Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



The evaporator is made of aluminum and consists of chambers which are separated by fins. The refrigerant flowing into the evaporator, expands, boils and absorbs heat from the surrounding air. As a result, water condenses on the fins and is drained off through a hose at the bottom of the evaporator housing.

200 Series

See Figure 1

  1. Following the instructions given above, remove the heater/air conditioning assembly from the vehicle.
  2.  
  3. Place the assembly on a cleared area and remove or disconnect the following:
    1. The upper hose from the heater core.
    2.  
    3. The air inlet rubber seal from the top of the housing.
    4.  
    5. The REC shutter clips from the left side.
    6.  
    7. The rubber seals from both defroster vents.
    8.  
    9. All clips from both the outer blower motor casings and remove the casings from the assembly.
    10.  

  4.  
  5. Remove the blower wheel locking clips from both sides and the blower wheels.
  6.  
  7. Remove the heater core drain hose, the vacuum tank assembly, the vacuum tank bracket screws from the left side, the REC shutter spring and the heater housing clips.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: A common air conditioning system evaporator-240 model shown; others are similar. Always reinstall the protective cover

  1. Remove or disconnect the blower motor screws, the heater control valve capillary tube from the attachment and the vacuum hoses from the T-joint.
  2.  
  3. Carefully separate the heater/air conditioning housing at the center seam.
  4.  
  5. Remove the blower motor, evaporator and the heater core assembly.
  6.  

To install:
  1. Install the heater core, the evaporator and the blower motor.
  2.  
  3. Using sealant, coat the heater/air conditioning housing halves and assemble the housings.
  4.  
  5. Install or connect the vacuum hoses to the T-joint and the heater control valve capillary tube.
  6.  
  7. Install the heater/air conditioning housing clips, the REC shutter spring, the vacuum tank bracket, the vacuum tank and the heater core drain hose.
  8.  
  9. Install the blower motor wheels and the blower motor wheel clips to both sides.
  10.  
  11. Install or connect the following items:
    1. The clips to both the outer blower motor casings and the assembly casings.
    2.  
    3. The rubber seals to both defroster vents.
    4.  
    5. The REC shutter clips to the left side.
    6.  
    7. The air inlet rubber seal to the top of the housing.
    8.  
    9. The upper hose from the heater core.
    10.  

  12.  
  13. Install the heater/air conditioning assembly into the vehicle.
  14.  
  15. Connect the evaporator lines to the evaporator, refill the cooling system and charge the air conditioning system.
  16.  
  17. Start the engine and check the system operation.
  18.  

740 and 760 Models With Climate Unit (CU) and Automatic Climate Control (ACC)

  1. Disconnect the negative battery cable and the throttle cable from the pulley. Safely discharge the refrigerant from the air conditioning system.
  2.  
  3. Disconnect, cap or plug the evaporator connections in the engine compartment.
  4.  
  5. Using 2 hose clamps, attach one to the water valve inlet hose and the other to the heater core inlet hose, pinching off the cooling system.
  6.  
  7. Disconnect the hose from the water valve.
  8.  
  9. Remove the lower panel from the left side of the dash. Remove the hose from the panel air vent.
  10.  
  11. At the control panel, move the selector to the FLOOR position.
  12.  
  13. Remove the following items:
    1. The accelerator pedal.
    2.  
    3. The ignition system control unit and bracket.
    4.  
    5. The cruise control connector (if equipped).
    6.  

  14.  
  15. Remove the evaporator cover and the evaporator.
  16.  
  17. Install the evaporator and the cover.
  18.  
  19. Install the water valve control cable clip, turn the valve to the left (counterclockwise), adjust the cable and install the clip. Connect the hoses to the water valve and the heater core.
  20.  
  21. Install the following items:
    1. The cruise control connector (if equipped).
    2.  
    3. The ignition system bracket and control unit.
    4.  
    5. The accelerator pedal.
    6.  

  22.  
  23. Connect the hose the panel vent below the dash and the lower panel.
  24.  
  25. Connect the throttle cable to the pulley.
  26.  
  27. Refill the cooling system and recharge the air conditioning system.
  28.  
  29. Start the vehicle, allow it to reach normal operating temperatures, check the system operation and for leaks.
  30.  

760 and 780 Models With Electronic Climate Control (ECC)
  1. Disconnect the negative battery cable.
  2.  
  3. Safely discharge the air conditioning system.
  4.  
  5. Disconnect the electrical connector and unscrew the receiver/drier from the wheel house.
  6.  
  7. Disconnect the electrical connectors from the firewall. Remove the cover plate and the foam rubber seal.
  8.  
  9. Remove the lower glove box panel and the glove box.
  10.  
  11. Disconnect the vacuum lines from the tank and remove the evaporator cover.
  12.  
  13. Carefully pull out the evaporator.
  14.  
  15. Carefully position the evaporator into the housing.
  16.  
  17. Install the evaporator cover and connect the vacuum lines to the tank.
  18.  
  19. Install the foam rubber seal and the cover plate at the firewall.
  20.  
  21. Connect the air conditioning lines and the vacuum lines.
  22.  
  23. Install and connect the receiver/drier at the wheel house.
  24.  
  25. Charge the air conditioning system.
  26.  
  27. Start the engine and check the operation of the air conditioning system.
  28.  

 
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