Guide: 760 88+ / 960 / Mk I S90 -V90 RHD dashboard removal & heater core replacement
(This thread is a work in progress until this text is removed)
This guide covers the COMBU type unit with air conditioning and ECC fitted in RHD cars only; LHD cars will be different.
"Step AAE#" refers to the Green Book designation for the process in LHD cars, if it exists.
References / sources of pics, etc :
- TP 31127/1 Green Book ("Body Fittings - Interior - Climate Units, 740/760")
- RobertDIY video - 'How to replace the heater core in the Volvo 960'
- writer's experiences
Before you begin:
- Order the following / have these on hand:
1 x replacement heater core for RHD COMBU unit - OE p/n is 1307277-2, but the 20528 heater core made by vehicleheaters.co.uk is readily available, well made, less expensive... and ships from the UK to OZ in about 10 days.
5x dashboard clips - p/n 1348040
1x replacement 4-port heater tap - Gates HV5631 or similar with 5/8 inch fittings
2x Calibre CH1780C or similar Z-shaped heater core hoses. (One of the OE heater core hoses for RHD cars is now NLA, so some improvisation is necessary)
8x good quality hose clamps for 5/8 heater hose. Adding the 4-port heater tap means you'll need 4 more hose clamps - 4 at the heater tap; 2 at the heater core; 2 at the engine.
(if your system suffers from loss of face-level air under acceleration, etc) Replacement vacuum motor(s). You may as well replace the perished one(s) while you're in there. Complete replacement 2-port units are AC Delco p/n 15-71438 or GM p/n 1996686, or @asiandriver sells a replacement seal for them.
Many, many replacement cable ties. Cable ties are a central design element of the Volvo 700/900 series.
- Tools list (minimum)
7, 8, 10, 12, 13, 14, 17, 19 mm sockets with a variety of extensions (and preferably also combination spanners of same sizes)
Needle nose pliers
A variety of flat blade screwdrivers - small and large
A variety of Philips head screwdrivers - small and large
A magnet (for collecting errant screws that want to screw around with you)
A plastic trim tool
A variety of Torx bits /drivers - you will need at least T10, T15, T20, T25, and T30 sizes.
An Allen key (for size, see Step AAE10)
- Prepare the car (Step AAE-0, not in Green Book)
Park the car so that the front wheels and steering wheel can be rolled backwards or forwards enough to point straight ahead. (You'll see why later).
If the car has power front seats - before disconnecting the battery, raise them and move them fore/aft so you can easily access the four 14mm bolts which secure the seats to the floor.
Empty out the centre console and oddbins box under the radio of personal effects.
All set? Let's begin.....