CSDentonTX · Post by **CSDentonTX** » 19 Dec 2025, 09:56

Done:
•replace knuckle bumpers (9140490)
•replace fuel injector o-rings (purchased)
•replace fuel rail (bought on Facebook from MVS group, started removing, lost one bolt in the void, sat in garage for three years, took to mechanic to pay $65 for install).
•motor mounts
•replace struts
•replace sway bar end links

To do:
•figure out how to fix front passenger seat which is stuck in backmost position
•fix washer fluid light that is stuck on despite refilling fluid
•fix a/c. Mechanic says most likely clutch only issue.