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Climateunit
(Heaterunit)
Repairs 240,260
andmaintenance 1975-
Heater unit
This manualdeals
with the repairand maintenance
of the standard and combined (CU) heating
Standardsystem{exceptUSA-Canadal
Combinedunit (CU)(USA-Canada)
IP 30282t2
4 5 0 0 . 12 . 8 3
UK/USA
Contents
Group87 Climateunit (Heaterunit)
Operation Page
Standardunit
Control panel and,/or cable,replacement A1-A10 2
Fan motor switch, replacement B1 _ 8 2 3
cl c24 4
D1-D23 I
Heat exchangerand,/or fan motol replacement(removedheater) E1_E9 14
Heater control valve,replacement F1-F20
Charts
A. Heatercontrols,standad lnit
B. Healer convols, CIJ
C. Standardheater unit
D. Heater housing,standardunit
E. Combinedheater unit, CU
F. Heater housing,CU
G. Hole template,standardunit
H. Conversiontable metric,/IJSAstandard
Index page 53
Standardunit
(except USA-Canada)
A. Controlpanel and/or cable,replacement
Disconnect
the groundleadfiom battery
a)
Remove:
- sldepanes andsoundproofingon bothsides
- ladio{if installed).
A2
Remove the cefire control panel and tront panel
on central console
A3
Remove the screws securing the control panel
moufirng
Pullthe mountingforwad somewhat.
-
k n o b ( 1 ) o n t h e c o n t r o lw h e r e t h e c a b l e
O)
cable sheath clip (2)
- l o c k i n gw a s h e r( 3 )
A7
Install:
- c a b l es h e a t hc l i p
Install:
control mounting
- front panelfor cenrral consoleand controt panel
- r a d i o( i f i n s t a l l e d )
- side panelsand soundproofingon borh sides.
Ato
Reconnect the battery ground lead
Standardunit
B. Fan motor switch, replacement
BI
Remove:
- soundprcofingandsidepanelson righthandside.
- control knob and nut. Mark up rhe cabes and
disconnectthe switch.
B2
o Install:
-
-
cable and switch
side panelsand soundproofng
Gtoup 87 Standad unit
Standardunit
C. Removal of heatel
Note:Two differcnt installations,tvpe A and B are in 'rse'
0)
Type A (modifled)
Disconnectl
- defrosterhoseircm the heater
Removalof healer
TypeA
c6
Attach two hose pliers:
- oneto theconvolvatve interhose(t )
- the otherto the heaterchangerinputhose(2).
C7
Disconnect the hoses 1 and 2 as indicated
c9
Remove the control valve {rom the bracket
Disconnect
rhe conrrolcablefrom the controlva ve.
Continued
at Cl3.
Type B
cto
Attach a pair of hose pliers tothe heat exchanger
inlet hose
cll
Disconnect the hoses as indicared
ct2
Remove the heater control valve capillary tube
from the heater housing. Carefully pull out-
Removal ol heater
ct3
Remove:
- bothscrewsfor the heaterlowermounting
- attachingscrewfor the ah ductto rearfloor.Lower
the ductslightly.
cl4
Disconnectr
t h e c o n t r o l c a b l e f oar i F m i x{ 1 ) a n dr e m o v eb o t ht h e
mountingscrews in the heaterhousing(2)alongwith
the fan motor ground l€ad.
Note: The illustlationshows type B. The control valve is
Irmoved from the bracket on type A.
ct5
Remove the glove compartment
ct6
Removethe extra instrumentcoverplate
Nots 1981-models only.
Grcup 87 Standa.d unit
ct7
Remove:
- the frame around the centre air vents
- the ar vents.They arc securedby a screw.
Note: A 1981 modet is shown in the i ustration.The air
vents are securedby two screws in 1975_198o modets.
The screws are locatedunder the vents.
cl8
Removethe air duct connecting the heater to the
ct9
Removethe soundinsulationandsidepanel
Foldback the carpeting
c20
Remove:
- the defrosterhose from the heater
- the attachingscrewsforthe rearftoorairducr Lower
it sljghtly
- lhe screw for the tower mounring on ftoor
- the heat exchanqerdrain hose.
Group 87 Standatd unit
Disconnectl
- fan motor switch from panel
- pos tive lead from the swilch
c22
Disconnect the control cables for the floor and
de{roster shutters
c23
Remove both the screws in the firewall for the
upper mounling. Then remove the heater and
mounting as one unit,
c24
Remove the heater via right-hand side
For type Ar the controlvalve and capillarytube are
attachedto the heater
FortypeB: the controlvalveis mountedon the bracket.
Gtoup 87 Standard unit
lnstallation of heatel
Standardunit
D. Installationof heater
D2
Install lhe heater trom the right-hand side
D3
Install both upper mounting screws to the fire-
wall
D4
Connectthe cables lor the floor and defroster
shutters.Adjust the shutters.
Group 87 Standatd unit
lnstallation of heatel
D5
Align the heat exchanger drain hosein the foot'
well
D6
lhstall:
- heater lower rnountrng
- air duct for rear floor
D7
Connect the heater positive lead to the switch.
Aftach the switch to the control panel
D8
Fold back the floor carpeting. Reinstall the sound-
proofing and side panel
D9
Install:
- contrcl cable for air-mix {1). Adjust the cable.
- both the upper mounting screws in the h€ater hou-
sins (2) along with the fan motor ground lead.
Nots A type B installationis shown where the control
valve is not removedfrom the bracket.
10
Group87 Standardunit
lnstallation of heatel
TypeA
Dl0
Connect the control cable to the heater control
valve. Adjust the operation,Mount the valve on
the bracket
o Dl .l
Connect hoses 1, 2 and 3. Removethe hose
pliers
Continued
at D15.
TypeB
Dt2
Insertthe controlvalvecapillarytubethroughthe
holein the heaterhousing.Securethe coil with a
rubberplug
Dt3
Connectthe hosestothe heatexchanger, Remove
the hose pliers
i
Group87 Standardunit
lnstallation of heater
D|4
Make sure that the Jloor shutter does not touch
the coil
Dt5
lnstall:
- bothscrewsfor the heatermounting
- the attachingscrew for the air duct to the rear
Dt6
0
lnstallr
- the air vent for the front floor
- the defrcster hose.
Dt7
Fold back the floor carpeiing. Fitthe soundprcof-
ing and side panel
12
Group87 Standad unit
lnstallationof heater
D18
Install the air ducts betwo€nthe heater and air
Dt9
Install:
D20
Install th€ 6xtra instrument cover Dlate
D2l
Installthe glovecompartment
D22
R€connecttho battery ground lead
D23
Checkthe coolantlevel and top-up if necessary
Group 87 Standard untt
Standardunit
E. Heat exchangerand/orfan motor, replacement
lHeater removed from vehicle)
Disconnect:
- the heatexchanger drainhose( t )
- theair intakeseal(2)
- all cips holdingthe heaterhousing halves to
E4
Transter the {an wheel to the new motor
14
Gtoup 87 Standatd unit
E7
Smear the bottom edge oI the heater housing
halves with Volvo sealant Pan No. 686 275-9.
E8
Install:
- theheater control
valvecapllaryrubeand clips(1)to
ihe heatexchanger. Pressiogetherthe heaterho!s
ing halves.
3llc ipsfortheheaterhousinghalves
E9
Connectl
t h e h e a te x c h a n g edr r a i nh o s e( 1 )
t h e a i r i n t a k es e a l( 2 )
Noter On assemblyof the he.ter housing,modifications
can be madeso that it is possibe to removeand inst.llthe
controlva ve capillarytube directlythrough the left-hand
side of lhe heater housing.See operations F9-F20 ior
0,
l5
Group 87 Standad unit
Standardunit
F. Heatercontrolvalve,replacement
Notq Two different instalations.tvDeA and B are in use, see below.
Type B {modified}
The heare'control valve capillarvlubeis nserlpdbetweFn T h e c o n t r o l v a l vcea p i l l a r y t u bcea nb e r e m o v e dt h l o u g ha
both parts of the heater housingand is connectedto the ho e in the left hand side of the he.ter housing
heat exchangerby clrps.
On replacementofthe controlvalve,modificationsshould
be made to convertthe installationto tvpe B
For details see operation F9 onwards
Remove:
- on left-handside
andsidepanel
the soundproofing
- the defrosterhose
disconnect
F2
Fold back the floor carpet and place a drip pan
below the healer
Group 87 Standard unit
Type A
F5
Removethe controlvalveJromthe bracket
Cut off the capillarytube behindthe heaterand teavethe
TypeB (modified)
F8
Removethe controlvalvetrom the bracket
pulloutthecapillary
Carefully tubeandrubberplugfrom
Continuefrom Fl2.
Group87 Standardunit
Heatercontrcl valve.rcplacement
F9
Cut out a template according to chan G. (back of
manuall. Place this template on top o{ holes for
the shutter spindles. Mark out the hole {or the
rubberplug.
Fto
Cuta 21 mm = 0.827"O hotewith a hotesaw
Ft2
Installthe rubberplug onto the capillarytube of
thenewcontrolvalve abour300mm=11.8,,from
the valve
14-15hn
Ft3
Wind the lube a.ounda screw or rod lO 14-15
mm = 0.5-O.6r').Make surc that there is space
beNveenthe turnings
l8
Group87 Standad unit
Ft5
Connectthe control cable and transterthe clip
lrom the old to the new controlvalve.
Adiustthe cable.
G
Ft6
Insertthecapillarytubethroughthe drilledholein
the side oI the heater.Secureit with the rubber
ptug
Fta
Make sure that the floor shufter does not rub
against the capillary tube
o
-l-
I
Group87 Standad unit i
Heater control vafue.replacement
Ft9
Connect:
- the defrosterhose (
Reinstall:
- the sidepanelandsoundproofing.
0,
0)
l
Gtoup 87 Combined unit (CU)
Disconnectthe batterygroundlead
G2
Remove:
- soundproofing andsidepanelson bothsides
- ladio(if installed)
- centrecontrolpanel,moveto oneside
- centralconsole,front side. Pull as far forwardas
G3
Removethe leverknoband disconnectthe cable
trom the leverand controlvalve
G4
Connectthe cableand reinstallthe lever knob
G5
Adjust the operation
21
Group87 Combinedunit (CU)
Reinsrall: l
- centralconsole
frontpanel (
- c€nl.e controlpanel
- radio (if installedl
- side panelsand soundproofingon both sides.
0 (
Combinedunit (CU)
H. Control panel and/or fan motor switch, replacement
0
Disconn€ctthe batterygroundlead
H2
Remove: .) (
- soundproofingand side panelson both sides
- radio {if installed)
- centre control panel,move to one sido
- central console front panel. Pull as far forward as
0
H3
Removeol disconnecti
- protectiveplateabovethe controlpanelvacuumhose
{1)
- fan motor switch (2)
- illuminationpan€l (3)
- control p8nel clips (4).
Note:The protectivep6nelabovethevacuum hosesis not
removableon vehiclesbuilt since 1981.
0
Mark up and disconnectthe hoseson the contrcl
panel
22
Group 87 Combined unit (CU)
H5
Connectr
- the vacuum hosesto the control panel
- p a n e l( 1 ) a n d c l i p s( 2 )
- i l l u m i n a t i opna n e l{ 3 )
- fan motor switch (4)
- protectivepanel above the vacuum hoses (5).
.T- r@
H6
lnstall:
- cenrralconsolefront panel
- centre control panel
- radio (if installed)
- side panelsand soundprcofingon both sides.
Reconnectbattery grcundcable.
Gombinedunit (CU)
l. Shutter actuatorfor rear floor vent, replacement
Disconnectthe batterygroundlead
t2
Remove:
- soundproofingand side panelson both sides
- radio (if installed)
t3
Freethe centrecontrolpanelandtront panelof
central console
Pull it as far forward as possibleto free ir from the radio
compartment.rt may be necessaryto detach the radio
23
Group87 Combinedunit (CU)
Shutteractuatorfor REc-'hutter.replacement
t4
Removethe locking clip lor the contrcl valve.
Disconnect the acfuatol lrom the bracket and
disconnectthe hose
t5
lnstall or conn6ct:
- the shutteractuator,
Usenewlockingclipsfor the
- thecentral frontpanel
console
- csntre control panel
- radio {if installed)
- side panels and soundproofingon both sides.
Combinedunit (CU)
J. REC-shutteractuator, replacement
KI
Disconnect th€ battery ground lead
K2
Move heatercontrolsto closedposition
K3
Remove soundproofing and side panels on both
sides
Remove:
- radio (if installed)
centre control panel. Disconnect any cables and
move the panel to one side.
Note lf the vehicle has an air conditioningsystem,take
carc to avoid damage to the heater capillarynrbe {heat
K5
Remove:
- the glovecompartment
- pry
the stripbelowthe ight-handair vent Carefullv
off with a screwdiver.
25
Group87 Combinedunit (CU)
Removalof heater
K6
Removgthe ste€dng wheel casings and discon-
nect tfio choke control {coverplate).
Nole: For v€hicles with th€ Cl (fuel inj€ction)
remove th6 coverplate for the choke,
K7
Remove:
- ths stripbelowthe left-handairv€nr
- th€ knobfor adjustingth€ instrumenttightinginten-
- the light switch knob. Do not removethe switch.
KA
Removethe extra instrument cover plate
Awlies to 1981- modelsonly.
K9
Disconnectthe speedometerdrivecableand arw
€lectricalconnectionsfrom the combinedinstru:
ment panel.Removethe instrumentpanel
0, (
Kto
Remov€:
- the storagecompartment
- the cgntrearrvents
- th€ instrum€ntpanelframe.
-'=-<
Or
Gtoup87 Combinedunit (CU)
Removal of heater
Ktl
O Unplug the windscreen/windshield
necto6
o Kt2
Disconnectl
- the air duct betweenthe heater and centre air
Kt3
Remove the dashboard
Applies to | 981- models onlY.
Kt4
Removeor disconnect:
- attachmentscrews for rear floor air duct. Lowerthe
duct slightly
lower heater mounting
hose to vacuum tank
cable to controlvalve
uppef and lower scrcws for central console
screws on the centre support
fan motor ground l€ad
inlet hose to controlvalve. Use hose pliels to clamp
27
Group87 Combinedunit (CU)
Disconnect:
Kt6 II
- hosesto theshutteractuators
Kt7
Slackenthe heateruppermountingscrews
KlA
Disconnect
- hosesto shutteractuators I
f
Ktg C'
Remove or disconnect
- the hosefrom the vacuumtank
- the screwssecurjngthe rearfloor duct. Lowerthe
ductslightly
- bothscrewsfor heaterlowermounting.Removethe
mountins.
K20
I
I
Detach the cemral console
Removelhe upperandlowermountingscrewsandmove {
the consoleto oneside. (
a
K2l
Remove the mountingscrewsfor the right-hand
supportlupright),Removethe support
K22
Disconnectthe plug from the heatertan switch
and alsoth6 Dositivelead
K23
0
Disconnectthe vacuum hose from the control
oanelIor REc-shqtter
Gtoup87 Combinedunit (CU)
Removalof heater
K24
Disconnectthe input vacuum hose from the
T-connectionto the lloor shutter actuators,
K26
Removethe uppermountingscrews and lift out
heater+ evaporatoras one un|t
'a.
I
29
Group87 Combinedunit (CU)
lnstallaton of heater
{ (
Gombinedunit (CU)
L. Installationof heater
LI
oI
Checkbeforeinstallingtheunitthatthe air intake
seal is intact
L4
Connect:
- vacuumhosetocontrolpanelfor RECshutterandfit
) the coverabovethe hos€s
- the plugsfor the fan motorswitch
- the fan motorpositivelead.
Grcup 87 Combined unit ICU)
lnstallation of heatel
L5
t.-
Install:
;-:
Connect:
- nosesro shutteractuatols.
c
Tightenthe heateruppermountingscrews
Connect;
upper water hose to the heat exchanger
Install or conhect:
lower heater mounring
hose to the controlvalve. Bemovethe ptiers
cable to the control vatve.Adi(rst the cabte
hose to the vacuum tank
air duct to rhe rear seat
upper and lower screws to the centrat console
screws to the centre support (upright)
I tan moto. ground te;d.
Group87 Comunedunit (CU)
lnstalladonof heater
Ll0
lndall the dashboald
Ll1
Connect
- air duct between heater and centre air vents
- elec.lead to glove compartment light
- defrcster vent grommets.
Lt2
wiper plugs
Reconnectwindscre€n/windschield
I
lnstall:
- instrumentpanelframe
Lt3
I
- centreair vents
- storagecompanment.
32
Gtoup 87 Combined unit (CU)
Installation ol heater
L|4
Install:
ro -
-
combined instrument panel and reconnect rhe
speedometerdrive cable and elec. leads
cover panel for extra nstruments.
Ll5
lnstall:
o
- light switch knob
- contro knob for instrumentlighting intensity
strip below outer leit-hand air venl.
Lt6
lnstall:
- sreerng corLrmncasrngs
- chokecontrclif installed
Note:ForCl{fuelinjection)
enginesrefitthecoverplatefor
l
Lt7
lnstall:
- strip below the outer right-handvent
- glove cornpartment,
,!
Group87 Combinedunit (CU)
lnstallation of heatel
L'8
lnstall:
- centrecontrolpanel.Reconnect elec.leads
- r6dio(if installed).
NotetTakecarenot to damagethe capillarytube (heat
sensodif the vehicleis equippedwith AC.
Lt9
Reinstallside panelsand soundproofingon both
sides
@a
Reconnectthe battery groundlead
L2l
Checkthe coolantlevel,top up if necessary.
(
{,
,ll
34
Gtoup 87 Combined unit (CU)
a
Combinedunit (CU)
M. Heat exchanger,replacement
(removedheater)
M2
Remove the lan wheel locking clips on both
sides
I
M3
{ t h e h e a t e rc o r ed r a n h o s e( 1 )
v a c u u mt a n k 1 2 )
r e t an r n gs c r e w sf o r v a c l u m t a n k b r a c k e to n e f t
R E Cs h u t t e rs p r i n g1 4 )
\
a l l h e a t e rh o u s i n gc l i p s( 5 ) .
35
Group 87 Combined unit (CU)
M4
Remove or disconnect:
- retainingscrewsforfan motor
- {)
heatercontrolvalvecapillarytubefrom attachmenr
- the shutteractuatorsrubberhosefrom the T-joint.
M5
Pull apart the heaterhousing
M6
Remove the heater core and fan motor
: -
Install:
heat exchangerand fan motor to heaterhousing.
Ivlakesurethatthe plasticcoverforthefan motoris
positioned
ca
correctly
- the shutteractuatorhoseto the T joint.
(
M8
Smear the lower edge of the heater housing
halves with sealant. Volvo part no. 686 275-9 or
equivalent.
0 I
M9
Insert the REC-shuftershaft inthe heater housing
at the same time as both heater housing halves
are assembled and the shutter actuator is instal-
led.
Mto
Install or connedt:
- BFc shutter cl p
{
all heater housingclips
- vacuum hose to BEc-shutteractuator.
36
Gtoup87 Combinedunit (CU)
Heat exchanger.replacement
M'1
Tigl|ten the fun motor screws
Mt2
Attach the he€ter cortrol valve capillarytube to
the mounting
M'3
lnstall:
- rotainingscrewsfor tn€ vacuumtankbracketand
- hsatercor€drainhosa
Ml4
Attach both fan wheels and secure with clips
l/^
f-I
Mt5
Installthe outer fan casings
Checkthattheshafts(I ) 6relocated
conectly.
Mt6
No\.vinstall th€ lollowing partsi
- allfanc.singcljp€(2)
- upperwaterhoseto heatercore(3)
G - airintakerubberseal(4)
- rubbersealsfor d€frostsrhosesinl€t bothsides
{5).
Group 87 Comhined unit (CU)
CombinedUnit (CU)
N. Fan motor,replacement
0e
Disconnect battery ground lead.
N2 ('l
Remove:
- sound insulationand side panelson both sjdes
radio (if installed).
N3
Detachthe control paneland certral console
0 (
Bemove or disconnect:
- centreair vents
- cableconnectors from the clock
- glovecompartment
air ductsfor the centreair vents.
Note:A 1975 1980 versionis shown.On the 1981
I
veFion,the air ventsare securedby a screw.
e I
N5
Remover
0,
3A
Gtoup 87 Combined unit (CU)
N6
Fold back the floor caroet
ic
Remove:
screwfortherearfloorairduct.Movetheductto one
sidesliqhtly
outerfan casing
NB
Disconnect:
lt -
-
fan motor switch from central console
elec. leadsfrcm the switch.
til
'&
H
N9
Disconnect:
rO - hosesto shutteractuatoE.
Nt0
Fold back the floor carDet
Nll
e
sideslishtly
- outerfan casing
39
Gtoup 87 Combined unit ICU)
Nt2
Remove or disconnect:
-
-
-
i n n e rf a n c a s i n g
hose to shutter actuator for rear foor
fan moror and ground lead.
1
N o t e :A 1 9 7 5 I 9 4 0 v e r s i o ni s s h o w n .
Ouantity
Sw tch
1 3 0 7 8 4 56
1 3 0 7 8 4 64
12599122
1
1
l
(t
Screw 955145-a 3
192444-2 2
P l a s t i cB u s h 1307391-1 3
Nt5
Mark up cable locations on the new switch
connector.Disconnectthe cables,
There is one part of the wiring p ug for the heater fan
switch which ls not used.When groundoff, the complete
pLugwil pass through the existingho e in the top of the
0_ t
40
Gtoup 87 Combined unit (CU)
Nl6
I nstalI plastic bushingsas illustrated. lf not instal-
f--
Passthecablesforthe resistorthroughtheupper
hole in the heater housing. Fit the rubber grom-
met
k
Nt8
Installthe motor
Use tne screws and washers in the installationkit.
I n s e n t h e c a b l easn dc a s i n gr h r c | ] g ht h e d r i l l e dh o l ei n t h e
Nt9
lnstall:
- i n n e r f a nc a s i n g
- control valve capillarytube in inner fan casing
N20
Connecthoseto rear{loor shutteractuator
i\
Group87 Combinedunit (CU)
Fanmotor, replacement
N2l
lnstall:
- oulerfancasing
- air ductfor rearfloor
N22
Fold back the lloor carpet
N23
Connect:
N24
Inat6ll:
- outerlan casing
- (if remov-
the supponundertheglovecompanm€nt
- air ductfor rearfloor.
N26
Connect
- hoseto shutteractuators,
-
;;;;;.1
?-
lgnition switch
Vehicles built 1979-'198O
Move the existingblack,/white cablefrom
fuse 3 to fuse 12 and connect it to
terminal 5 on lhe switch connector.
Note- lt may be necessaryto extend this
cable. Use a new cable and connect it
Switch f r o n rf u s e 3 t o t e r m i n a l 6o n t h e c o n n e c -
'|
259912-3
Connect the AC relay on the cable
b e t w e e nf u s e 1 2 a n d t e r m i n a l5 o n t h e
swltch connecto. use a Scotch-ocktype
lgnition switch
43
Gtoup87 Combinedunit (CU)
N28
Connect:
- cablesto plugsaccordingto prevrousrv
maoe
N29
Join the connectors
N30
Connect the connector to the switch
)
pt
N31
Fir:
- the switch io the central console
- the switch knob.
N32
Connectthe air ducts for the cerrtreair vents.
N33
Reconnectthe elec. leads to the clock
N34
lnstall:
-
-
air vents and Padding
glove companmenr.
e.,I
N35
lnstall or connect:
- central consoleand control panel
- fan motor ground lead
- radio (if installed)
- side panels and soundProofingon
central console.
N36
Beconnectthe batterygroundlead.
Group87 Combinedunh ICU)
unit (CUl
Combi.ned
O. Heater control valve, replacement
ol
R€movethe soundproofingand side pan€16on
loft-hand side of central console
02
Disconnectthe control csble lrom the contnol
valve.
o3
Pull out the control valve from the moufiing
Attachhosepliersto the inletandoutlgthoses,Discon-
Install or conn€ct
- the controlvafue
- the contrcl cabl€.Adjust the cabts
- soundproofing andsidepanels.
GauD87 Air distribution, 975-198O
Air distribution
P.1975-1980
Remove:
- lightswitchknob
- strip belowthe air vsnt
- boththe air vent retainingscr€ws.Removethe air
Disconnoctthe batterygroundlead
P3
R6move:
- glovecompanment
- strip belowairvents
- retainingscrewsandairvents..
P5
Install the air ducl
0
O
lnstall:
0 -
-
strip below air vents
glove compartment
Reconnectthe battery ground lead.
Remove:
- soundproofingand side panel
- frcnt retaining nuts for front seat. Lift the seat
P'O
Removelhe front air duct
P'2
Position the carpet and fit the retainers
\ lnstall:
- doorsill
- front retainingnuts for front s€at
- sidepanelandsoundprooting.
r Gtoup 87 Ait disttibution l98t-
a
Air distribution
R. 1981-
0
Outer air vent, replacement
RI
Remove the strip under the vent
Carefullypry off with a screwdiver.
Remove the retaining screw and push down the
clip on top of the vent, Remove the vent
R2
Press in the new vent and tighten the screw
Befitthe strip underthe vent.
I
c
Centre air vent and/or duct, replace-
ment
49
Group 87 Ait disttibution l98l-
R5
Removethe rim ol lhe air vents
Removethe retainingscrews and pull out the
R6
Removethe air duct betweenthe heaterand air
vems
Reinstallthe glovecompartment
Bt4
Removethe front air duct
Rt5
lnstall the new duct
Rl6
Po6itionth6 carpet and fit the retain€]s
R'7
Install:
- doorsill
- front rstainingnuts lor front seat
- sidepanelandsoundproofing.
Group87 Heaterunit
lndex
Index
r s m o v a.l, . . , , , , , , , , , , , . . . . . BI N1 - N1 2 38
i n s € | | a t i o. .n. . . . . . . . . . . . . . . . m o d i f i c a t i o n . . . . . . . . . . . . . . . . . N13-N 14 40
i n s t a l l a t i.o. -n. . . . . . . . . . . . . . . N18-N35 41
Fan motor {r6mov€d unirl c o n n € c l i o n . . . . , . . . . . . , . , , , , . N27 43
14
fanwheel,transferr6nce....... E4 14
b r a c k ei nt s t a l l a t i .o. n ..... --.. E5 14 remova|,................... HI-H4 22
i n s l a | | a t i.o. ,n. , , , , , , , , , . . . . . i n s t a l l a t i.o. .n. . . . . . . . . . . . . . . H5-H7 23
Operation Page
0 Air distribution1975-1980
46
i n s t a | j a t i o. .n. . . . . . . . . . . . . . . . P2 46
centre,.emoval P3 46
i n s t a l l a t i o. .n. . . . . . . . . . . . . . . . P6 47
rear,removal P1 47
i n s t a l l a t i.o. .n. . . . . . - . . . , . . . . P8 47
f.ont, removal P9-P1O 47
I n s r a l l a t r. o. .n. . . . . . . . . . . . . . Pi1 Pl3 48
Air distribution1981-
R1 49
R2 49
R3-R5 49
R8-R10 51
rear,rcmoval 811
i n s t a l l a t i.o, ,n, . . . . . . . . . . , , , , R12
front,removaj Rl3-R | 4 52
i n s t a | | a t i.o. .n. . . . . . . . . . . . . . . R 1 5 - R t 7 52
tr
'4-
S-''oo
12. Clip
13. Lighrdistributor
3. TEMPconl.oldisc 14, Ughrdistributor
4. AlRlVllXcontroldbc
6. FTOOR
controldisc 17. Nut
18. Knob
8. Sheath
9. Cable 20. Sp ng washsr
'lO. Ciank
Chart A. Heatercontrols,standardunit
tt,
1.
2.
3.
CliP
5.
6.
7.
a.
L
10.
1',I.
12.
13.
1 3 . Clip
Clip
17.
14.
13. Sealring
54. Grating
54b.Cllp
56. Knob
19. Nui
23. Hose
63. Int€rmedialeflange
26. Hose 64. Lid
65. Gasket
29. Nipple
33. Hose
73. Clamp
36. An doct right
37. Ai jet 75. Nipple
38. Sc€w 76. O ins
78. Springnut
Brr.Br9.B?r,823
7"-@
53A Ii%*r*-'"
@ @
O-s2
Ghart C. Standardheaterunit
o
2. Casins
3. qip
11. Gssk€t
'12, Shutt€r,floor
13. Shutter,defGter
18. S€aldng
l9- Clip
20. Air dastdbutor,left
21. Air distributor,
.ight
23. Clamp
26. Hos6
28. Hose
29. Grommst
30. Spdcer
35. ScEw
36. Scl6w
37. Spdngnut
34. Flatpin
42. Clamp,left
43, Clamp,dght
45. Crip
o
rum4B
t5 ,
Chart D. Heaterhousing,standardunit
55. Nipple
56. Plug
57. Plug
54. Lock plug
60. Plug
1 2 a .N i p p l e
20. Lockplug
21. Shaft
22. Spnng
25. Inlermediate
lubo
26. Clip
31. Tube
32. Joint
91. Intermediat6flange
92. tid
38. Hose
39. Clip
95. Pin
41. Clip
1 0 0 .C l a m p
1 0 2 .N i p p l e
1 0 3 .O j i n s
51 0
b P i.&J A
q9
56
aD. sl9.6a.aa
(TG
o.i L ,8
\? _/
99 105
Chart E. Combinedheaterunit
3. Casingleft 42. Bush
4. Casins,risht
46- Nut
20. Clip
21. BEckel left
22, Brack€!right 60. Shutt€r
23. Scew
24, Clip 62, Clip
25. Clip 63. Clip
26. Gask€t
27. Gasket 65. Hose
66. Clsmp
29, Pipe
30. PiF 68. Hose
30, Pip€
76. Clamp
36- Joint
34. Spring
tr
22
50
5t
38
10
39
2res
,u$
Chart F. Heaterhousing,CU
Template.actual size
I 762m 152,4@
0,015625_ 0397 121,391 152,191 1 7 4 , 1 9 7 2 0 3 , 5 9 71 2 2 3 , 9 9 7
1132 0,03125" 2 6 , 1 9 4 51,59,4 102,394 r53,r94 174,594 203.99.1229,3s4
3tu 0.046475 1,19r 26,591 51,99r 1 0 2 , 7 9 t 1 2 8 , 1 9 1 1 5 3 , 5 9 1 1 7 3 8 9 1 m4.&1 229.791
r/r6 0,0625" 1,544 26BaA 52,336 7 1 , t a a r 0 3 , 1 8 8 t2a,5aa 153,98€ r 79384 204,744 230,184
0.079125', 1984 213U 52,194 7a,l94 r€884 205,144 230,544
3132 o,o9375 2,341 27,741 5 3 , 1 4 1 78,581 1033b1 129.3€ r i 5 4 . 7 8 1 1 8 0 , 1 8 1 2o5,5al x0,941
0,r09375" 2,714 2A,174 5 3 , 5 7 4 7 8 9 ? 3 r04,374 129,718 r 5 5 , 1 7 8 i80,5?8 2 O 5 , 9 7 a1 2 3 1 , 3 7 8
1ta 0,r25" 3.175 8,515 t9.3',t5 1 3 0 , 1 7 51 5 5 , 5 7 5 1 8 0 9 7 5 206,375| 231,-t15
9/64" 4,140625 3,512 B 312 u,37? 19,112 105,1',t2 130.572 1 5 5 8 7 2 191,312 ?06,172| 232,rn
5t32" 0,r5625" 3p69 29.369 54,?69 40,169 105,56S 130.969 156,38 1 4 1 , 7 5 9 2ai ,1@ | 232,5e,9
o,1t18?5" 4,356 4,166 5s.166 40.566 1 0 5 p 6 6 1 3 1 , 3 6 5156,766 t a 2 , 1 6 6 2O1 ,a6 I 232,966
3t16" o,1875" 4,162 30,162 55,562 40p62 106,362 1 3 r , 7 6 2147,162 142,562 201,962 213,162
o,203125" 30,559 ro5.759 1 3 2 , 1 5 9 r 8 2 9 5 9 208,359 23J,7s9
t 132" o,21AJ5 30956 56,356 81,756 1 0 7 , 1 5 6 1 3 2 , 5 5 61 5 7 8 5 6 1 8 3 , 3 5 6 20€.756 234,156
o,23,4314" 31,353 42,153 1 0 7 , 5 5 3 1 3 2 9 5 3 l5ap53 183,753 209,153 234,553
6,350 31,7S 57,lC) 42,550 133,350 159,750 20-o,s60234950
I 19t32'
39tg'
5t8
0,574125_
0,59375
0.625"
15,G1
40,874
1 5 , 4 7 5 41,275
55,444
6s,881
6,2J4
66,675
90,aa4
91.678
92,075
116244 t6?,€4 192,444 211,451213241
1 1 5 , 6 8 1 r42,Oa1 157,{81 r92,881 2 1 8 2 4 r1 2 4 3 . 6 a 1
r93274 21A.6tA 1244,O7A
142,815 r64,275 i93,675 219,O75 244,114
o,641]625' 16,272 61,O12 9 2 t J 2 111,412 143212 164,672 219,172 214.572
2|/32" 0,65625 16,6e 67.469 92,4e 1 1 4 , 2 e 143,6€ r69,0@ 2 r 9 , 4 @1 2 4 5 , 2 e
iO 0.6718r5"
0,6475"
17,O55
'11.462 42,462 68,262
93266 1 t 4 , 6 6 5
93,662 1 1 9 , 0 6 2
I @,465 194.S66 220,266 1245,666
195262 220,6621216.6)
0 , 7 0 3 1 ? 5 " 17,€59 43,259 64,650 94,O5e 1 r 9 , 4 5 9 t 7 0 2 5 9 195,648 221,O59124549
23132' 1 8 , ? 5 6 43,656 @,056 1 1 9 , 3 6 6 1 4 5 , 2 5 61 7 0 , 6 5 6 r95,O56 221,4561246,66
13,653 @,453 94,853 120.253 1 7t , 6 3 r96.453 221,453 1241,253
4,15" @,60 95,250 120,650 196,S50 22250 1241,69
0,765625_ 95,647 222.641 l2Aa,M1
?5t32" o , 7 g r ? 5 "
5 1 / 6 4 " o,796S75' 20,241 198,O41 723,441 l2aA,U1
1 3 / 1 6 " o,ar25" 20,638 46,03 1z2.24 173,034 223,434 i249,234
53164" o,828125" 21,034 71,434 122,6U 194.434 224.8a ]24s.634
2t t3? 12231 97,63t 1 2 3 , 0 3 1 r?3,431 24,631 250,031
o . 3 5 9 3 7 5 " 2 1 , 4 2 8 41,228 r2,624 93,024 123,428 ta3,E2a 't14,224 199,624 225,OA 250,428
lta 22,225 123,&25 149,225 'i4,625 2m,o25 225.4?5 250,825
o,490625- 22,622 a4.022 94.472 124,222 149,62? 't /5,o22 2]o,422 725,@2 t251,222
29132 23,019 99,2r9 124.619 2 0 0 , 4 1 9 2 2 6 , 2 1 9l 5 r 5 1 9
a921at5 23,416 99,616 r 2 5 , 0 1 6 r 7 5 , 8 r 6 201,216 2 2 6 , 6 r1 6 2 5 02 r 6
r5116 49315 23.8t2 1 2 5 . 4 1 2 r 5 0 , a r 2 1 1 6 , 2 1 2 2 0 r , 6 t 2 2 2 ) , o 1 21 2 5 2 . 4 1 2
0,953r25" r 25,a09 5 1 , 2 0 9 176,609 202,009 221.4(B 1252,8O)
3 1 1 3 2 " o,96475" r26,206 5r,606 221,806 1243,206
25 J03 75,803 1 2 6 , 6 0 3 52,OO3 ?02,4o3 , 3 , 2 o r l ? 5 3& 3
H. Conversiontable
National
Inslitutelor
AUTOMOTIVE
SERVICE
EXCELLENCE
VOLVO
SUPPORTS VOIJJNIARY
MECHANIC
CEFTIFICATIOI{
8YTHEI{.I,A.S,E,
(U.S.A.
only)
Your
most mportant
specialtool