Who has done a RHD XC90 heater core?
 

Hi All,
I'm in the process of attempting to replace the heater core in an Australian right hand drive 2007 XC90 which was initially clogged and then sprang a leak after chemical cleaning.
The coolant pipes are disconnected and up out of the way but the core jams between the white plastic plenum (the bit that has the pollen filter) and the main dashboard plastic when only halfway out during removal.
I've tried tilting and twisting it as it slides from its installed position but there just doesn't seem to be room to accommodate it's path for removal.
Can anyone shed some light as to the method of removal? The prospect of having to remove the dash fascia or the fan plenum assembly is not attractive.
Cheers,
Andrew

Can you upload a picture ?

I've found a solution and will post some photos shortly.
A quick and dirty hack to avoid a massive disassembly is to cut into the fan plenum to allow the core to slide out for removal and replacement.
The plenum plastic is quite thin and can be cut with a sharp utility knife. Once the core has been replaced the plastic piece can be reinstated and sealed with some polyurethane.
I cut the old core in half with my radial arm saw to inspect the tubes. All were choked with some sort of hard precipitate.
Chemically cleaning with an organic acid was a waste of time, replacement is the only option to restore the heater function.
I also removed the fan and oiled it's bushes as it had an annoying squeek at low speeds and vibrated at high speeds due to old leaf litter being caught in the squirrel cage fan. All smooth and quiet now.
I hope this helps anyone else that is contemplating a heater core replacement in a right hand drive XC90.
Cheers!

I actually attempted this last weekend on my aussie 2007 XC90 D5. The heater blows cool air and tried flushing/backflushing etc. I got to the point of cutting into the plenum but the wife was watching :tounge_smile:

Might try again this weekend as Canberra is pretty cold at the moment.

Well I got the new heater core in last friday, used a utility knife and small saw to cut the plenum and the core slid out fairly easily. Used 2-part epoxy and gaffa tape to ensure the plenum was sealed up tight again.

Overall it took just over an hour to complete.

I now have toasty (almost too hot) heat coming through the vents now!

Great stuff. Good DIY fix!

Great job! I may add, never use a garden hose to 'flush' the coolant system. The coolant system cannot be completely drained so remaining tap water will mix with the coolant will leave deposits in there. Use only distilled water when mixing with coolant (pharmacies will usually sell distilled water).

Very useful thread as my heater is blocked and am contemplating the dreaded replacement at the moment. I thought about cutting the plenum as well but it is a scary thought cutting into the Volvo with a knife although if anyone has any pictures that would be much appreciated. Otherwise I will find a wreck and practice on that first.

I see the Behr heater cores from FCP Euro in the States are $123 US so is pretty cheap with postage to WA being good as well. Also will order a new heater blower motor as well as am sick of the squeal - and I broke it getting it out as well that wasn't helpful. That was a very difficult job as the floor sound deadening was in the way and prevented it coming out. Another near impossible job due to the the car was designed left hand drive - just like the heater core I guess.

Knowing my luck the Perth winter will finish before I have it sorted.

Thanks

Before replacing the heater core, may I recommend the Prestone flush (read the instructions as it requires several rinsing with distilled water). It fixed a rather mild warm air, now getting really hot air 80C+

https://www.amazon.com/Prestone-AS10.../dp/B00B99U088

Heater Core Pictures
 

Hi,

About to change the core in my 2005 D5 whilst the weather is warm! ( bloody cold last winter, preferred to use my old disco and V70 as they were toasty!)

Any chance someone could send the pictures showing me what i need to cut, before i start (i like to be prepared)

Thanks

John