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The evaporator on my '98 quit at 101,000 miles. Mine was one of the first '98s to fail according to my dealer. Supposedly "improved" after the 850, the evaporators still seem to be failing regularly. The "approved" method is to add dye to the AC system and then look for the dye in the AC condensate. If there is dye in the condensate, then the evaporator must be leaking. The dye test is critical, there is a lot of other stuff in the system that can and does leak. The AC has never been a strong point of Swedish cars. Sometimes the leaks are slow, if you can get by with recharging the system annually, (or even biannually) that's an option to consider. Most of the cost is in the labor, the evaporator is deeply buried in the dash, which needs to be removed.
Some Volvo techs are getting very fast at performing this repair!
-Punxsutawney Phil
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