Hey everybody! New to the forum. I replaced the heater core in my 91 745 turbo last week, I guess you could say I'm a proper Volvo owner now lol. Here's some pictures that I took of the process.
Time to remove the core was 3.5 hours. Total time was probably around 12 hours over 3 days because I removed all of the carpets to pressure wash them.
Tools you will need:
7mm and 10mm 1/4 inch sockets
1/4 inch extensions
Universal joints
Socket wrench
10mm wrench
7mm ratcheting wrench (not necessary but very helpful)
Plastic pry bars (for interior pieces)
Philips and Torx drill bits.
Drill + small drill bit
Various screwdrivers
Sealant for heater core box
Hammer
Brass plumbing elbows
Flashlight
Small hands
Small phillips screw (For replacing the rivet)
4 cups of coffee
Cigarettes (optional)
First I bypassed the heater core with some brass plumbing pieces. (and disconnected the battery of course)
Then I took out the center console
Then the glove box
Then the ash tray and center storage/cig lighter assembly
Stereo and its housing (phillips screw deep in there)
Now you can remove the center side panels and the kick panels
Unclip the relay tray and move it to the side
Remove the heater control panel, make note of wiring and vacuum lines
Here's where the fun starts. Start removing ducting. Its a fairly strong plastic and can handle twisting and pulling.
Rear floor vents removed
Drill out the rivet on the distribution box and remove. Remove rest of floor ducting
Here's the heater core box. There's about 11 7mm bolts around it
Box is removed. Getting those bolts out took me about an hour
Closeup of heater core
Core is out yay
Old vs new. Idk why the company painted the new one silver. It's a Spectra brass/copper core ($70 on rock auto)
Time to remove the core was 3.5 hours. Total time was probably around 12 hours over 3 days because I removed all of the carpets to pressure wash them.
Tools you will need:
7mm and 10mm 1/4 inch sockets
1/4 inch extensions
Universal joints
Socket wrench
10mm wrench
7mm ratcheting wrench (not necessary but very helpful)
Plastic pry bars (for interior pieces)
Philips and Torx drill bits.
Drill + small drill bit
Various screwdrivers
Sealant for heater core box
Hammer
Brass plumbing elbows
Flashlight
Small hands
Small phillips screw (For replacing the rivet)
4 cups of coffee
Cigarettes (optional)
First I bypassed the heater core with some brass plumbing pieces. (and disconnected the battery of course)
Then I took out the center console
Then the glove box
Then the ash tray and center storage/cig lighter assembly
Stereo and its housing (phillips screw deep in there)
Now you can remove the center side panels and the kick panels
Unclip the relay tray and move it to the side
Remove the heater control panel, make note of wiring and vacuum lines
Here's where the fun starts. Start removing ducting. Its a fairly strong plastic and can handle twisting and pulling.
Rear floor vents removed
Drill out the rivet on the distribution box and remove. Remove rest of floor ducting
Here's the heater core box. There's about 11 7mm bolts around it
Box is removed. Getting those bolts out took me about an hour
Closeup of heater core
Core is out yay
Old vs new. Idk why the company painted the new one silver. It's a Spectra brass/copper core ($70 on rock auto)