The kit the mechanic was talking about is NOT designed to stop an exsisting leak. But, if the kit is installed after the leak is properly fixed (new evap), it is supposed to add life to the repair.

This kit consists of a hepa filter and brace that covers your new evaporator.

The whole dash must be removed for the repair and when done correctly, could cost from $1000 to 1200.

It's not a cheap repair and a common problem. There needed to be a class action suit against VOLVO for the 850 AC problems. Plenty of stories - just like yours - from the Volvo faithfull.

I have a '95 850 Turbo. My evaporator went about a year ago. I bought the kit and replaced myself over the past weekend. The kit consists of; a new evaporator, receiver dryer can, and pollen filter and filter holder. The 'upgrade' to the blower motor is a cover (1 inch piece of plastic) to lower the air that is re-circulated to the blower motor, some upgrade! Once the system was apart, I ended up getting a new blower motor. The old one was squeaking, but the real issue was the brushes on the motor were worn. And when you spend 8 hours getting the dash and heater core out, you better take the opportunity to change it while it is easy. It was a lot of work, but turned out great. The advantage of doing it yourself is you tend to fix everything you find along the way. After 114k miles, there’s a lot of broken mounting connections under the dash. The dash squeaks less now than it did before thanks to lots of Teflon tape. The disadvantage is it takes a really long time to do and is a very hard job. The entire job took me 20 hours. I am sure the dealer will do it quicker, but they won't take the time to fix all the broken stuff and tighten all the loose screws.

There is no kit/fix I know of to fix it without replacing the evaporator. The seal kits don't work; I tried the cryo-chem one. And once you see what a leaking evaporator looks like, you understand why it can't be sealed from the outside, very ugly!

I am just praying that the new evaporator does not leak EVER!!!

-Joe Gerber

volvo makes a upgrade kit that is an option to the new evap install. the kit is the Pollen filter/fan motor vent kit?. there is some upgrade to the fan motor that helps to keep moisture out of it, i think it is just some sort of add on cover.

go to www.cyrochem.com they have a Self Sealing Refirgernat kit R134 for about cost varies depending on where you get it from. I talked to a guy who paid I think about 140.00 and i have seen it for 199.00

Dan

There are stopleak kits, but they are not made by Volvo. Do a search on the forum for the last few weeks, and you'll find some discussions. As always, there are pros and cons to the approach.

Gerald C