I have a 1993 Volvo 940 GL which has been running well until recently when all the sudden the cooling system just completely died. The mechanic replaced the radiator hoses, water pump and checked the heater valve (where the initial leak was located) and repaired the hose which connected the heater water valve with the rest of the system by cutting it back (but not replacing it). That hose was spraying water throughout the engine compartment.

When we finally had everything fixed, the connecting piece on the radiator snapped clean off. We were using the heat when this occurred.

I figured I needed a new radiator and that this issue was separate from the original, so I just ordered a new radiator and intend to install it myself.

However, now I am not so sure and fear that the whole system is over pressurized. I ordered a new expansion tank cap in case it was faulty. The tow truck driver said that maybe the coolant froze and weakened the plastic connector, and it had been extremely cold between -10° to -25° F overnight.

What is the likelihood that the problems I am experiencing are more profound? Is this a just a bad run of luck, or is there something else I need to be thinking about? Should I replace more hoses, or am I OK just installing the new radiator and pressure cap? The vehicle never overheats provided that there is coolant available, runs well. I’d think if there were a blockage, I’d have some other symptoms.