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

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.
1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70
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chuckcintron
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Volvo Evaporator Replacement: Step-by-Step guide with photos

Postby chuckcintron » Tue Sep 04, 2007 2:51 am

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
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Location: Novato, CA USA

Postby Ubergeek » Tue Sep 04, 2007 4:12 am

AWESOME writeup. :shock:
95 850 T5-R (yellow)

95 850 GLT Killed by the wife

98 V70R AWD replacement for above

97 850 GLT



(Hello, my name is Scott and I have a Volvo addiction)

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akitawagon
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Joined: Thu Mar 30, 2006 10:22 am
Year and Model: 1997 855 R
Location: San Francisco, CA

Postby akitawagon » Tue Sep 04, 2007 5:56 am

Yes, a very thorough and useful writeup. Thanks!
1997 855R 107K
1995 855GTA 281K
1993 850GLTS 201K KIA...

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egornygr
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Location: Troy, NY

Postby egornygr » Tue Sep 04, 2007 1:40 pm

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.
--Gregor



2000 V70 SE

1995 850 (RIP)

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chuckcintron
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Joined: Sat May 12, 2007 2:03 am
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Location: Upstate New York

Postby chuckcintron » Wed Sep 05, 2007 10:48 pm

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
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Joined: Thu Mar 31, 2005 2:14 pm
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
Flag: United States of America

Postby MadeInJapan » Thu Sep 06, 2007 1:04 am

Added to the repair database. Thanks, chuckcintron !
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

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volvoaddict007
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Year and Model: 850 Turbo 760 Turbo
Location: Los Angeles, CA

Postby volvoaddict007 » Fri Sep 07, 2007 4:01 am

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


Hmmm...



Terrifically thorough instructions... Thanks chuckcintron. :D


va007
'95 850 Turbo, Yellow Cream R clone, 205K

'90 760 Turbo Wagon 304K.
5 speed ( 940 turbo eng. + trans., fr. rotors)
Konis, diesel springs, 2.5" exhst., 850 T5 wheels

'93 300ZX 2+2, 147K

anadem
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Location: California

Postby anadem » Thu Oct 18, 2007 12:34 am

Brilliant writeup. Thanks so much!

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

karageorge2
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Postby karageorge2 » Thu Oct 18, 2007 4:03 am

:D awesome write-up :D .

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

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

thanks :!: :!: :!:

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chuckcintron
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Postby chuckcintron » Thu Oct 18, 2007 3:03 pm

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. :roll:

-Chuck


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