1800E Heater Rebuild

[LawsonJD]

Guys could you check my work here please.
01) The valve thermocouple, am I doing that right and where should it exit the housing?
02) I'm not putting anything around the new matrix, it was such a tight fit i've actually had to squash it in a vice to get it in, ok?
03) Entry & exit pipes, manual lists a grommet 653207 which I can't find, will I be ok just like this?
04) Drain pipe, am I doing that right?
05) Should I bung these little holes up with something?
Thanks very much.
David.

[Derek UK]

Looks good. You can probably pull the tube through the loops a bit more and complete the circle with the soldered end tucked into the loop. Having excess between the case and the heater valve means you have to tuck it away somewhere but don't make it too short or it will all have to come out again! I mentioned that there isn't a small relief notch for the tube so be careful. From the factory the matrix had a layer of foam abut it to reduce the amount of air that gets past the sides for a bit more efficiency. Yes it disintegrates over time as you probably found out. I had some 3mm scrim sponge and used that on my Amazon one. It wasn't a problem to get in. No idea about the grommet but you could probably adapt one or put a ring of sponge around it.
The 2 centre holes are for the screws that hold the sprung door clip. On my Amazon one the outer 2 have press in rubber bungs and the small one down the side just has a small self tapper in. The screw doesn't do anything at the moment but I might find a use for it after fitting. It's a short stubby one so just a blanker at the moment.
The plastic plug in the drain hose is the spreader I mentioned.
Nice pictures, thanks for posting them.

[c1800]

I used closed cell weather stripping to seal the halves of the heater box. Generic stuff from the home store. 3/16 thick x 3/8 wide, compresses nicely.
I found rubber grommets at the auto parts store for the heater core inlet and outlet.

Even with a new heater valve the heat is either on or off so I'm not sure the copper tube positioning makes much difference.

Pictures look good.

[LawsonJD]

Guys thanks.
Derek thanks for that and for reminding me about those sprung door clips, I'd forgotten all about them, still in the box luckily.
C1800 I was going to use something called Sikaflex to join the half's but I'll go your tape route instead, it is going to be a hell of a lot easier to split if I've made a mistake.
Anyone you know this one, the gasket kit contains 2 100mm rings, the sponge one is No. 101 I'm guessing, does the other one go on the intake side too?
Thanks again.
David.

[Derek UK]

Check them individually here.
https://www.classicvolvoparts.co.uk/...r_Foam_Gaskets

The 1800 and Amazon use different gaskets here.

I will be using butyl tape for the case seal. Various widths and thickness available on the Bay. Not expensive.

[Jocky66]

I used standard 20mm electrical grommets for the 2 pipe outlets.

[c1800]

Originally Posted by LawsonJD

Anyone you know this one, the gasket kit contains 2 100mm rings, the sponge one is No. 101 I'm guessing, does the other one go on the intake side too?

I couldn't determine where the large o-ring belonged. I checked with the supplier and they didn't know either, so I left it out.