So in trying to figure out how I'm going to attack two different 240's with A/C issues, I have a couple of questions. Both are the older TXV systems and one has already been retrofitted and mostly blows cold (going to the 91+ system would be time and cost prohibitive at this point). The other car could be redone a couple of different ways since I will be fitting a Diesel-Kiki to it and all the hoses need to be replaced.

I also have an 86 that I retrofitted several years ago with the full Volvo kit, which included the newer parallel flow design evap core, which does an amazing job of blowing cold even in 100+ temps with R134. The original core sucks with 134, which is what I have in my 90 245. If I ever junk this car, I will pull that evap out before it goes. So some questions/observations:

1) The TXV retrofit kit is no longer available anywhere (unless you have one, then sell it to me!). Thus, you can't get the newer parallel-flow evap core. Are the dimensions of the '93 core the same as the older tube and fin version? Is it actually a parallel flow? If you got one and simply had the fittings changed over (braze the TXV stuff onto it), how would this work? It appears to be plate and fin, but I'm not familiar with the way it's designed.

2) You can get lots of different sizes of parallel flow condensers from places like ackits.com for a nominal cost. It would be easier to change the condenser than the evaporator and there are many more options. If you were to weigh the impact of one over the other, which is more important in the system? (Ie. if I did just the condenser, would I see a 30% increase in efficiency with using the old evap vs. if I concentrated on changing the evap, then would I see a 70% efficiency?) I think I know the answer, given what was in the Volvo retrofit kit, but where's the best bang for the buck if you're stuck with an R134 TXV conversion and all the components in the system are in good service, but it's just not as cold as it could be when it's 100+ outside?

3) Pusher fans. Yep, I have one. I used a 2-speed 850 e-fan, so it blows a high volume of air over a large area in front of the condenser when the AC is on. It's larger than the 93 240 pusher fan.

4) According to the retrofit TSB, if you do the upgrade, you aren't supposed to insulate the TXV. Why is that? I don't remember if mine in the two retrofits were insulated or not (or if that valve is normally insulated). If they are, could this be causing the system to ice up and not function? How much of that stupid valve are you supposed to insulate? I remember that the Volvo kit included enough Butyl to insulate from here to China and I didn't use all of it. I've also heard that it's possible to put a little butyl insulation between the large pipe below the TX valve and the capillary coil (I think I have those correct -- I don't have the drawing in front of me) and that this will cause the system to run cooler, but I also question if that will raise the pressure in the system.

Found this to be a good thread:

http://www.brickboard.com/RWD/volvo/626725/220/240/260/280/1986_volvo_240_ac_recommendations.html

Also wondering if anyone has done step-by-step documentation of swapping a 91-93 system into an 82-90 car.

Thanks for feedback.

B