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Old 05-03-2017, 10:16 PM   #51
DET17
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Nice work Matt..... it will be quite awhile before I have ice cubes blowing out of the vents.
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Old 09-19-2017, 12:55 AM   #52
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Default '93 blower box into '85

I'm swapping a '93 blower box into my '85 and noticed that the upper blower outlet spacing is ~1.5" narrower on the '85 box, and there's a visible inward jog in the outlets. The lower blower outlets are about the same, or maybe the '85 is a tad wider than the '93 (or it may just be the slop in my boxes). The outer fan housing dimension seems to be the same on both.

'85 on left, '93 on right (click on image for full size):




How do folks make this fit properly? Trim the plastic ductwork somewhere? Swap the black blower housings? Just bend the ductwork as needed?

Thanks - Bob
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Old 09-19-2017, 02:09 AM   #53
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^Grab the 1991-93 heater vent duct assembly...

I'm soon to be doing the same swap on my 245Ti. Plan to use R12a instead of R134a, tho.

-J
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Old 09-19-2017, 06:44 AM   #54
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Quote:
Originally Posted by John242Ti View Post
^Grab the 1991-93 heater vent duct assembly...
Indeed. I pulled the entire vent ductwork system, from rooter to tooter......
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Old 09-19-2017, 06:50 AM   #55
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I fit the whole works from a '92 in my '79. Might use the slot for the AC evap for a cabin air filter...
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Old 09-19-2017, 11:37 PM   #56
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Thanks all, I rummaged around and found the missing center vent piece for the '93. Whew! I'd be really annoyed if I left something so simple behind at the salvage yard.



The main left/right dashboard duct assemblies, and the under seat ducts, seem the same between '85 and '93.
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Old 09-20-2017, 01:10 AM   #57
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I've done this swap so many times I lost count. Doing another one at the moment. Not sure if anyone mentioned it, but dont forget to get the right side firewall panel and when you get the bracket for the accumulator, make sure to get the foam wrap with it. There is no PN for that foam part and an accumulator wont fit without it. I'm sure you could rig something up but the foam looks better.

Gotta put a R134 decal on it too.....makes it colder.
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Old 09-20-2017, 11:49 PM   #58
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More pics (click on thumbnail for full size):


As mentioned before, the left/right dashboard duct assemblies, and the under seat ducts, seem the same between '85 and '93. If you're going to go to all the work to pull a blower box in a salvage yard, why not keep the spares that are ~10 years newer?

Last edited by bobxyz; 09-21-2017 at 11:10 PM.. Reason: added a couple pics
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Old 09-21-2017, 01:58 AM   #59
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Another thing, if the car is pre-'91, grab the 1991-93 integral reservoir PS pump with its lines, if you aren't going manual steering. On the 1985-90 240 non-turbo cars, it gets rid of the exxon valdez on the driver's inner fender. On the turbo cars and pre-'85 non-turbo cars, it replaces the old P-type Saginaw pump with one that's compatible with the rotary compressor.
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Old 09-21-2017, 08:05 AM   #60
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Also for what it's worth this is an excellent time to take all the vents and run them through your dishwasher, clean with soap and a brush, etc. All this time I thought I was enjoying "old volvo smell" when it was really just 35 years of accumulated dust, dirt, grime, and who knows what else...
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Old 09-21-2017, 01:35 PM   #61
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^Good idea. Especially if the car was formerly a smoker's car.
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Old 10-19-2017, 05:51 PM   #62
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...

Last edited by trapper240; 02-13-2019 at 03:42 AM..
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Old 09-06-2019, 10:41 PM   #63
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Default Mounting a 1993 AC Condenser in a 1985

I've been accumulating the parts to swap a '93 AC system into my '85 for several years and _finally_ have working AC!

I figure I'd update this post with more pics and info since this post seems to have the most details already. A few other good posts are:
- 15A's 92 vs 93 240 AC Brackets: http://www.forums.turbobricks.com/sh...d.php?t=348196
- Harlard's 240 AC Retrofit: https://forums.turbobricks.com/showthread.php?t=345488
- 240 AC Components with parts catalog diagrams: http://forums.turbobricks.com/showthread.php?t=322912

Here's briefly what I did to mount the '93 condenser into my '85. Click pics for full size.

1) Opening for condenser (oil cooler on right).
2) 93 condenser, with rubber feet and stacked washers to adjust height
3) Home Depot nailing plates used for mounting brackets
4) Trial fitting with top of condenser wedge into desired location and rubber feet on bottom of condenser resting on flange. Temporarily screw on the 2 hard lines and adjust the stack of washers to give some clearance between the frame rail and hard lines. Hold up the brackets and mark the hole locations on condenser.
5) Mount the brackets to the condenser
6) Put the condenser back in place, check the hardline clearance, and when happy, mark the final hole locations on the sheet metal. Remove the condenser, drill the sheet metal, re-assemble.
7) View from underneath showing hardlines cleanly coming through corner of bumper air deflector and going back under the belly pan.
8) Engine compartment view
9) One issue that I ran into that I still need to solve is that the original '85 uses a single big J bracket to hold the hood latch, the top panel, the front panel, and the cross member all together. There isn't enough clearance at the bend in the J to mount the '93 electric pusher fan. I'll need to use a smaller fan, or see if I can find non-J brackets from a newer car.







If you have access to sheet metal and a brake, it would be a cleaner install to use a roughly foot long continuous bracket instead of the nailing plates. This would better seal the air gap and should be a little more efficient.

10) Picture of '93 hoses and hard lines. The compressor to crossmember combined hardline and rubber hose is still available from Volvo. I think the other lines are NLA.
11) Here's a picture of some of the '93 lines compared to '91 lines. The condenser to evaporator lines seem to be inter-changable but the high pressure switch threaded connector, and the switch, are different. The condenser to crossmember line looks the same. Some of the '93 lines are aluminum while the '91 lines are steel.


Last edited by bobxyz; 09-06-2019 at 10:56 PM.. Reason: fixed link
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Old 09-06-2019, 10:51 PM   #64
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Default O-rings for 1993 240 AC

I ordered a kit of orings that was supposed to be correct for the '93 AC system. Some were correct, others were not included, so I ended up painstakingly figuring out all the needed O-rings for a 1993 240 AC system.

Order these o-rings, and add a few extra just in case
- Volvo part numbers from pages 1014-1019 of: Volvo Parts Catalog 240-260 series 1988-1993 from gcp.se.pdf and from Tasca "replaced by" lookups
- Santech part numbers from web searchs for Volvo numbers
- Dimensions from online Omega Santech Master Technician Catalog http://fs1.omega-usa.com/SantechCata...dex.html#p=205
- Pipe dimensions from my measurements

Qty Volvo Santech Description Dimensions Pipe CARiD.com
- 3537797 MT0288 orifice tube oring 0.256" id, 0.061" wall not measured n/a
1 3537499 MT0237 lower condensor 0.301" id, 0.070" wall .335" $0.08
2 3537501 MT0291 pressure switches 0.351" id, 0.072" wall .38" $0.48
1 3545628/988838 MT0243 fill valve oring 0.364" id, 0.095" wall .408" $0.24
5 3537503/988840 MT0293 rest 0.426" id, 0.070" wall .458" $0.28
1 3537507/988843 MT0295 compressor big 0.551" id, 0.070" wall .565" $0.28
3 3537521 MT0297 rcvr/dryer/evap 0.676" id, 0.070" wall .693" $0.24
$3.68 total for 1 set, no spares

Dimensions from online Omega Santech Master Technician Catalog
MT0288 0.256" id, 0.061" wall
MT0237 0.301" id, 0.070" wall - pipe is .335"
MT0291 0.351" id, 0.072" wall - pipe is .38"
MT0243 0.364" id, 0.095" wall - valve is .408"
MT0293 0.426" id, 0.070" wall - pipe is .458"
MT0295 0.551" id, 0.070" wall - pipe is .565"
MT0297 0.676" id, 0.070" wall - pipe is .693"
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Old 09-09-2019, 09:53 PM   #65
DET17
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Nicely done Bob! I'll be fitting the 93 system to my 84 242 someday, so thanks for the 411.

BTW, enjoyed Boulder last year, and a morning trip to El Dorado State Park.
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Old 09-10-2019, 08:50 AM   #66
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Very nice. My 93 A/C swap has been going strong now for 3 hot Georgia summers. Well worth it if you want freezing cold A/C.
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