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VOLVO SERVICE MANUAL Pdf Download | ManualsLib

Vehiclerestingon wheels. Check play. Checksteeringrod ends. Checkrubber sealsfor damage. Checkthat nuts are locked. Checksteeringrod for damage. Jigglewith a pair of pliers. Checkthatjoint doesnot haveanywear. Squeezejoints with a pair of pliers to checkfor axialplay,as shownin illustration. Roddamaged: serviceimmediately. Checkcontrolarmsfor damage. Checkcontrolarm bushingsusinga pry bar as shownin illustration. Checkfor wear,cracksor other damage. Checkstabilizerbar and links.
Checkthathosesare correctly installed andthatconnectionsaretioht. Checkthatbrake hosesarenotchafedandareiree lrom sharp edgesor other obiectsthat could. Checkthat all brakelinesare correctlyinstalled and secured. Also checkthat they arefreefrom 0 d a m a g ea n d d o n o t. LnecKTor teakaoe.
Checkthat rubberbellows,outercablesand sus- pensionarein order. E4 0 Service at: 5-go. Checkwheel brakes. Checkfor signs of leakageat caliperor connec- tion.
Checkfreeplayof clutchtork. Throw-out bearinghasa smallpre-load appliedby a springat pedalbracket. Clearance betweenpositionsD and N shallbethe sameas clearance betweenposition2 and 1.
Checkpropellershaft and support bearings. Checkthat U-jointboltsaretight. Turnshaftsto find out it U-jointsareworn. Checksupponbearings for play. Checkrearsuspension, Manually check shock absorberattachment. Usea pry barto checkbushings for trailingarms, Checkfor leaks.
Specificationsare provided as a guide for tighteningloosehardware. Nm ft. Service at: s-go-tho usand mil es Checkexhaustsystem. Checkfor leakage and oil level. Oil levelshouldbe up to fillerplughole. Useoilswith properadditivesfor carsequipped with limitedsiipdifferential.
Manual4-speedtransmissionwith over- drive,M Checkfor leakage andoil Level. Oillevelshouldbe up to Jillerplughole. Transmission andoverdrive arelubricated by the sameoil. J, Oilfilteris normallyreplaced at 15, mileinter’ vals. Oil newfilterrubberseal.
Checkinstallation instruc- tions on filter. Screwon oilfilter by hand,retorqueif necessarys. Drainengineoil, Checkthat engine does not leak oil, fuel or oil drainptug. Reinstall 0r. Gasolineengines Oil and filter changes Replacedfirst time at ,mile ‘1,, Ouality: km insoection. Seechanbelow: Syntheticor semisynthetic oils may be usedif specificationscomply. Fuel-saving oils are recommended, When using suchoils,oil changeintervalsrecommended Volvomust be Jollowed.
Replaceoil filter. Oilfilteris normaly replaced at 15, mileinteF vals,However,any advefseconditionsrequireoil filter change more often. Use specialtool to removeold oil fllter. Oi new filter rubber seal. Checkinstallationinstruc- tions on filter. Screwon oil filtef by hand, retorqueif necessary. J4 Drainengineoil. Check that engine does not eak fuel or coolant. Reinstalloil d r a i np l u g. Ouality: Oil and filter changes. According CD minimum. Drivlnsunderadverse E a c h7 , 5 0 0m i l e s 1 2 , 5 0k0m c o n d i t i o n ss e eb e o w or everyth rd monlhwilh oiL fiherchangeeverysecond.
Capacities: D24i o SAE15W40is recommendedfor useln extremedrlvingcondl- t i o n sr h a ti n v o l v eh i g ho i l r e m p e r a r Lar n mounlaind rivingwilh tfequentdecelerario driving. Coolingsystemshouldalwaysconlain waterplus anti-freeze, evendufing summer. Expenence has Coolant:checkanti-freeze.
Seruiceat: K2 3l thousand mi les s Lthousa nd km Inbruals: 30,miles : Removereservoirfiller cap. Useonly VolvocoolantTypeC, blue-green. Fluids Serviceevery 7,miles : Brakefluid level. In enginecompanmenL, checkbrale lines and rese;voir brake-fluid for leaks. I- Checkbrakefluid levelwithoutremovingcap. Checkoil levelof power steering reseryoU.
Checkfluid levelwith eng;neidling while Jluid is still hot from driving. Wipe reservoirclean. Fluid levelshouldbe within markingson dipstickwhich is attached to cover,.
Fill with distilled wateronlv, Checkbaftoryholddownbracketfortightnessand that cablesare secured. Discolorationand smell can be causedby heavy tnteruals Follow procedurcs Volvoautomatlctransmlsslonotl cooler must be outlinedin L7-L ObseNelegalrequirements of the sratein whichthe drainplug. FollowDrocedures outlinedin L2-L6. Drainingthroughdrainplug L2. Dlain automatictransmission. Disconnectoil coolerreturn pipefrom rearend of transmission.
Connectone end of a transoarentolastichoseto oilcoolerreturnpipe. Letotherend ofplastichose end in enginebay with a drip pan beneathhose end. Fill2 quartsol AutomaticTransmission Fluid. S, – Runengine. Stan engineand let idle. SwitchengineOFFwhen alr bubblesbecomevisible in hose. Fill2 quartsof AutomaticTransmission 0 Fluid. I Runengine. Startengineand let idle. SwitchengineOFFwhen air bubblesbecomevisible in hose. Checkconditionof AutomaticTransmis- sionFluid.
Fluidmustnot carryimpurities, sme. L6 Reconnectreturn pipeto automatic transmission. Fill2 quartsof AutomaticTransmission Fluid. Oil can be scalding hot if vehiclewas recently. Removeoil pan. Cleanoil pan,strainerand particlemagnet. Alsocleanoil cooler. Reinstalloil pan and filler tube.
D Applyoil to pan gasketpriorto installation. Torques: Nm ft. L10 Filloil. Totalojl capacitycannotbe refilled. DONOTstartengineuntiloil is tilled. Startengineand adjustoil levelas described in nextoperation. L11 Dipstickmarkings. Seruiceevery 7, miles : 12,km. Checkoil levelforautomatic transmission. Fluidto fill AutomaticTransmission lf necessary, normal level. This whendrivingfor about30 minutes. Whenchecking ragthatwill not leavelint. M1 Seruiceevery 7,5 n miles : 12,km. Automatictransmission: Adiust kickdowncable.
Checkcablelengthat closedand open throttle engineoff. Adjustif necessary. Open throttle measurementshould be checked with throttlepedalin cardepressed,NOTby actua- ting linkageby hand. Checkenginecontrols Checkjoints,bushings andthrottleshaftfor wear.
Checkthatcable,linksandspringsareserviceable installed. Lubricateioints,usinga lightoil. NOTE: Do not applylubricant to cable. Turncamshaft to positionfor firingNo 1 cylinder. Bothcam lobesfor No 1 cylindershouldpointup at equallylargeangles. Pulleytimingmarkshould be at 0′. NOTE: Alwayscheckvalveclearancewith cylinderat top deadcenter. Attachtool and deDressvalve depressors. Screwdown tool spindleuntil depressorgrooveis just dboveedge ard accessiblew th plie’s.
Use micrometer to measurcdisc thick- ness. Calculatethicknessot discto be used. Example: Measuredclearance0. Correctclearance 0. Measuredthicknesson existinq disci 3. Correctthicknesson new discw-illthus be 3. NOTE: Installdiscswith marksdown.
Check clearanceas. N12 0 I Cy[2: Repeatprocedure. Nt3 t. Re-checkon all cylinders. Turnenginea few turnsbeforechecking. N15 Installvalvecover. Lineup timing belt. Removeold belt.
Firstplacetiming belt on crankshaftsprocketand then on intermediateshaftsprocket. Two lineson timing beltshouldtit towardcrankshaftmarks.
Nextmark shouldthen lit toward intermediateshaft marks, etc. Stretchon tensionsideand fit timing belt on camshaftsprocket. Fit timing belt on tensionerroller. Useof toolsmay damagetimingbelt. Tensiontiming beli. Loosentensionernut to let springtensionaq on rollerandthustensiontimingbelt. Checkmarksand torque nut. Rotateclockwiseand re-checkmarks. Checks haustsystem. Checkcondition, alignmentand suspension. Checkdamperoil level. AutomaticTransmission Fluidto 6 mm fromtopof cylinder. CheckoDerationof chokecontrol.
Checkthat indi-. I Breakerpoints,checkcondition. Botor,capand cables,checkcondition. Alsocheckrubbersealsand attachments.
ChecUadrust dwell angle. Shouldbe”t 3″. Check”Pulsair”air iniectionsystem. Disconnectair hoseat air cleaner. Checkthat air is beingdrawnin andthat no back oressureexists, t, I I. In caseof problems: Disconnecthosesat Pulsairvalves, Startengineand hold hand abovevalves.
Seryice following at: O- t 5 0-t h ousan d k m. Volvorecommends cleaninqflame quaroaL 15, mile intervals. Checkhosesfor conditionand clogging. Clean nippleandflameguard. D Replacesparkplugs. Sparkplugsmustbe tightenedto specifictorque for properoperationand to avoid damageto threads. Lubricatedistributor lelt wickin distributor Removerotorandlubricate shaftcentersparingiy. NOTE: Maximumamountof oil requiredis drops. Checkand adiusttiming. Disconnect vacuumhoses. Disengage tionerRunengineat a sufficiently tor centrilugal advanceaystem.
Increaseenginespeed,Observemovementol EGRvalverod in observation housingwhenvalveopens, window in valve el Release throttlequicklvand observethat valve closes. Checklhat lhe EGRvalve o p e n sl. Try a newone. Alternarive ted method, D meihodisto usethe stong vacuumdeated An ahernaiivetesi in enqineintakemainfoldal idle.
The connectionis lsed for vacuunconrrolofignitiondistriburoror for powerbrakeunrt, lfthisvacuunisconhected to EGFvalvewhenen9ineisidling, valveshouldopen. Exhaostgases aredivertedto engineandit shouldrun very poorlyor stop-. Disconnedvacuumhoseat EGRvalveand vacuumamplifier lcornectionmarked”B’.
Use mourhto blow throughand checklhat thermostaticvalveis open and vacuurnlinesnol. D s : Cleanfuel pumpstrainer. Alsocleanfuel pumpsludgeaccumulator Carefullycheckseal and s;aling surfacesbefore re-installing. Replaceair filter cartridge. Whendrivingunderdirtyanddustyconditions, air filter cartridgeshouldbe replacedmore olten.
Fordry, dusty,pollutedregionsan air tiltercart- ridgewith superiorfilteringabilityis available. No increase, or smail in- crease, indicates defective distributor mecha, nism. Checkfuel linesfor tightness. Checkthatthereare no tuel leaksin enginecom- panmenL Alsocheckfor oil andfluid leaks. Disconnecthosefrom a t r cleaner. Plug discon- necteoend,. Adlustidle speed. Engineat normaloperatingtemperature. During and afterCOadjustment,idle speedshouldbe: 1 50 rDm.
COvaluesof 2. Priorto readingsincrease enginespeedmomentarily to rpm to allow coldfuelto entercarburetor,. TheCOadjustment screw is sealedfrom access. Pressup adiustmentassembly. Pressup fuel needle and adiustmentscrew approx. Pressdown adiustmentscrew. Usea ounchmax. Upperlock adlustment washershouldremainat top. COadiustment: a9. Removelockwasherand flat washer. Turnlockwashersideways andusea steelwireto removeit, Shakeout flatwasher.
Usetool Installretaining screwlor fuelneedle. Install piston, diaphragmand needle assemblyin carburetor. Priorto checking : – Checkdamperoil level. Use tool to adjustluel needlepositionin carburetor. Adlustingrangeis approi. Turning tool clockwise increasesCO. Makesure tool lugs grip recesses in air valve spindle. Otherwisecarburetordiaphragmmay oecomedamageo,.
Install adiustmentseal. Use paperto absorbit or removeoistonand oourit out. InstallnewIlatwasherandnew lockwasherUse tool Checkthat drops. To confirmthat Pulsairis functioning.
Adiust idle speed. Engineat normal operatingtemperature. Duing and after CO adjustment,idle speedshould be: t 50 em. Seruiceevery 7,miles : 12,km R1. Tightennuts,checkfor leakage. Sealon controlrod from pressurercgulatorto wastegateactuatormust be unbrokenand intact, Sealcanbe a compressed sleevenut or wire and leadseal. It isimportant to windwiretightlyaroundactuator rod,as shown,otherwisesealwill loosendueto vibrations.
Volvoanti-tamper sealtongs,PartNumber have”Volvo”stampedon grips. Fourclamps,two at eachendot intermediate betweencompressor betorqued, andthrottlehousing, pipe should ol Torque:3 Nm Usepumpandgaugenormallyusedto testradia- tor pressure. Plughose removed. Connectinstrumentto checkLamboa systemduty cycle.
Forthispurposea highqualitydwellmetercanbe used. Checktiming retard. Startengine,run at idle. Note ignitiontiming. In caseof incorrect reading: checkdistributor, replace distributorpressure unit,as appropriate. Reinstalland clamoDressure hose. Connectair pressurepump and gaugein line leadingfrom intakemanifoldto pressure switch on firewall. Air pressure readingat thatinstantshouldbe Checkoverloadprotestionswitch, Pumppressureuntil enginestalls,Air pressure.
At the sametime air pressuregaugeon instru- ment panelshouldgo to red and red “Turbo” l0 -‘l71,”.. In total, that’s over pages of content dedicated to your Volvo We get a lot of people coming to the site looking to get themselves a free Volvo Haynes manual.
We’ll send you a quick email a new Volvo document is added. Spam free: Maximum of 1 email per month. Workshop Manual Pages. Get your hands on the complete Volvo factory workshop software. Volvo – – Parts catalogue – – Other Manuals Pages. Volvo – – Workshop Manual – – Other Manuals 12 Pages. In , , new Volvo cars were sold worldwide an increase of 8.
For the first time in its history, Volvo Cars crossed the milestone of 0. The largest markets are China more than 81 thousand cars sold , Sweden more than 71 thousand , the USA more than 70 thousand , the United Kingdom, Germany. The best-selling model in is the Volvo XC60 , cars sold. All content on the site Carmanualsclub. The site administration does not bear any responsibility for illegal actions, and any damage incurred by the copyright holders.
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Volvo Repair & Service Manuals (22 PDF’s
Checksteeringrod ends. Checkrubber sealsfor damage. Checkthat nuts are locked. Checksteeringrod for damage. Jigglewith a pair of pliers. Checkthatjoint doesnot haveanywear. Squeezejoints with a pair of pliers to checkfor axialplay,as shownin illustration. Roddamaged: serviceimmediately. Checkcontrolarmsfor damage. Checkcontrolarm bushingsusinga pry bar as shownin illustration.
Checkfor wear,cracksor other damage. Checkstabilizerbar and links. Checkthathosesare correctly installed andthatconnectionsaretioht. Checkthatbrake hosesarenotchafedandareiree lrom sharp edgesor other obiectsthat could.
Checkthat all brakelinesare correctlyinstalled and secured. Also checkthat they arefreefrom 0 d a m a g ea n d d o n o t. LnecKTor teakaoe. Checkthat rubberbellows,outercablesand sus- pensionarein order. E4 0 Service at: 5-go. Checkwheel brakes. Checkfor signs of leakageat caliperor connec- tion.
Checkfreeplayof clutchtork. Throw-out bearinghasa smallpre-load appliedby a springat pedalbracket. Clearance betweenpositionsD and N shallbethe sameas clearance betweenposition2 and 1. Checkpropellershaft and support bearings. Checkthat U-jointboltsaretight. Turnshaftsto find out it U-jointsareworn.
Checksupponbearings for play. Checkrearsuspension, Manually check shock absorberattachment. Usea pry barto checkbushings for trailingarms, Checkfor leaks. Specificationsare provided as a guide for tighteningloosehardware. Nm ft. Service at: s-go-tho usand mil es Checkexhaustsystem. Checkfor leakage and oil level. Oil levelshouldbe up to fillerplughole. Useoilswith properadditivesfor carsequipped with limitedsiipdifferential. Manual4-speedtransmissionwith over- drive,M Checkfor leakage andoil Level.
Oillevelshouldbe up to Jillerplughole. Transmission andoverdrive arelubricated by the sameoil. J, Oilfilteris normallyreplaced at 15, mileinter’ vals. Oil newfilterrubberseal. Checkinstallation instruc- tions on filter. Screwon oilfilter by hand,retorqueif necessarys.
Drainengineoil, Checkthat engine does not leak oil, fuel or oil drainptug. Reinstall 0r. Gasolineengines Oil and filter changes Replacedfirst time at ,mile ‘1,, Ouality: km insoection. Seechanbelow: Syntheticor semisynthetic oils may be usedif specificationscomply. Fuel-saving oils are recommended, When using suchoils,oil changeintervalsrecommended Volvomust be Jollowed. Replaceoil filter. Oilfilteris normaly replaced at 15, mileinteF vals,However,any advefseconditionsrequireoil filter change more often.
Use specialtool to removeold oil fllter. Oi new filter rubber seal. Checkinstallationinstruc- tions on filter. Screwon oil filtef by hand, retorqueif necessary. J4 Drainengineoil. Check that engine does not eak fuel or coolant. Reinstalloil d r a i np l u g.
Ouality: Oil and filter changes. According CD minimum. Drivlnsunderadverse E a c h7 , 5 0 0m i l e s 1 2 , 5 0k0m c o n d i t i o n ss e eb e o w or everyth rd monlhwilh oiL fiherchangeeverysecond. Capacities: D24i o SAE15W40is recommendedfor useln extremedrlvingcondl- t i o n sr h a ti n v o l v eh i g ho i l r e m p e r a r Lar n mounlaind rivingwilh tfequentdecelerario driving.
Coolingsystemshouldalwaysconlain waterplus anti-freeze, evendufing summer. Expenence has Coolant:checkanti-freeze. Seruiceat: K2 3l thousand mi les s Lthousa nd km Inbruals: 30,miles : Removereservoirfiller cap. Useonly VolvocoolantTypeC, blue-green. Fluids Serviceevery 7,miles : Brakefluid level. In enginecompanmenL, checkbrale lines and rese;voir brake-fluid for leaks. I- Checkbrakefluid levelwithoutremovingcap.
Checkoil levelof power steering reseryoU. Checkfluid levelwith eng;neidling while Jluid is still hot from driving. Wipe reservoirclean. Fluid levelshouldbe within markingson dipstickwhich is attached to cover,. Fill with distilled wateronlv, Checkbaftoryholddownbracketfortightnessand that cablesare secured. Discolorationand smell can be causedby heavy tnteruals Follow procedurcs Volvoautomatlctransmlsslonotl cooler must be outlinedin L7-L ObseNelegalrequirements of the sratein whichthe drainplug.
FollowDrocedures outlinedin L2-L6. Drainingthroughdrainplug L2. Dlain automatictransmission. Disconnectoil coolerreturn pipefrom rearend of transmission. Connectone end of a transoarentolastichoseto oilcoolerreturnpipe.
Letotherend ofplastichose end in enginebay with a drip pan beneathhose end. Fill2 quartsol AutomaticTransmission Fluid. S, – Runengine. Stan engineand let idle. SwitchengineOFFwhen alr bubblesbecomevisible in hose. Fill2 quartsof AutomaticTransmission 0 Fluid. I Runengine. Startengineand let idle. SwitchengineOFFwhen air bubblesbecomevisible in hose. Checkconditionof AutomaticTransmis- sionFluid. Fluidmustnot carryimpurities, sme. L6 Reconnectreturn pipeto automatic transmission.
Fill2 quartsof AutomaticTransmission Fluid. Oil can be scalding hot if vehiclewas recently. Removeoil pan. Cleanoil pan,strainerand particlemagnet. Alsocleanoil cooler. Reinstalloil pan and filler tube. D Applyoil to pan gasketpriorto installation. Torques: Nm ft. L10 Filloil. Totalojl capacitycannotbe refilled.
DONOTstartengineuntiloil is tilled. Startengineand adjustoil levelas described in nextoperation. L11 Dipstickmarkings. Seruiceevery 7, miles : 12,km.
Checkoil levelforautomatic transmission. Fluidto fill AutomaticTransmission lf necessary, normal level. This whendrivingfor about30 minutes. Whenchecking ragthatwill not leavelint. M1 Seruiceevery 7,5 n miles : 12,km. Automatictransmission: Adiust kickdowncable.
Checkcablelengthat closedand open throttle engineoff. Adjustif necessary. Open throttle measurementshould be checked with throttlepedalin cardepressed,NOTby actua- ting linkageby hand. Checkenginecontrols Checkjoints,bushings andthrottleshaftfor wear. Checkthatcable,linksandspringsareserviceable installed. Lubricateioints,usinga lightoil. NOTE: Do not applylubricant to cable. Turncamshaft to positionfor firingNo 1 cylinder. Bothcam lobesfor No 1 cylindershouldpointup at equallylargeangles.
Pulleytimingmarkshould be at 0′. NOTE: Alwayscheckvalveclearancewith cylinderat top deadcenter. Attachtool and deDressvalve depressors. Screwdown tool spindleuntil depressorgrooveis just dboveedge ard accessiblew th plie’s. Use micrometer to measurcdisc thick- ness. Calculatethicknessot discto be used.
Example: Measuredclearance0. Correctclearance 0. Measuredthicknesson existinq disci 3. Correctthicknesson new discw-illthus be 3. NOTE: Installdiscswith marksdown. Check clearanceas. N12 0 I Cy[2: Repeatprocedure. Nt3 t. Re-checkon all cylinders. Turnenginea few turnsbeforechecking. N15 Installvalvecover. Lineup timing belt. Removeold belt. Firstplacetiming belt on crankshaftsprocketand then on intermediateshaftsprocket.
Two lineson timing beltshouldtit towardcrankshaftmarks. Nextmark shouldthen lit toward intermediateshaft marks, etc. Stretchon tensionsideand fit timing belt on camshaftsprocket.
Fit timing belt on tensionerroller. Useof toolsmay damagetimingbelt. Tensiontiming beli. Loosentensionernut to let springtensionaq on rollerandthustensiontimingbelt. Checkmarksand torque nut. Rotateclockwiseand re-checkmarks. Checks haustsystem. Checkcondition, alignmentand suspension. Checkdamperoil level. AutomaticTransmission Fluidto 6 mm fromtopof cylinder. CheckoDerationof chokecontrol. Checkthat indi-. I Breakerpoints,checkcondition. Botor,capand cables,checkcondition.
Alsocheckrubbersealsand attachments. ChecUadrust dwell angle. Shouldbe”t 3″. Check”Pulsair”air iniectionsystem. Disconnectair hoseat air cleaner. Checkthat air is beingdrawnin andthat no back oressureexists, t, I I. In caseof problems: Disconnecthosesat Pulsairvalves, Startengineand hold hand abovevalves. Seryice following at: O- t 5 0-t h ousan d k m. Volvorecommends cleaninqflame quaroaL 15, mile intervals. Checkhosesfor conditionand clogging.
Clean nippleandflameguard. D Replacesparkplugs. Sparkplugsmustbe tightenedto specifictorque for properoperationand to avoid damageto threads. Lubricatedistributor lelt wickin distributor Removerotorandlubricate shaftcentersparingiy. NOTE: Maximumamountof oil requiredis drops. Checkand adiusttiming. Disconnect vacuumhoses. Disengage tionerRunengineat a sufficiently tor centrilugal advanceaystem. Increaseenginespeed,Observemovementol EGRvalverod in observation housingwhenvalveopens, window in valve el Release throttlequicklvand observethat valve closes.
Checklhat lhe EGRvalve o p e n sl. Try a newone. Alternarive ted method, D meihodisto usethe stong vacuumdeated An ahernaiivetesi in enqineintakemainfoldal idle.
The connectionis lsed for vacuunconrrolofignitiondistriburoror for powerbrakeunrt, lfthisvacuunisconhected to EGFvalvewhenen9ineisidling, valveshouldopen. Exhaostgases aredivertedto engineandit shouldrun very poorlyor stop-.
Disconnedvacuumhoseat EGRvalveand vacuumamplifier lcornectionmarked”B’. Like the Volvo , it was designed by Jan Wilsgaard. It overlapped production of the Volvo series introduced in As the remained popular, only the was displaced by the series — which Volvo marketed alongside the for another decade. The series was replaced a year before the was discontinued. Production ended on 14 May after nearly 20 years. Fuel diesel.
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