Volvo 240 Heater Valve Instructions 1348252 9131998 upgrade kit
Before removing the old heater valve you will want to drain off some of the coolant from the system or place a couple of towels under the heater valve and carpet to catch any coolant that spills. A couple of wooden plugs whittled to block the heater hoses might be handy.
Remove the old heater valve and the bracket that holds it.
Cut 1 ¼” / 30mm off of the heater hose that comes from the firewall.
Remove the metal ferrule on the old cable. (See picture.) You may want to remove the cable to do this. With the cable out you can carefully hacksaw through the metal, the insert the blade of a screwdriver and give it a twist to spread the crimped part so you can take it off. A Dremel tool or die grinder will do the same thing without taking the cable out.
Install the heater valve in the hoses without the clamps so you can see how the cable fits. (See second picture.) Tighten the cable clamp and you can begin to form the loop at the end of the wire. You probably will need to take the heater valve out of the hoses to finish forming a loop on the end of the cable wire.
Operate the heat control slide lever several times to be sure the valve closes all the way.
Note that the picture shows the valve assembly without the supporting foam pad. Push the valve assembly forward slightly and place the foam pad under the valve in such a way that the hoses are not kinked and the valve lever operates freely.
Test the operation of the valve before replacing the plastic kick panel and trim. Top up the coolant.
