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Hi NormL,
1) A reman'd compressor would be easier to install then just the clutch. Good idea about the later model R134a compressor but I don't know what else was changed by Volvo to deal with the change to R134. The newer compressor model might nrequire a different evaporator or condensor. Check with someone who knows for sure.
2) I bought my PAG oil from the dealer. Wasn't too badly priced but I only bought a small can. A/C outfits should have it and cheaper as well.
3) The 20K mile timing belt was upgradeable to a 50k belt (IIRC) with a kit from Volvo changing out the gears, pulleys, etc... They did not offer a kit to go to the 70K belt on the 95-later models to my knowledge. I don't know if you can just take the parts off a later model and go 70K.
4) The water pumps on these engines last a long time. I just did the T-belt R&R on our 95 with 152,000 miles and did not replace the water pump. No leaks, noises or other unusual signs so I left it in on the recommendation of Volvo mechanics who said "don't change it if there's not a problem".
5) Don't know about the rotor size but any shop can tell you. But have you checked the wheelk lug torque on each nut?
DEWFPO
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1998 S90 068,300 and 1995 964 152,300
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