Hey everybody! New to the forum. I replaced the heater core in my 91 740 turbo a few weeks ago, I guess you could say I'm a proper Volvo owner now lol. Here's some pictures that I took of the process.

Time to remove the core was 3.5 hours. Total time was probably around 12 hours over 3 days because I removed all of the carpets to pressure wash them.

Tools you will need:
7mm and 10mm 1/4 inch sockets
1/4 inch extensions
Universal joints
Socket wrench
10mm wrench
7mm ratcheting wrench (not necessary but very helpful)
Plastic pry bars (for interior pieces)
Philips and Torx drill bits.
Drill + small drill bit
Various screwdrivers
Sealant for heater core box
Hammer
Brass plumbing elbows
Flashlight
Small hands
Small phillips screw (For replacing the rivet)
4 cups of coffee
Cigarettes (optional)

First I bypassed the heater core with some brass plumbing pieces. (and disconnected the battery of course)


Then I took out the center console


Then the glove box


Then the ash tray and center storage/cig lighter assembly


Stereo and its housing (phillips screw deep in there)


Now you can remove the center side panels and the kick panels


Unclip the relay tray and move it to the side


Remove the heater control panel, make note of wiring and vacuum lines


Here's where the fun starts. Start removing ducting. Its a fairly strong plastic and can handle twisting and pulling.
http://i292.photobucket.com/albums/m...styuejghh.jpeg

Rear floor vents removed


Drill out the rivet on the distribution box and remove. Remove rest of floor ducting


Here's the heater core box. There's about 11 7mm bolts around it


Box is removed. Getting those bolts out took me about an hour


Closeup of heater core


Core is out yay


Old vs new. Idk why the company painted the new one silver. It's a Spectra brass/copper core ($70 on rock auto)

 

Wow! Thanks for dropping in and sharing.

I know I'll be in for a similar level of excitement when the time comes for a new core in the 960 under my care. In the meantime, premium coolant is the name of the game...

(Love that sticker in pic 2)

 

Hhahahahahaha thank you! Its really not too bad of a job. And you can thank taco time for that one

 

HI ! could someone tell me how exactly the heater core is secured to the bulkhead ? I've removed two 10mm bolts and the hoses (engine side) plus 7mm bolts and copper brackets (inside car) is that all ?
I can provide a picture if required.

=> auto solved nothing else needed, it was a little stucked.

Thank you.