A/c-Heater System - Automatic: Removal & Installation Volvo 850 I

REMOVAL & INSTALLATION

1. Remove radio.
2. Put hand underneath control module. Push up locking button on underside of control module. Push control module loose from behind one rear corner. Remove control module.
3. Disconnect three connectors from control module.
4. Install in reverse order. Ensure wires are not pinched.

Turn ignition off. The A/C relay and power stage are located on A/C climate control unit, behind glove compartment. Remove glove compartment. Remove A/C relay. Disconnect connector from power stage. Hold catches in and pull connector straight out from power stage. see scheme 17 To install, reverse removal procedure.

1. Remove 3 screws holding passenger side sound wall. Remove 4 screws holding glove compartment. Remove glove compartment. (Scheme 21)
2. Disconnect fan motor connector (G3). Remove cable duct from motor and remove connectors from brackets. Remove 4 screws holding motor and remove motor. (Scheme 22)
3. Install in reverse order.

Scheme 21

Scheme 22

1. Disconnect negative battery cable.
2. Remove dashboard. See «DASHBOARD»(ref-13719-S03081478482004012800000).
3. Drain A/C refrigerant.
4. Open quick-release connectors on evaporator pipes using Spring Keys (999-5385 & 999-5472). Cover pipe openings. Remove cover plate and rubber seal over evaporator port in firewall. (Scheme 23) Clamp heater core hoses closed. Disconnect quick-release connectors on hoses by compressing catch and pulling hose outward. Cover heater core openings. Remove cover plate and rubber seal over heater core port in firewall. (Scheme 23)
5. Disconnect electrical connectors for blower fan motor, recirculation shutter motor, and blower fan resistor. Pull cable duct out from fan motor. Disconnect connectors from brackets. Remove blower fan relay and relay socket. Open control box and disconnect lighting control connector. (Scheme 24)
6. Remove floor console. Remove ashtray and cigarette lighter compartment and then remove screws holding floor console. Move gear selector to neutral, apply parking brake and remove cover plate form over parking brake hole. Lift floor console forward and upward. (Scheme 25)
7. Remove floor carpet support plates. Remove connection to rear floor ducts. Remove amplifier bracket and drain hose. (Scheme 26)
8. If vehicle is equipped with cruise control, disconnect vacuum regulator from climate control unit. If vehicle is equipped with manual HVAC system, disconnect cable for right-side temperature shutter. Remove 4 screws holding climate control unit and lift unit out. (Scheme 27)
9. Follow reverse order of removal to install.

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove air intake hose and hose connection to fan cover. Remove control box air intake hoses and Electronic Control Units (ECUs) from control box.
2. Remove control box air intake hoses and disconnect inlet hose connection from fan cover (2 clips). Remove fan cover. Disconnect relays and cables from fan cover (2 tie strips).
3. Remove fan cover (4 screws). Remove relay shelf and spacers. Disconnect 2-pin connector from fan relay and connector from fan motor. Remove fan cover. (Scheme 28)
4. Shield radiator. Disconnect harness connectors from compressor. Disconnect snap-on connectors on receiver-drier. Remove right side headlight casing. Remove receiver-drier bracket screw.
5. Remove air guide. With bracket hooked onto side member, lift receiver/drier out. Plug receiver-drier pipe ends. Disconnect drive belt.
6. Disconnect compressor connector and temperature sensor. Remove compressor. To install, reverse removal procedure. Lubricate new "O" rings with compressor oil.

Scheme 28

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect air intake hose. Remove hose connector to fan cover.
2. Remove Electronic Control Units (ECUs) from control unit box. Disconnect control unit box air intake hoses. Remove inlet hose connector to fan cover (2 clips). Disconnect relays from relay casing. Disconnect fan cover (4 screws), fold cover back towards engine. Remove relay shelf and spacers. (Scheme 28)
3. Disconnect pipes from condenser. Disconnect high-pressure sensor connector. Remove high pressure sensor. Disconnect condenser screws. Lift condenser out.
4. To install, reverse removal procedure. Transfer high-pressure sensor and rubber gasket to new condenser. Lubricate new "O" rings with compressor oil.

Turn ignition off. Remove soundproofing from center console. Remove glove compartment. Disconnect connector from damper motor (located on A/C control unit). Hold catches in on both sides of damper motor and pull motor straight out. (Scheme 29) To install, reverse removal procedure.

Scheme 29

1. Disconnect negative battery cable. Disable air bag system. See «AIR BAG RESTRAINT SYSTEM»(ref-12932) article in RESTRAINTS.
2. From engine compartment, remove windshield wiper nuts (marked "A"), windshield wiper well cover panel screws (marked "B") and wiper well. Remove wiper motor mountings. Remove outside dashboard bolts (marked "C"). (Scheme 30)
3. From passenger compartment, remove steering wheel air bag module if applicable. See «AIR BAG RESTRAINT SYSTEM»(ref-12932) article in RESTRAINTS. Mark steering wheel position relative to steering wheel shaft. Remove steering wheel nuts and steering wheel.
4. Remove steering wheel stalks. See «STEERING COLUMN SWITCHES»(ref-12952) article in ACCESSORIES & EQUIPMENT. Remove steering wheel stalk connector.
5. Remove dashboard covers. See «DASHBOARD COVERS»(ref-13719-S29004671342004012800000).
6. Remove A/C Heater Control Panel. See «A/C HEATER CONTROL PANEL»(ref-13719-S04677175532004012800000).
7. Remove cigarette lighter connector.
8. Remove dashboard mounting screws and lift off dashboard.
9. To install, reverse removal procedure. Ensure wires are not pinched.

Scheme 30

1. Remove side defroster cover plate (marked A). Roll panel vents (marked B) downward and pull out or pry sideways using a screwdriver. (Scheme 31) Remove right-side air duct behind vents.
2. Remove left and right side speaker covers, and speakers.
3. Remove cover screws and lift dashboard covers off. (Scheme 32)
4. Install in reverse order. Ensure hooks on right side of cover plate fits into upper frame section. (Scheme 32)

Scheme 31

Scheme 32

1. Remove climate control unit. See «CLIMATE CONTROL UNIT»(ref-13719-S41425865302003121900000).
2. Remove central screws and clips. Then remove evaporator cover screws and clips. Lift evaporator out. (Scheme 33)
3. If reusing evaporator, clean thoroughly and treat with a deodorizing agent. Inspect rubber seal. If not visibly damaged it can be reused.
4. Install in reverse order.

Scheme 33

1. Clamp heater core hoses at firewall. Press clips on quick-release hose connectors inward and pull heater core hoses out.
2. Remove left-side insulating panel from underneath dashboard. (Scheme 34) CAUTION: Airbag system MUST be disabled before working around airbag module to prevent injury from accidentally deployed airbag. NOTE: Glove compartment must be removed to remove right-side insulating panel.
3. Remove glove compartment. Remove right-side insulating panel from underneath dashboard. (Scheme 21)
4. Pull carpet away from floor console and remove support plates. (Scheme 35) Remove amplifier bracket and amplifier if applicable.
5. Remove drain hose. (Scheme 36) Remove heater core case screws. Disconnect heater hose pipes. Remove heater core and heater core case as an assembly by pulling towards rear of vehicle. Remove heater core from heater core case.
6. To install, reverse removal procedure. Use NEW "O" rings on heater core hoses. Bleed and top off cooling system when installation is complete.

Scheme 34

Scheme 35

Scheme 36

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect air intake hose and remove hose connector to fan cover. Remove control unit air intake hoses and Electronic Control Units (ECUs) from control unit box.
2. Remove control unit box air intake hoses and remove inlet hose connector to fan cover (2 clips). Remove fan cover. Disconnect relays and wires from fan cover. Remove fan cover (4 screws), remove relay casing and spacers. Disconnect 2-pin connector from fan relay and connector from fan motor. Remove fan cover. (Scheme 28)
3. Shield radiator. Disconnect suction pipe from compressor. Disconnect snap-on connectors from receiver-drier. Remove right side headlight cover. Remove screw from receiver-drier bracket.
4. Remove air guide. Remove receiver-drier and bracket. With bracket suspended from side member, lift receiver/drier out. Remove receiver-drier from bracket.
5. To install, reverse removal procedure. When replacing receiver-drier, fill new receiver-drier with 3 ozs. of new oil. Lubricate new "O" rings with compressor oil.