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

chuckcintron · Post by **chuckcintron** » 03 Sep 2007, 20:51

VolvoEvapReplace.pdf: (2.1 MiB) Downloaded 5002 times

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 · Post by **Ubergeek** » 03 Sep 2007, 22:12

AWESOME writeup.

Post by **akitawagon** » 03 Sep 2007, 23:56

Yes, a very thorough and useful writeup. Thanks!

Post by **egornygr** » 04 Sep 2007, 07:40

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 · Post by **chuckcintron** » 05 Sep 2007, 16:48

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

Post by **MadeInJapan** » 05 Sep 2007, 19:04

Added to the repair database. Thanks, chuckcintron !

volvoaddict007 · Post by **volvoaddict007** » 06 Sep 2007, 22:01

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

Hmmm...

Terrifically thorough instructions... Thanks chuckcintron.

va007

anadem · Post by **anadem** » 17 Oct 2007, 18:34

Brilliant writeup. Thanks so much!

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

karageorge2 · Post by **karageorge2** » 17 Oct 2007, 22:03

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 · Post by **chuckcintron** » 18 Oct 2007, 09:03

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