1996 Volvo 960 Engine cooling Problems

“As of july 29, 2005, my 1996 Volvo 960 started losing speed and the engine stalls without warning! Thus far, no injuries have been sustained. The car has been taken off the road. On august 1, 2005, wbal-tv reported the same problems with 1999-2001 volvos. My car has always been maintained and up to now has been in excellent working condition. Please advise.”

“At 110k I noticed coolant level dropping faster than usual, and coolant on garage floor. Dealer removed side engine cover and showed me a line of pinhole leaks in the aluminum block. Technician said this was a manufacturing defect he had seen before, and that the engine would have to be replaced. Volvo offered no help, out of warranty. I purchased a used 1998 960 engine for $1900 and dealer installed for $1800, including incidental parts. Soon thereafter, radiator blew and ruined cylinder head. The 1 year used engine warranty covered cylinder head and I paid about $800 for new radiator. …”

“Thermostat was sticking, causing vehicle to overheat, when consumer got vehicle back, he had to take it back because the coolant cap and reservoir were not holding pressure. Radiator neck was broken. Ignition coils had hair line fractures. Inside door handle was loose and needed replaced. Brake pads and rotors were replaced. Battery failed.”

“Upon starting up vehicle engine would not start. A neighbor started yelling for her husband to get out of vehicle. Vehicle had caught on fire, and flames were coming from below the vehicle while engine attempted to start, even though the key was removed from ignition. No determination has been made as to cause of this fire. Insurance company was going to have vehicle removed. Area of fire origin was in the engine are, possible engine failure.”

“Consumer was traveling about 40mph on higway in rush hour traffic and engine check light came on dashboard panel. She pulled over to the shoulders. Vehicle started overheating. Dealership was aware of problem.”