I just entered the 240 world about three weeks ago with my first 240 purchase ​​​. Just as I was starting my big weekend project (heater blower motor replacement) I noticed coolant soaked into the carpet on the floor of the driver's side. I figured it would be easier to find the leak if everything was out for the blower motor. Once I got into the blower motor compartment, I stuck my finger down into the heater core base and it was dry and the core looks good. I found coolant spray near the coupling where the heater hoses enter the firewall. I pulled a hose off and examined it. It looks pretty good. The metal hose coupling looks pretty rusted and I'm guessing that's where the failure is, I guess it could be somewhere else but it's not obvious to me what else it could be. I thought I'd buy a new coupling and replace it, but I can't find new ones anywhere. Just a few really bad looking ones on eBay. BTW, this is a simple metal coupling with hose clamps, not the plastic snap on ones found on other models. See pic attached.

Any idea if these are available anywhere? If not, what should I do? Sand off the coupling to make it smooth? Fabricate my own coupling out of copper pipe or something?

Thanks!

Aaron

1992 Volvo 240 GL 200,000 miles. Glen Echo, MD

 

It looks like there is a deep rust spot near the end of the coupling. Can it be cleaned and brazed with filler? Can you double clamp it to create a seal further up the pipe as well as down by the pipe opening to retain the hose on it after brazing? Just throwing stuff out there. Heck, a good clean up and some J B Weld might fill that spot as long as it is not fully through the pipe.

 

"Spacer", part 461405, $12 at a volvo dealer supposedly available.
https://www.volvopartswebstore.com/p...57/461405.html

 

I never would have guessed that the part would be called a “spacer”. Thanks!

 

yah, sometimes I wonder, other times I'm sure. I got the PN and description from "VADIS" which is the old Volvo dealer parts catalog on CD. I got the picture by googling 'volvo ########' and landing on volvopartswebstore which is a genuine dealer who sells parts wholesale online.

afaik from the pics thats the two pipe stubs and the firewall plate they go through.

 

I understand you because I had the same situation, but with a home carpet.
I accidentally poured oil on the carpet, and it was a terrible stain. I spent more than two hours replacing a piece of carpet with a new one, but the seams were very uneven. I decided to find a company that can help me fix the carpet and come across https://www.dazzlingcarpetrepairs.com.au/.
They provide excellent services. I liked their service and the quality of work, and after two weeks, the carpet was like new. If you are also interested in their services, here is their number.

 

Hmm, fascinating segway--from a rusty Volvo heater pipe problem to a carpet repair company in Australia! Not sure how the two relate but what do I know.