New Heater Control Valve For Climate Control System (GROUP 87, NO. 211)

Publication date: 1993-09-01
Reference number: GROUP 87, NO. 211

NEW HEATER CONTROL VALVE FOR CLIMATE CONTROL SYSTEM

TECHNICAL SERVICE BULLETIN

Reference Number(s): 87-211, Date of Issue: September, 1993

NEW HEATER CONTROL VALVE

Model(s): Volvo 240, All

Section: 8 - Body

Group: 87 - Climate Control, Air Conditioning

Bulletin No.: 211

Market: US and Canada

Date: September, 1993

REFERENCE

TP 31120/1 (ENGLISH); 12/87; BODY FITTINGS, INTERIOR, HEATING AND A/C

NEW HEATER CONTROL VALVE FOR CLIMATE CONTROL SYSTEM

A new heater control valve, P/N 3540503-4, has been introduced on production models from 1992 on. The new valve, which has an improved low-temperature control characteristic, is easier and smoother to operate, and supersedes the earlier type as a replacement.

Conversion kits have been produced to permit the earlier type of valve to be replaced by the new type. The part number of the kit is P/N 9131998-8.

WARNING: Care should be taken when working with coolant at operating temperature.

A) REPLACEMENT OF HEATER CONTROL VALVE, MODELS TO 1991 INCL.

A1) CLAMP HEATER HOSES

Open hood.

Clamp heater hoses with hose clamping tools. See Fig 1 .

Loosen expansion tank cap to relieve pressure in system.

A2) PREPARATIONS FOR DRAINING COOLANT INSIDE CAR

Remove/disconnect:

Soundproofing panel and knee bolster/support bar on left-hand side.
Center console side panel.
Carpet (fold back).
Cover beside accelerator pedal.

Place container under heater hose connection to collect coolant. See Fig 2 . Use clean rags to absorb any spillage.

Remove/disconnect:

Soundproofing and center console side panel on right side.
Bolts holding center console panel.

A3) REMOVE VALVE AND MOUNTING BRACKET

Remove/disconnect:

Control cable from valve.
Valve incl. capillary tube and bracket from heater housing (pull towards left).
Support (A) between body and heater. See Fig 3 .
Reinstall capillary tube rubber grommet (reseal tube hole with duct tape or butyl tape).

A4) REMOVE VALVE AND CONTROL CABLE

Refer to Fig 4 .

Heater hoses in engine compartment must be clamped.

Clamp hose (A) from heater by applying hose clamp tool beside valve in car.

Undo hose clamps (B) and remove valve (C) with hose.

Disconnect cable (D) at control panel (E) and remove cable.

A5) ATTACH NEW CABLE TO NEW VALVE

Insert wire in hole in valve control arm.

Adjust position of cable in clip (A) so that valve opens fully end closes fully. See Fig 5 .

CAUTION: Control arm is easily broken and must be treated with extreme care.

Bend mounting bracket (B), 90° to left. Route cable between heater housing and radio compartment, and through hole (C) in heater mounting bracket. See Fig 6 .

A6) INSTALL NEW CONTROL CABLE

Attach cable to control lever. See Fig 7 .

Adjust position of cable in clip so that valve opens fully when control lever is set to maximum and closes fully when control lever is set to minimum.

A7) ASSEMBLY OF MOUNTING BRACKET, HOSE, VALVE, PLASTIC FOAM PACKING AND HOSE RETAINER

Install/connect:

Plastic foam packing (A) and hose retainer (B) in bracket with screw. See Fig 8 .
Hose from heater to valve. Tighten hose clamp.
Secure hose in retainer.
Close valve and remove hose clamping tool.

NOTE: Valve must be closed or coolant will leak from heater.

A8) INSTALL MOUNTING BRACKET AND VALVE

Refer to Fig 9 .

Push bracket (A) into slot in heater and secure with clip (B).

Bend mounting bracket (C) back into position.

A9) INSTALL NEW HOSE AND REFIT SUPPORT

Refer to Fig 10 .

Install:

New hose (A) between firewall connection branch end valve. Tighten clamps.
Support (B) between body and heater.

A10) REMOVE HOSE CLAMPING TOOLS

Remove clamping tools from heater hoses in engine compartment. See Fig 11 .

A11) CHECKING PROCEDURE

Check:

Coolant level and tighten expansion tank cap.
Operation of heater with engine running.
Inspect for leakage.
Top up coolant, if necessary.

A12) REINSTALL COMPONENTS

Remove container and rags from underneath heater hose connection in car.

Reinstall/reconnect:

Cover beside accelerator pedal.
Carpet (refit).
Bolts on center console panel.
Center console side panels.
Soundproofing panels and knee bolster/support bar

B) REPLACEMENT OF HEATER CONTROL VALVE, MODELS FROM 1992 ON

B1) CLAMP HEATER HOSES

Open hood.

Clamp heater hoses with hose clamping tools. See Fig 1 .

Loosen expansion tank cap.

B2) PREPARATIONS FOR DRAINING COOLANT INSIDE CAR

Remove/disconnect:

Soundproofing panel and knee bolster/support bar on left-hand side.
Center console side panel.
Carpet (ford beck).
Cover beside accelerator pedal.

Place container under heater hose connection to collect coolant. See Fig 2 . Use clean rags to absorb any spillage.

Remove/disconnect:

Soundproofing and center console side panel on right side.

B3) RELEASE MOUNTING BRACKET AND VALVE

Refer to Fig 12 .

Disconnect support (D) from mounting bracket (C) by loosening bolt (A) and removing bolt (B).

Bend mounting bracket (C) 90° to left.

Bend the two stops (E) downward and pull mounting bracket (F) and valve 30 mm to left.

B4) DISCONNECT CONTROL CABLE FROM VALVE

Remove:

Clip (A) securing cable sleeve. See Fig 13 . Pull gently towards left sufficiently to free cable from valve control arm.
CAUTION: Control arm is easily broken and must be treated with extreme care.
Valve, by clamping hose from heater with hose clamp tool and undoing hose clamps.

B5) ATTACH CABLE TO NEW VALVE

Insert wire in hole in valve control arm.

Adjust position of cable in clip (A) so that valve opens fully when control lever is set to maximum and closes fully when control lever is set to minimum. See Fig 13 .

CAUTION: Control arm is easily broken and must be treated with extreme care.

B6) ASSEMBLY OF MOUNTING BRACKET, HOSE, VALVE, PLASTIC FOAM PACKING AND HOSE RETAINER

Refer to Fig 14 .

Install/connect:

Hose from heater to valve. Tighten hose clamp.
Secure hose in retainer (A).
Close valve and remove hose clamping tool.

NOTE: Valve must be closed or coolant will leak from heater.

B7) INSTALL MOUNTING BRACKET END VALVE

Refer to Fig 15 .

Push bracket (A) into slot in heater and secure with clip (B).

Bend mounting bracket (C & D) back into position.

B8) REINSTALL HOSE AND REFIT SUPPORT

Refer to Fig 10 .

Install:

New hose (A) between bulkhead connection branch and valve. Tighten clamp.
Support (B) between body and heater.

B10) REMOVE HOSE CRAMPING TOOLS

Remove clamping tools from heater hoses in engine compartment. See Fig 11 .

B11) CHECKING PROCEDURE

Check:

Coolant level and tighten expansion tank cap.
Operation of heater with engine running.
Inspect for leakage.
Top up coolant, if necessary.

B12) REINSTALL COMPONENTS

Remove container and rags from underneath heater hose connection in car.

Reinstall/reconnect:

Cover beside accelerator pedal.
Carpet (refit).
Center console side panels.
Soundproofing panels and knee bolster/support bar.

WARRANTY INFORMATION

WARRANTY STATEMENT: Claims may be submitted under the New Car

Limited Warranty when a manufacturing defect is

present using claim type: 01 for the conversion

kit on a one-time basis only.

WARRANTY INFORMATION

Operation Number	Labor Description	Time Allowance
873513	Heater control valve, climate control system, replace, including conversion kit - models to 1991 incl.	1.1 hr.
873512	Heater control valve, replace - models from 1992 on.	0.6 hr.