Turbo Brick Heater Valve Help!

[phil_lihp]

Hopefully someone can shed some light on this for me because I'm running out of ideas.

 

Since I got the 940 the heater hasn't worked properly and I've recently noticed the car steams up constantly suggesting a damp interior.  I found the heater valve was leaking, a common issue on these, and being non-aircon it was a Volvo-only part whch cost me £73 for a small plastic valve.

 

It's the bit here next to the clutch pedal with the pipe going into it:

 

 

(not my car)

 

I have had an absolute nightmare with this, the valve is horribly inaccessible although the replacement process seems dead simple:

 

Disconnect battery ground and remove left side dash under panel and air hose

Remove the accelerator pedal and the the ignition control box and, if you have it, the cruise control connector, all for better access.

Clamp off lower hose from valve to heater core

Clamp off lower hose in engine compartment then disconnect

Place cloth on carpet to soak up spilled coolant

Remove lower hose inside car connected to valve

Remove control housing from water valve

Remove plastic valve by rotating clockwise. Unhook cable

To Install:

 

Reconnect cable to water valve

Install valve by placing it on the mount and turning counterclockwise

Mount and adjust the control housing

Reconnect hoses under dash and in engine compartment

Remove hose clamps

 

The problem comes when attempting to remove the old valve by rotating clockwise - you can't because the clutch pedal bracket is in the way.  You can see it in the above photo, it's the angled metal plate almost touching the valve body.  It stops you rotating the valve enough to engage the tabs in the slots to remove it but only by a few degrees, frustratingly.

 

I spent so long on this today that I got a bit fed up and managed to more or less force the old one off - it's absolutely knackered and well overdue for replacement anyway but this wasn't really a good idea as I cannot get the new one on because the clutch pedal bracket is in the way.  None of the instructions I've seen mention this problem.  

 

There are two bolts on the pedal bracket but it's held on firmly by the clutch mechanism that passes through it and looks like a permanent part of the car.  I cannot see how on earth it can be removed to allow the valve to be turned enough to slot in.

 

I'm now at a complete loss.  The car is immobile on my driveway with clamped off water hoses and a driver's footwell carpet now absolutely swimming in coolant.  I've cut my hands to shreds on the nasty sharp plastics behind the dash and frankly I'm getting a little concerned that I've dug myself into a hole and perhaps I should have just left the old one in place.

 

I think I'm missing something here, anyone done this job or know how these things work enough to give me a pointer?  I'll be endlessly grateful if so!

[red5]

I'd take the clutch pedal out there tbh. Can't see how that valve will clear the clutch pedal bracket.

[phil_lihp]

I agree - I think the instructions were written for an automatic.  My problem then is how to remove the pedal as even with the two bolts taken off, the bracket is rock solid, I'll have to have another bash at it in the next few evenings when I have a spare hour or two.

[Sigmund Fraud]

I'd take the clutch pedal out there tbh. Can't see how that valve will clear the clutch pedal bracket.

 

+1, you must take the pedal off to replace that valve in manual 700/900s. I don't think you need to take the bracket or master cylinder off, though.

[danthecapriman]

As above, clutch pedal must come off.

If it's any consolation though, when I did this job on my old 740, which was an auto, it was still an absolute bastard to twist and pull out! I'm sure I ended up removing the brake pedal too, for more access/space to work. As you say access is crap. I was laying upside down on top of the seat with head up under the dash!

 

Mine was the original item from 1987 so was we'll in there. I don't think there's any way around it other than to struggle I'm afraid!

 

Also I got a Bosch one (identical to OE) from Brookhouse Volvo parts for £54 (I think from memory).

[phil_lihp]

Thanks chaps, at least I know now. Any tips on how to remove the clutch pedal? Does it come off from the engine bay side?

 

This has been one of the most unpleasant jobs I've ever done on a car, yet the actual valve replacement itself is so simple!