Volvo Evaporator Replacement: Step-by-Step guide with photos

[chuckcintron]

In case anyone was wondering how I spent my Labor Day

Here's the documented results of the recent evaporator replacement I performed on my 1997 850GLT wagon. I went into the job intending to create this "how-to" guide, since almost everything I found out on the 'net was lacking in some aspect. I took around 50 photos, and netted them down to the ones that ended up in this PDF.

The repair took me about 12 hours to complete. I hope these instructions can help others...I have a feeling that most of these cars have already had the evap job done by now, but there may be some stragglers out there (like me) who can benefit from this.

Anyway...enjoy...and let me know what you think.

Click here for the evaporator replacement info

Peace,
Chuck

P.S. I went the PDF route because I figure that most people will need to print this and keep it nearby while doing the repair. It should print out looking a lot like a 'repair manual' style layout.

[Ubergeek]

AWESOME writeup.

[akitawagon]

Yes, a very thorough and useful writeup. Thanks!

[egornygr]

Great guide! I wish I had that last summer when I did the job.

FYI - I recall using many configurations/lengths of torx bits & also several brands of the plastic line disconnection tools as many broke trying to set that connection free.

[chuckcintron]

Thanks...yeah those plastic spring-lock separators will break if you use them for anything other than moving the circular spring away from the flange. It is tempting to try to use the tool to help pull the union apart, but that's when the cheap plastic tool will break.

-Chuck

[MadeInJapan]

Added to the repair database. Thanks, chuckcintron !

[volvoaddict007]

Volvo mechanic at the dealership told me they have this procedure down to about 3 hours !!!


Hmmm...



Terrifically thorough instructions... Thanks chuckcintron.


va007

[anadem]

Brilliant writeup. Thanks so much!

I'm about to do just the heater core, but having such detail will be a terrific help.

[karageorge2]

awesome write-up .

i think i'll just go mess mine up so i can fix it with with this write-up.

you definitely need to do a class on how to do write-ups.

thanks

[chuckcintron]

Wow, thanks everyone for the kind words! My only goal with this was to help someone else who may be facing the same repair. I spent a lot of time even convincing myself I should attempt it, so hopefully it helps someone get over that hurdle.

Yeah, funny thing...the repair took me around 12 hours (including handling the camera)....the write-up took another 10 hours.

-Chuck

[jtp]

Wow, I think there's a whole career in what you did called 'tech writing' or something like that. My evap is still original so I'll use this some day... thanks a ton.

[swm]

wow, amazing write up. while my skills would never get me through a project like that, i have much respect for your work in putting that how to together...great job.

[Baie215]

Wow awesome i like your work

[ShagVolvo]

Awesome writeup, I am chugging through it currently. I have a turbo 850 with apparently enhanced sound system. I found I needed to take the top of the dash first to pull the vacuum line off the turbo gauge; it looked all but impossible with the top still on (with my limited knowledge).

The insulation/padding is falling apart, especially on the duct connections and wrapped around wire bundles. Does nayone have any advise on replacing it? Any good generic roll or strips that can be used?

Take care.