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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
chuckcintron
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Location: Upstate New York

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

Post by chuckcintron » Mon Sep 03, 2007 8:51 pm

VolvoEvapReplace.pdf
(2.1 MiB) Downloaded 739 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
Posts: 15
Joined: Fri Jul 14, 2006 1:33 pm
Year and Model:
Location: Novato, CA USA

Post by Ubergeek » Mon Sep 03, 2007 10:12 pm

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)

akitawagon
Posts: 169
Joined: Thu Mar 30, 2006 3:22 am
Year and Model: 1997 855 R
Location: San Francisco, CA

Post by akitawagon » Mon Sep 03, 2007 11:56 pm

Yes, a very thorough and useful writeup. Thanks!
1997 855R 120K
1995 855GTA 325K KIA...
1993 850GLTS 201K KIA...

egornygr
Posts: 15
Joined: Fri Aug 03, 2007 11:01 am
Year and Model:
Location: Troy, NY

Post by egornygr » Tue Sep 04, 2007 7:40 am

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)

chuckcintron
Posts: 478
Joined: Fri May 11, 2007 8:03 pm
Year and Model:
Location: Upstate New York

Post by chuckcintron » Wed Sep 05, 2007 4:48 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
MVS Moderator
Posts: 13274
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Post by MadeInJapan » Wed Sep 05, 2007 7:04 pm

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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Joined: Tue Jul 24, 2007 2:00 am
Year and Model: 760 Turbo
Location: Los Angeles, CA
United States of America

Post by volvoaddict007 » Thu Sep 06, 2007 10:01 pm

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
1990 5 speed 760 Turbo Wagon 310K.
( '91 940 turbo eng. + trans.)
Konis, diesel springs, 2.5" exhst., 850 T5 wheels

1993 300ZX 2+2, 171K

1999 Ford Windstar LX, 90K

anadem
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Joined: Wed Jul 26, 2006 9:07 pm
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Location: California

Post by anadem » Wed Oct 17, 2007 6:34 pm

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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Location:

Post by karageorge2 » Wed Oct 17, 2007 10:03 pm

: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 :!: :!: :!:

chuckcintron
Posts: 478
Joined: Fri May 11, 2007 8:03 pm
Year and Model:
Location: Upstate New York

Post by chuckcintron » Thu Oct 18, 2007 9:03 am

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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