My AC loses its charge every 7 - 10 days, juicing it is getting old. According to my newly borrowed leak sniffer, the evaporator is suspect. So, I thought I'd simply drop the bottom half of the plastic box beneath it and verify by finding AC oil in there or on the evap, before shelling out the bucks. According to the Volvo manual its easy, right; well wrong, I can't get the plastic box off. I've got all the screws out, but no movement. Is it the black sealer tape holding it up? If I remove it should I have new black sealer tape (butyl tape?) ready to go? Am I missing something else? Thanks for any help.

If this is similar to my 1990 740 than you might be able to take off the fan resistor and take a peek in there with a light and small mirror.

When I replaced my evap. I took a dremel and cut the housing apart!! Not a good way, but it worked.
jc
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1985 740gle na, 1990 740gle 16 valve

Was it glued together with something other than the black butyl? Did you cut it around the joint or somewhere else? How did it go back together?

The lower plenum is a pain. After making sure you've removed all the screws, including the semi-hidden ones in the back, then pry the halves apart. They are stuck together with the butyl sealer.