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Hello,
you'll probably will have a lot of posts on this one. replacing the fan is quite doable, but tedious. i've done about 2 replacements and it's no fun.
taking the dash off will make the access the easiest. but most people, i'm sure, keep the dash on.
good news, you won't have to use the dremel on later model 240s (86-). there are no mounting bosses to cut off in the later models.
art bernstein has this post.
http://users.erols.com/benstein/
another post, more than just blower info.
http://www.sonic.net/~zipzippy/volvo/volvo%20240%20faq.html#blowermotor
you will be taking a lot of parts out. taking the front seats out will help much.
be careful when removing the side round ducts, they are plastic and can tear if too much force is used. also, the later 240s (eg '93) black side round ducts don't match up with the earlier 240s (eg '86).
i tore my 86 245 side round black vent duct and retrieved a 93 side mount black duct prelacement and wound up taking all of the inner & outer, both sides & top duct from the '93. definitely increased my frustration. i went ahead with the 93 ducts because they were newer and in great shape--i took the dash from the 93, so it was easy to get to all the parts.
be careful not to bend the fan blade thing that attaches to the motor when removing too. and if it has a retaining clip, push it with a small screwdriver while holding it against the fan blade thing. if it pops off, it will fly.
just a thought, while your in there, you may want to replace the fan speed resistor, my '86 resistor was falling to pieces.
there's more info to be added by others.
the blower motor--it's just one of those things.
regards,
byron golden
86 245
92 245
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