Volvo 240 1975 User manual

Service
Manual
Repairs
andmaintenance
Section8 (87)
Climateunit
(Heater
unit)
240,260
1975-

Heater
unit
Thismanualdealswith
therepairandmaintenance
of the standardand combined(CU) heating
Standardsystem
{except
USA-Canadal
Combinedunit(CU)(USA-Canada)
IP 30282t2
4500.1
2.83
UK/USA

Group87 Climate
Contents
unit
(Heater
unit)
Standard
unit
Control
panel
and,/orcable,replacement
Operation
A1-A10
B1_82
cl c24
D1-D23
E1_E9
F1-F20
Page
14
Fanmotorswitch,replacement
Heat
exchangerand,/orfanmotol
Heatercontrol
valve,replacement
Airdistribution
1975-1980
1981-
replacement
(removed
heater)
2
3
4
I
Combined
unit
(CU)
USA-Canada
Heatercontrcland,/orconrol cable,repla
cemeni c 1
-G
7
Contrcl
panel
and,/orfan motor
switch,replacement
.. .... . ...
Shutteractuatorfor rcar floorvent,replacemenr
REC
shLtte'.replacement
Hedler,.emoval
...
Insrallarron
..
Hedl
erchanger.repldLement
rremov€d
h.ater)
t.n motor replacemenr
Heatercontro
valve.replacement.......
H1-H7
t1-t6
J] J2
K] K26
L1 t21
M] Ml6
N1-N36
o1-06
P1-P13
R1-R17
21
22
23
24
25
30
35
38
45
46
49
Charts
A. Heatercontrols,
standad lnit
B. Healer
convols,CIJ
C. Standard
heaterunit
D. Heater
housing,standard
unit
E. Combinedheater
unit,CU
F. Heater
housing,
CU
G. Holetemplate,
standard
unit
H. Conversion
table metric,/IJSA
standard
Index
page
53
fhismanualdealswith heaterunits
only.Air conditioning
is
dealtwlthinanothernran!al.
Volvos
aresold
inversionsadaptedfordifferentmarkets.
Theseadaptionsdependonmanyfactors
includinglegal,
laxation
and
market
requirements,
This
manualmaylhereforeshowillustrations
andtext
whichdonotapplytocarsin
you.
country.

Group
87 Standa.dunit
Control
paneland/or cable,replacement
Standard
unit
(except
USA-Canada)
A.Control
panel
and/or
cable,replacement
Disconnect
the
ground
leadfiombattery
Remove:
- slde
pane
s andsound
proofing
onbothsides
- ladio
{if
installed).
A2
Remove
the cefire control paneland tront panel
on central console
a)
A3
Remove the screws securing the control panel
moufirng
Pullthemountingforwadsomewhat.
knob
(1)on thecontrolwherethe cable
- cablesheathclip(2)
- lockingwasher
(3)
Slacken the disc and unhook the cable
O)
O)
Disconnect
the control cablefrom the shutter

Adjust the control cable
Install:
control
mounting
- front panelfor cenrral
console
andcontrot
panel
- radio
(if
installed)
- sidepanels
andsoundproofing
on borhsides.
GroupB7 Standardunit
Fanmotor switch, replacement
Ato
A7
Install:
- cable
sheathclip
- contro cableto shutter
Reconnect
the battery ground lead
Standard
unit
B.Fan
motor
switch,replacement
BI
Remove:
- soundprcofing
andside
panels
onrighthand
side.
- controlknoband nut. Mark up rhe cabes and
disconnect
theswitch.
Install:
- cableandswitch
- sidepanels
andsoundproofng
oB2

Gtoup87 Standad unit
The
heatercontrol
valvecapiLlarv
tube
isinsened
between
bothparis
ofthehealerhousing,
and
rsconnectcn
to the
heatexchanger
by clLps.
Standard
unit
C.Removal
of heatel
Note:
Twodiffercnt
installations,
tvpeA and
Bare
in'rse'
0)
Type A (modifled)
The
controlvalve
capilla
ry
tubecanbe
removedthrough
a
holeinthe left handsideof the heater
housing
Dlsconn.ct thc bettery ground lcad
Movethe heater controlsto closed
Remove
the side paneland soundproofing
Disconnectl
- defroster
hose
ircmthe
heater
Foldbackthe floor carpetin9.
Placea drip pan underthe heater I

Gtoup87 Standatd unit
Removal
of healer
Type
A
Attach two hosepliers:
- oneto
theconvolvatve
inter
hose
(t
)
- the
other
totheheat
erchanger
inputhose
(2).
Disconnect
the hoses1 and 2 as indicated C7
c6
CB
c9
oDisconnect
and remove hose3
Remove
the control
Disconnect
rheconrrol
Continued
atCl3.
valve{rom the bracket
cablefrom
thecontrolvave.
Type
Bcto
Attach a pair
of hose
pliers
tothe heatexchanger
inlet hose
cll
Disconnect
the hoses
as indicared
ct2
Removethe heater control valve capillary tube
from the heater housing. Carefully pull out-
Donotremove
thecontrolvalve
frcmthebracket
)'

Group
87 Standardunit
Removalol heater
Starting
frcmCl3 thework
procedures
arethesame
cl4
Disconnectr
thecontrolcableforaiFmix
{1)and
removeboth
the
mountingscrews
intheheaterhousing
(2)alongwith
thefan motorground
l€ad.
Note:Theillustlationshows
type B.Thecontrol
valveis
Irmovedfrom the bracketontypeA.
ct5
Removethe glove compartment
ct3
Remove:
- both
screwsfortheheater
lowermounting
- attaching
screwfortheah
ductto rearfloor.
Lower
the
ductslightly.
ct6
Remove
theextra
instrumentcover
plate
Nots 1981-modelsonly.

Grcup87 Standa.d unit
ct7
Remove:
- theframearound
thecentre
airvents
- thear vents.
Theyarcsecured
by ascrew.
Note:
A 1981 modet
isshowninthe i ustration.
Theair
vents
are
secured
bytwo screws
in 1975_198o modets.
The
screws
arelocated
under
thevents.
cl8
Remove
the air duct connecting
the heater
to the
NoteA 1981modet
is
shown
inthe
i usrrarion.
Remove
thesoundinsulation
Fold
back
thecarpeting
ct9
and
side
panel
c20
Remove:
- thedefroster
hosefrom the heater
- theattaching
screws
forthe rearftoorairducr Lower
it sljghtly
- lhe screw
for the tower
mounring
onftoor
- the heat
exchanqer
drain
hose.
..---

Group87 Standatd unit
Disconnectl
- fan motorswitchfrom panel
- pos
tiveleadfrom theswilch
Disconnect
the control
de{roster
shutters
c22
cables for the floor and
c23
Remove both the screws in the firewall for the
upper mounling. Then remove the heater and
mountingasone unit,
c24
Remove
the heatervia right-handside
FortypeAr the controlvalveand capillarytube are
attachedtotheheater
FortypeB:thecontrolvalveismountedonthebracket.

Gtoup 87 Standard unit
lnstallation of heatel
Standard
unit
D.Installation
of heater
o
oCheckbef
ore
installing
theheaterthatthe
air
inlet
sealisintact
andcorrecllvinstalled DI
Smear
sealingcementaround
thescrewholesin
the right-hand
mounting
NOTE:lvlakesurcwheninstalling
rhehearer
thattheair
intakesealis not displaced.
Nots A tvpe A installatio.is shown where the control
valve
andheaterareremoved
andinstalled
asone unit.
Installlhe heatertrom the right-handside D2
Installbothupper
mounting
wall
D3
screws to the fire-
D4
Connectthe cableslor the floor and defroster
shutters.
Adjusttheshutters.

Group87 Standatd unit
lnstallation of heatel
Align the heat exchangerdrain
well
D5
hoseinthefoot'
D6
D7
Connect the heater positive lead to the switch.
Aftach the switch to the control panel
lhstall:
- heaterlower rnountrng
- airductfor rear
floor
D8
Fold
backthefloorcarpeting.
Reinstallthe sound-
proofingand sidepanel
D9
Install:
- contrclcablefor air-mix
{1).
Adjustthe cable.
- boththe uppermountingscrews
inthe h€aterhou-
sins(2) along
with thefan motorground lead.
Nots A type B installationis shownwhere the control
valveisnot removedfrom the bracket.
10

Group
87 Standard
unit
lnstallation of heatel
Type
A
Connect the
valve.Adjust
the bracket
Dl0
control
cableto the heater
control
the operation,Mountthe valve
on
Dl .l
2 and 3. Remove
the hose
o
i
Connecthoses1,
pliers
Continued
atD15.
TypeB Dt2
Insertthecontrolvalvecapillarytubethroughthe
holeintheheaterhousing.Securethecoilwith a
rubber
plug
Dt3
Connectthe hosestothe heatexchanger, Remove
the hosepliers

Group87 Standardunit
lnstallation of heater
D|4
Make sure that the Jloorshutter doesnot touch
the coil
Dt5
lnstall:
- bothscrews
fortheheater
mounting
- the attaching
screwfor the air duct to the rear
0
Dt6
lnstallr
- theairvent for the front floor
- thedefrcster
hose.
Dt7
Foldbackthe floor carpeiing.Fitthe soundprcof-
ing and sidepanel
0
12

Group
87 Standadunit
lnstallation
ofheater
D18
Install
the airducts
betwo€nthe heaterandair
Dt9
Install:
- the
fram€around
theairvents.
D20
Install th€ 6xtra instrument cover Dlate
Install
theglove compartment
D22
R€connect
tho battery groundlead
D23
Checkthecoolantlevel
andtop-upif necessary
D2l

Group87 Standard untt
Heat exchanger
and/or fan motoL rcplacement
Disassemblyof heatet housing
Disconnect:
- theheatexchangerdrainhose
- theairintakeseal
(2)
- all cips holding
the heater
(t)
housing halves to
Note The
illstration
showsatypeA nstalatlon.
Ontype
B versionsthe control valve remainsattached to the
replacementof fan motor is necessary:
removethe
twoscrewswhich
securethefan
motor
and
liftoutthe
motor.
Separate the halves of the heater housing
Removethe
clipssecuringthecontrolvalve
capilarytube
to the
healexchanger
(1).
Lrftup the heatexchanger.
Transferthe sealif the hest
exchanger
isto be replaced.
Note:The
illustratonshowsa
typeA instalaton.
For
type
B versonsthe controivalvecaplary tlbe is already
ff
Transterthe {an wheel to the new motor
14
Standard
unit
E.Heatexchanger
and/orfan
lHeater removedfrommotor,replacement
vehicle)
Attach the fan motor to bracket
E4

Gtoup87 Standatd unit
Heat exchangerand/or fan motor, rcplacement
Assembly of heatet housing E6
lnstall:
- theheatexchanger
NotaOnassemblymakesurethaithefanmotorhold€ris
ocatedcorectlyinthe heaterhor.rsing
Smear the bottom edge
halves
with Volvo sealant
E7
oI the heater housing
Pan No.686275-9.
E8
Install:
- theheatercontrol
valvecapllaryrubeand
clips
(1)to
iheheat
exchanger.Pressiogether
theheaterho!s
inghalves.
3llcipsforthe
heaterhousinghalves
E9
Connectl
theheatexchangerdrainhose
(1)
the
airintakeseal
(2)
Noter
Onassemblyof the he.ter housing,
modifications
canbemadesothatitis
possib
etoremove andinst.llthe
controlvavecapillarytubedirectly
throughthe left-hand
sideof lhe heaterhousing.
SeeoperationsF9-F20 ior
0,
l5

Group87 Standad unit
heater contrcl valve.replacement
Standard
unit
F.Heatercontrolvalve,
Notq Two differentinstalations.
tvDeA andreplacement B arein use,seebelow.
Theheare'
control
valvecapillarvlube
is nserlpd
betweFn
bothparts
ofthe heater
housing
andisconnected
to the
heatexchanger
by clrps.
Onreplacement
ofthe controlvalve,
modifications
should
be madeto convert
the installation
to tvpe B
For
detailssee
operation
F9 onwards
Type B {modified}
Thecontrolvalve
capillarytube
can
beremovedthlough
a
hoe inthe lefthandsideof the he.ter housing
Remove:
- thesoundproofing
andsidepanel
on
left-handside
- disconnect
thedefroster
hose
F2
Fold back the floor carpet and place a drip pan
below the healer

Type
A
Attach two hosepliers
- one
pair
tothecontrolvalve
inlethose
(1)
- theorhertorhecontrolvalve
ouderhose
(2)
Disconnect
the hosesindicated
F5
Remove
thecontrolvalve
Jromthebracket
Cutoffthecapillarytubebehind
theheaterandteave
the
Remove
the control
valvemounring
screwsanddiscon
nectthecontrolcables.
Fot modiflcation continue frcm K).
Type
B (modif
ied)
Attach two hosepliers:
- onepaironthe controtvalve
jntet
hose(1/
- theotheronrhe controtvatve
outtet
hose(2)
Disconnect the hoses indicated
Group87 Standardunit
Heater control vafue,
rcplacement
F8
Remove
thecontrol
valve
tromthebracket
Carefully
pulloutthe
capillary
tubeand
rubber
plug
from
Remove
the control valve and disconnect
the control
Continue
fromFl2.

Group
87 Standardunit
Heater
contrclvalve.
rcplacement
F9
Cut out atemplate according
to chan G.
(backof
manuall. Placethis template on top o{ holesfor
the shutter spindles.Mark out the hole {or the
rubber
plug.
Fto
Cuta21mm
=
0.827"
Ohote withahote
saw
Make
ahole
intherubber
plug
{32040,1-7)wirh
a
smallscrewdriver
(see
tig).
Ft2
Install
therubber
plug
ontothecapillarytubeof
thenew
controlvalve
abour300
mm=11.8,,
from
thevalve
Ft3
Windthelubea.ounda screwor rod lO 14-15
mm= 0.5-O.6r').Makesurcthat there is space
beNveentheturnings
l8
14-15hn