Bearing is squealing so its time to replace the motor. How long should it really take me? I've read the Chainsaw method, the modified chainsaw method, and the hole-saw method. Why does the Bentley manual not refer to cutting out the venturi? Are the later 240 models designed so that the venturi need not be cut? If I choose to use the no-cut method, what is the best way to get at ducts coming off the upper portion of the blower box?

Thanks for your assistance before I begin this task.

Hi Mark:

I started at 9:45 a.m. and finished at 6:00 p.m. I was taking my time and was also doing it in 100 degree Texas heat. Stopped to eat lunch, do a failure analysis on the old part, test the new unit several times as I was putting everything back together, and several Gatorade breaks.

I suggest writing down some of your best cuss words, because I guarantee that you will use up your usual list of choice words several times before finishing this job. Once you have the entire job completed, you WILL experience a great deal of satisfaction for finishing this job.

Be sure to look up my post from July 1, 2010 and learn from my experience, this probably being the most important:

"One important note, the old motor, when viewed installed from the driver’s side, has its two power wires at about the 7 o'clock position. There is a flat part to the motor flange, and it rests facing the front of the car. On the new motor, the wires exit at about the 10 o'clock position, so don't let this confuse you."

Good luck.
--
If it needs to be maintained, repaired or replaced on a 1990 240, I've probably done it. '90 240DL, 291K looking forward to 300K badge (or sticker??). >>You haven't really worked on a car until you draw blood<< :-}

Thanks to all for info and pictures. I plan to attempt next thursday and friday. I think I will remove the dash cover. This old body needs as much access room as possible. I did the heater valve last spring.

Mark

I have done about 12-15 of those over the years.The book calls for 6 hours. Without saws or torches it takes me about 6-8 hours. Shortcuts on this job mostly cause more problems. One of the tricky parts is the rear floor vent flaps. Make sure they are correct before proceeding.

The newer cars with 4-speed blowers don't require grinding the blower case.

The defrost-outer dash duct does not need to be removed from the car.Remove the outer L- bend that hooks to the outer vent and slide the duct toward the doors.I don't remove the dash cover, work through the glove box and panel holes.

Bill

Hi Mark,

I can guarantee you'll have it done in one day if you work at my pace. Well, you asked how long it will take you.

AS for the other questions, getting the upper vents disconnected requires you get behind the glove box and instrument cluster. Once you've removed those two items, you're only a handful of screws from having the dash out, which will make the rest of the job seated and comfortable.

The Bentley venturi question I don't get. Are you saying Bentley suggests chainsawing the blower motor? I missed that one.



The first few pics in this heater core replacement history deal with getting the dash out. From that page you can also see Volvo's green book manual with step-by-step procedure for dash removal and motor replacement.
--
Art Benstein near Baltimore


Duct tape is like 'The Force'. It has a light side and a dark side, and it holds the universe together.

Art if I remove the dash cover, must I remove the center console first? Also am I correct to assume that I must pop off the defrost vent covers? In the heater core replacement pics it shows a secret screw and attached brace - t what does the back end of the brace attach?

Thanks!!!

Mark

i prefer to do it properly and avoid hacksaw. budget two days for a thorough job, because you will likely get sidetracked into fixing up small things under the dash as you dig deeper. cleaning grounds, replacing bulbs, bundling wires and vacuuming leaves, etc. test the new blower motor BEFORE you start tearing things up.

i recommend taking the dash off for the job, and replace the heater valve at the same time.

I would say a good eight hours if it's the first time. The chainsaw method will take quite a bit less. When the Swedes built your car, they started with the blower motor on a little stand and built the entire car around it. Make sure you mark all of the wires and take a few pics on disassembly...Have fun!
--
http://www.facebook.com/#!/album.php?id

Hello Mark,

When I did it for the first time, I started at 8am and finished disassembly by lunchtime.

I didn't get done til 11pm that evening with reassembly.

I had my 19 year old help me til about 6 when he got disgusted and left. My wife then came out to babysit me.

If you are deliberate and careful, and use Art B's instructions, you can probably get the job done in 8 hours, maybe less. I've heard "stories" that those versed in the art of blower replacement can do it in 3 hours.

If you have a son or daughter, I'd grab them for assistance or company. A wife will work too.

Good luck.

Marty