1986 Volvo 240 heat-AC switch levels 1,2 not working...
 

So I just bought a 1986 Volvo 240DL and the heat-A/C control switch, has four levels and levels 1 and 2 do NOT work. Levels 3 and 4 work fine.

I went on eBay and bought the entire piece shown below and swapped out just the control knob and mechanism behind it and to my surprise I still have the same issue! 1 & 2 not working, 3 & 4 working fine.

Any ideas what could be causing levels 1 & 2 to still not be working even though I've swapped out the control switch?


https://cimg9.ibsrv.net/gimg/volvofo...f5a166fc4a.jpg

https://cimg9.ibsrv.net/gimg/volvofo...9f372b3bdd.jpg

You need to replace the blower motor resistor. It give you the 4 speeds.

Tx. I'm seeing info all around on replacing the blower motor but not too much on the resistor, do you know of any links?

the resistor is on the back side of the motor.

So with everything I'm reading about how much of a job changing out the blower motor is I should just change that as well since I'll already be all the way in there. Do let me know if I'm on the wrong track here and should leave the old (1986) motor in there but I don't think I am! Tx.

well, if the original motor is still in good shape, I'd consider leaving it alone, as the replacement stuff is much cheaper construction quality.

With the motor out of the vehicle, I might play around with applying 12V to the various resistor terminals and listening to how it runs on a bench, seeing how smooth and free of shaft play, etc.

Yeah good points. I guess once I change out the resistor and figure out how to get there and everything it won't be that bad if I have to eventually revisit it to swap out the motor. Tx.

there's two options for changing a 240 blower (or the attached resistor).


the official method involves a massive diassembly and removal of the entire dashboard to get to the airbox.

the chainsaw method involves cutting access holes in the sides of the airbox to remove the fans and motor, and then using the cutouts as 'doors'.


thhis random pic I cribbed has the dash mostly removed but the airbox is still in place. the fan is buried in there still...

https://cimg5.ibsrv.net/gimg/volvofo...ff0737c01d.jpg

Yeah from everything I see it's a nasty 10 hour minimum job.

Two related questions:

1 - Any idea if the heater core is in the same area? I'm noticing heat issues with the car as well and might want to swap that out if it's close by.

2 - And when I run my A/C I'm noticing a slight water drippage issue from condensation buildup that's appearing on my passenger side floor. Anyone notice that before and know a fix for it? Tx.

unless the core is leaking, heater issues are more likely the valve, which, on a 240, is a mechanical cable driven valve just to the right of the drivers foot. you can replace the somewhat complicated volvo valve with a variety of altenratives, I like this one...

Volvo 240 heater valve kit replaces 1348252 9131998 $59! Volvo 240 heater valve kit replaces 1348252 9131998 $59 [] - $59.00 : EuroPartsHouse, Bargain parts for European cars!
Volvo 240 heater valve instructions 1348252

this is, I believe, a heater valve from a 1980s Dodge Truck, with the adapters needed to make it work in the Volvos. it will outlast your car and work great.

Tx. Any ideas about the leaky A/C condensation on the passenger floor?

thats a function of the drain hoses from the air box to the underside of the car. they are probably plugged up or entirely rotted away... in high humidity the AC condenser inside the airbox sheds quite a lot of water, this needs somewhere to go.