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Old 11-22-2015, 06:00 PM   #1
The Turd
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Default 740 Heater Core Replacement (Pictures)

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)
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Old 11-22-2015, 06:53 PM   #2
brickyard92
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Nice job on the pics..
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Old 11-22-2015, 07:29 PM   #3
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Thanks!
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Old 11-22-2015, 08:09 PM   #4
Maxdabreaker
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Thanks a ton! Need to get mine replaced before it gets freezing cold here in California... just kidding, that'll never happen.
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Old 11-22-2015, 09:47 PM   #5
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You're lucky haha. I live up in Washinton. It's supposed to be in the 20s this week
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Old 11-22-2015, 10:19 PM   #6
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Great set of soo very clear pics...Thanks
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Old 12-08-2015, 12:10 PM   #7
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Finished the job yesterday. Gotta say, an electrice ratchet, and a wobbly 7mm will be your best friend trying to get the box off.
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Old 12-09-2015, 07:12 PM   #8
poulrais
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I have the sugary smell in my 1990 740 so it'll be my turn to rip my knuckles off soon! I did a 940 and a 240 in the past so I know what I'm getting into!
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Old 12-11-2015, 07:52 PM   #9
15A
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I've had the utter pleasure to do 7 of these in the last 18-24 months.

fwiw, if for any reason you pull your dash (replacement, better color, etc), DO THIS regardless whether its officially leaking or not. The last 3 I pulled was for that reason alone and all of them had green streaks on the seams or had started to weep. I'm prepping to swap a gray interior into a 940 in about 2 weeks and will do this again. With the dash out of the way its a 45-60 min job.

Break it on your terms as they will never fail on a sunny 75F day either.

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Old 12-22-2015, 11:40 AM   #10
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Nice job on the write-up. Brings back some fond memories of mine... not. The only positive thing I remember about doing that job was discovering some good new music on Pandora playing on the background.
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