1991 Volvo 940

Introduction:

The 1991 Volvo 940 is a mid-size luxury sedan known for its safety, reliability, and comfort. It was available with a variety of engine and transmission options, including:

• Engine Options:
  • 2.3-liter inline-4, 114 hp, 125 lb-ft torque
  • 2.3-liter inline-4 turbocharged and intercooled, 162 hp, 184 lb-ft torque
  • 2.4-liter inline-6, 141 hp, 162 lb-ft torque
• Transmission Options:
  • M46 4-speed manual transmission
  • M90 5-speed manual transmission
  • AW30-43 4-speed automatic transmission

Engine

2.3-liter Inline-4

• Vacuum Leak:
  • Description/Symptoms: Engine runs rough or stalls at idle, check engine light may illuminate.
  • Solution: Replace or repair vacuum hoses.
  • Estimated Cost to Fix: $100 - $300
• Intake Manifold Gasket Failure:
  • Description/Symptoms: Coolant or oil leak from the intake manifold, engine may overheat.
  • Solution: Replace intake manifold gasket.
  • Estimated Cost to Fix: $300 - $500
• Valve Stem Seal Issues:
  • Description/Symptoms: Excessive oil consumption, exhaust smoke.
  • Solution: Replace valve stem seals.
  • Estimated Cost to Fix: $500 - $1,000

2.3-liter Inline-4 Turbocharged and Intercooled

• Turbocharger Failure:
  • Description/Symptoms: Loss of boost, reduced engine power.
  • Solution: Replace or rebuild turbocharger.
  • Estimated Cost to Fix: $1,000 - $2,000

2.4-liter Inline-6

• Head Gasket Failure:
  • Description/Symptoms: Coolant leak, overheating, loss of coolant, engine damage.
  • Solution: Replace head gasket.
  • Estimated Cost to Fix: $1,500 - $2,500

Transmission

M46 4-Speed Manual Transmission

• Gear Grinding:
  • Description/Symptoms: Difficulty shifting gears, grinding noise when shifting.
  • Solution: Replace worn or damaged gears.
  • Estimated Cost to Fix: $500 - $1,000

M90 5-Speed Manual Transmission

• Input Shaft Bearing Failure:
  • Description/Symptoms: Noise when depressing clutch pedal, difficulty shifting gears.
  • Solution: Replace input shaft bearing.
  • Estimated Cost to Fix: $1,000 - $1,500

AW30-43 4-Speed Automatic Transmission

• Solenoid Failure:
  • Description/Symptoms: Transmission slipping or refusing to shift gears.
  • Solution: Replace solenoid.
  • Estimated Cost to Fix: $500 - $1,000

Suspension

• Strut Mount Failure:
  • Description/Symptoms: Noises when driving over bumps, uneven tire wear.
  • Solution: Replace strut mounts.
  • Estimated Cost to Fix: $200 - $400
• Lower Control Arm Bushing Wear:
  • Description/Symptoms: Clunking or squeaking noises when turning or braking.
  • Solution: Replace bushings.
  • Estimated Cost to Fix: $100 - $200

Electrical

• Alternator Failure:
  • Description/Symptoms: Battery not charging, dimming lights.
  • Solution: Replace alternator.
  • Estimated Cost to Fix: $500 - $1,000
• Starter Motor Failure:
  • Description/Symptoms: Engine won’t start, clicking noise when trying to start.
  • Solution: Replace starter motor.
  • Estimated Cost to Fix: $300 - $600

Exterior

• No Issues Found

Interior

• Door Lock Actuator Failure:
  • Description/Symptoms: Door locks not functioning properly, difficulty locking or unlocking doors.
  • Solution: Replace door lock actuator.
  • Estimated Cost to Fix: $200 - $400

Recalls:

• NHTSA Recall 02V225: Fuel tank strap may fail, causing fuel to leak.
• NHTSA Recall 02V149: Front seat belts may not retract properly.
• NHTSA Recall 01V315: Headlamp switch may overheat, causing fire.

Summary:

The 1991 Volvo 940 is generally a reliable vehicle, but it does have some potential issues, particularly with the engine, transmission, and electrical system. The severity and cost of these issues can vary depending on the specific model and year, but many of the repairs can be made for a relatively low cost.