I am about to tackle the ac system. A car that sat for 20 years will have some issues. Ha. I have read that a scroll type compressor, a cross flow evaporator, electric fan, receiver drier, pressure switch, lines, and oil are what are probably involved in switching over to r 134. Lines, seals and gaskets after 32 years are tired. It would have to be changed either way.
Has anyone merrily skipped down this road to hell before.? I have a friend with a hivac license and evacuation system. Parts numbers and vendors would be appreciated.
Started to read some ****, ""The Hack Mechanics Guide to Vintage Air Conditioning.".

 

and hope the evaporator thats buried in the dash hasn't corroded and is ready to split the instant its pressurized again.

you really don't want to have to replace the evaporator on a 240, it involves removing the entire dashboard and center console and is probably easier if you take out both front seats first... when you finally get down to the evap, the interior of your car will look like a bomb has gone off inside. suggested that if you DO have to replace the evaporator, also replace the heater core at the same time, and get a quality new hvac blower too. the foam seals on all the air duct flaps that control airflow are likely crumbling, the vacuum bellows are probably brittle, and all that stuff is unobtanium nowdays.

 

With a non functioning compressor after evacuating the system can I charge it with nitrogen sufficiently to test the evaporator and condenser?

 

probably but i'm not an hvac expert. not even sure you have to evacuate it before pressurizing with N2 or whatever... if the nonfunctioning compressor leaks, then the pressure test won't be of much use.

 

Would it be possible to fabricate replacements from other vacuum hoses? Or did Volvo use a weird specific size?

 

well, the bellows aren't hoses, they are air-to-motion, they open and close the air control flaps. you might be able to adapt bellows from another newre model car that were approximately the same size...

and the foam seals around the flaps, those could be cut from flat foam rubber of a suitable thickness... I dunno if they are glued or riveted to the air flaps.

when the flap seals fail, you just get air leakage, like the vents won't completely shut off, nor will the recirculation flap completely seal, but everything will still more or less work. however when the bellows fail, then things don't open/close properly and you'll have issues with heat not going where it should, like no floor vs defrost control at all.

fun, one particularlly hot day, I fired up my 740 wagon, turned the AC on and cranked the fan up to 4, and the left dashboard vent blew a whole face full of foam crumbles at me...


(does some googling), supposedly this part will replace the single port bellows on a 7/9
https://www.stockwiseauto.com/acdelc...-door-actuator

no idea if its compatible with a 240. ah, no, its not, just 740/940 ...

and wow, ok, belows for a 240 ARE still available, at least hte one that fits the middlin' late 240s, I looked up 1987 cuz thats what we had. its PN 1215465, and 1215466, and https://www.volvopartswebstore.com/p...6/1215465.html and https://www.volvopartswebstore.com/p...1/1215466.html shows they are available.