Hi, I'm new to this forum, if my post has anything inappropriate or incorrect feel free to comment me, thanks.

Long story short, the blower started to make lots of smoke, so ends up replacing it today. Used Chainsaw method, the online instruction is very accurate.
The entire replacement took about 3~4 hours, including cutting, cleaning and wiring. The actually time to fish in and out the motor plus wiring was only 30 mins. Most of time was used to fight with the blade cover and the fan blade.

The cutting was straight forward, but took much longer time to avoid those wires other than actual cutting. Didn't make it a round shape as I have no plan of taping the plastic back. When cutting, I made sure the hole is as big as possible cos I know there will be a fight with the fan blade.

Somehow pulled out the fan blade, need to cut the inner ring to get the motor.

Here I did something different from the online instruction. I cut the old motor wires instead of took off more things under the dash to get the plug, this really made my life a lot easier


The red wire coming out is the motor power wire, the ground is shorter inside, both are the old motor wire. Simply cut off the wire skin, and connect it with new motor.

Everything was tested before put back in, the resistor was fine and the connecting remains good. Juncktion point of wires are protected by heat shrink tubes and the extra wire can be stucked below the motor with no problem.

To cover the hole, don't try to tape the plastic back, they will fall eventually. I used a thick piece of aluminum foil from a big aluminum baking tray. Simply put it on, cut it into the shape you want, fold the edge to make it fit better and tape it on. The good thing is, the foil can be made into any shape you want and much easier to play with, you can even put small screws to lock it on rather than using bunch of tapes. Next time the motor fails, replacement would be much easier.

 

On the bright side, you have a working fan. Otherwise, I can't see doing this to a car I care about...

 

Ya, it is bit ugly, if spend more time trim the edge won't be that bad but if you got time and space definitely properly take everything apart. Unfortunately I don't have that much time for it and winter is coming. But functionality wise it doesn't affect that much, so I would say it may be a suitable way for some people.

 

In my opinion 240 design is on of the worst volvos ever!! They overlooked alot!!!!!!!

 

the 240 was designed in the 1970s, and was really just a minor upgrade of the 140 which was designed in the 1960s.

 

+1 on that

 

the biggest single difference in the original 240 over the 140 was switching to mcpherson strut front suspension and rack and pinion steering. the redblock SOHC B21 engines came a couple years later, replacing the classic pushrod B18/B20 engines used on the 140's, which date back to the 1950s and the 544 and Amazon (122). The initial cosmetic changes were really minor, even the interior was pretty darn similar, except the instrument panel, going from a linear speedo to a more conventional 'clock' style speedo. 240's got a front and rear end treatment a few years later to the body style that was kept up til the end.