1971_144GL;68304 wrote
You are almost guaranteed to break a couple of the rubber hangers from the duct system, if they are not already broken, so have spares.
Seconded with Gav - excellent write-up.
I'll just add these minor points -
- One way to avoid breaking the little rubber hangers on the ducts is to unbolt / unscrew them - the floor ducts are attached to a bracket which unbolts, while the demister duct brackets are screwed into the dashboard top.
- While you're in there, it's also worth considering the replacement of the 40 year old rubber hoses between the heater core and the firewall flange.
Volvo's official service document for the 240 HVAC is TP30282/2.
http://www.scribd.com/doc/115217504/Volvo-240-Heater-and-Blower-Unit-Green-Workshop-Manual-TP30282-2#scribd
Of interest is this:
Vehicles buiit during 1975-1980 have a field wound fan motor. 1981- vehicles have a 4 speed permanent magnet motor. In the future only this type of motor will be stocked as a spare part. When installing a new type motor on 1975-1980 vehicles modifications and additional parts are required to obtain correct fit.
Given a choice between the old Electrolux field wound motor and the new permanent magnet one, I'd stick with the Electrolux and give the brushes and bushes a birthday as
@1971_144GL suggested.