Haynes Volvo 340 and 360 Series 1976 to 1991 (Up to J Registration) Service and Repair Manual 1859602312, 9781859602317

Citation preview

340 & 360 Series 1976 to 1991 (up to J registration)

Haynes See and Repair Manual

Includes Fault Finding and MOT Test Check Sections

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‘Excellent value for money, beginners and experts should find it equally useful...’ Motor

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There is almost certainly a Haynes Manual to cover your specific vehicle, whatever its age. Each manual features clear, easy-tofollow text linked to hundreds of step-bystep photos that guide you through each task. From the simplest service to a major rebuild, Haynes shows you how and saves

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Written for the DlYer, good enough for the professional! Each of these vehicle system or technique specific manuals is packed with practical information supported by step-by-step photo sequences and diagrams.

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a u n a M r i a p e R ervice and

Colin Brown

(715-320-2Y7)

Models covered All Volvo 340, 343 & 345 models; 1397 cc & 1721 cc All Volvo 360 models; 1986 cc Does not cover LPG conversion

ABCDE FGHIJ

© Haynes Publishing 1996

i

A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this in any form or by any means, photocopying, recording or by any without permission in writing from

e

book may be reproduced or transmitted electronic or mechanical, including information storage or retrieval system, the copyright holder.

ISBN 1 85960 231 2 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ

Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 PARIS, France

Safety First!

Page

O0°5

General dimensions, weights and capacities

Page

0°6

Routine Maintenance

Page

0°8

Jacking, towing and wheel changing

Page

0°14

Jump starting

Page

0°15

Tyre checks

Page

0°16

Identifying leaks

Page

0°17

Page

0°18

Roadside Repairs

Recommended

2 424.287 ve /

Lubricants and Fluids

eph7g0

Contents REPAIRS & OVERHAUL Engine and Associated Systems Engine (also see Chapter 11)

Page

1e1

Cooling system

Page

2e1

Fuel and exhaust systems (also see Chapter 11)

Page

3e1

Ignition system

Page

4e1

Clutch

Page

5e1

Transmission and final drive

Page

66e1

Page

/7e1

Page

8e1

Page

9e1

Page

10¢1

Supplement: Revisions and information on later models

Page

11e¢1

Wiring Diagrams

Page 12¢1

Transmission

Brakes Braking system

Suspension Suspension and steering systems (a/so see Chapter 11)

Body Equipment Bodywork and fittings (also see Chapter 11)

Electrical Electrical systems (also see Chapter 11)

Additional Information

REFERENCE MOT Test Checks Checks carried out from the driver’s seat

Page

REFe1

Checks carried out with the vehicle on the ground

Page

REFe2

Checks carried out with the vehicle raised

Page

REFe3

Checks carried out on your vehicle’s exhaust emission system

Page

REFe4

Tools and Working Facilities

Page

REFe5

General Repair Procedures

Page

REFe8

Fault Finding

Page

REFe9

Conversion Factors

Page

REFe12

Buying spare parts and vehicle identification numbers

Page

REFe13

Glossary of Technical Terms

Page

REFe14

Index

Page REFe19

oe4 INtroduction

Introduction to the Volvo 300 Series The Volvo 343 three-door Hatchback was introduced in the UK in September 1976,

being built with traditional Volvo expertise, and incorporating many safety features such as impact bars in the side doors. The first models were available only with the double belt continuously variable (CVT) automatic transmission, which was carried over from the Volvo 66 model. Manual versions became available in September 1978 and were fitted with a rear mounted manual gearbox similar to that fitted to the 240 series. The 345 five-door Hatchback models were introduced in January 1980. In 1982 the models were redesignated 340 DL and GL, and at the same time the 360 Series was introduced with a2 litre engine and transmission torque tube. The top of the range GLE model was introduced in late 1983 and incorporated a boot. It was available with a carburettor or fuel injection engine. In May 1985 the 360 GLS was redesignated the GL and in August of the same year the 1.7

litre 340 GL and GLE were introduced. Both 340 and 360 models have received periodic updates to incorporate a number of modern motoring developments; maintaining Volvo’s reputation for safety and solid dependability.

Volvo 340 GL Hatchback

Acknowledgements Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of AB Volvo, and are used with their permission. The cars used for workshop and photographic purposes were kindly loaned by F W B Saunders of Sherborne, Dorset and the Yeovil Motor Company of Yeovil, Somerset. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by errors in, or omissions from, the information given.

Project vehicles The vehicles used in the preparation of this manual, and appearing in many of the photographic sequences, were an early Volvo 343, a 360 GLEi, a 360 GLS with B200 engine, and a 340 GL with B172 engine.

Volvo 360 GLE Saloon

Safety First! os Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

General hazards Scalding © Don’t remove the radiator or expansion tank cap while the engine is hot. © Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

Burning ¢ Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.

Crushing e When working under or near a raised vehicle, always

supplement the jack with axle stands, or use drive-on ramps.

yy

==

/; ft) (qa

Never venture

a

=

under a car which is only supported by a jack. e Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.

e Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.

Fume or gas intoxication e Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine ina confined space such as a garage with the doors shut. e Fuel vapour is also © poisonous, as are the vapours from some cleaning solvents and paint thinners.

Poisonous or irritant substances e Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially

antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes,

seek medical advice. e Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. e Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). it can also cause skin

burns on contact.

Fire

Asbestos

e Fuel is highly flammable; fuel vapour is

e Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.

explosive. e Don’t let fuel spill onto a hot engine. e Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). e Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over an inspection pit. e Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. e Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.

e Ignition HT voltage canbe dangerous, especially to

219 & ie

the engine running or the ignition switched on.

gets onto the skin, it may be necessary to amputate the limb concerned.

e When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

The battery e Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.

Air bags e Air bags can cause injury if they go off

accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.

Diesel injection equipment e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.

DON’T

* Do use eye protection when using power tools, and when working under the vehicle.

¢ Don’t attempt to lift a hea com which may be Roe your caper

e Do wear gloves or use barrier cream to — protect your hands when necessary.

assistance.

© Don’t rush to finish a job, or ‘ unverified short cuts.

that all is well when working alone on the vehicle.

e Don’t use il-fitting tools wichma ailp and cause injury.

® ‘Do keep loose clothing aaa long hair well

e Don’t leave tools or parts Whe around where someone can trip over them. Mop — up oil and fuel ‘Spills at once. —

© Do remove rings, wristwatch etc, beforeworking on the vehicle — especially the electrical system.

© Do ensure that any lifting or jacking 3 ;

e This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it

DO

out of the way of moving mechanical parts.

people with heart ae problems or a pacemaker. Don’t _work on or near the ignition system with

Hydrofluoric acid

Remember...

° Do get someone to check periodically

Electric shock

Special hazards

equipment has a safe working load rating adequate for the job.

* Don’t allow children or pets to p near a vehicle being worked on.

o6 General dimensions, weights and capacities

Dimensions Overall length: Models up to 1981

165.4 in (4200 mm) 166.7 in (4235 mm)

1982 models Models from 1982 to 1989: Hatchback. cauiosta-w =casz Saloon Models from 1989: Fatchbackevnr ssc : Saloon Overall width

169.3 in (4300 mm) 173.8 in (4415 mm)

170.2 in (4380 mm) 175.3 in (4450 mm) 65.4 in (1660 mm)

Overall height (unladen): 340 series: Wtog OS aie ere eicteinans From 1984 360 series: Carburettor:

Models up to 1982 1982 and 1983 models Models from 1984 Fuel injection: 1983 models 1984 models

.

Models from 1985

Wheelbase:

340 series (except 1.7 litre) 360 series and 1.7 litre

56.7 in (1440 mm) 56.3 in (1430 mm)

57.1 in (1450 mm) 56.7 in (1440 mm) 56.3 in (1430 mm)

56.0 in (1423 mm) 56.3 in (1430 mm) 55.9 in (1420 mm) 94.3 in (2395 mm) 94.5 in (2400 mm)

Track (front): 340 series:

Models up to 1980 Models from 1980 360 series

53.1 in (1350 mm) 53.9 in (1370 mm) 54.3 in (1380 mm)

Track (rear): 340 series:

Models up to 1980 Models from 1980 360 series

Turning circle (between kerbs): 340 series (except 1.7 litre) 360 series and 1.7 litre

54.3 in (1380 mm) 55.1 in (1400 mm) 55.3 in (1405 mm)

30.2 ft (9.20 m) 30.7 ft (9.35 m)

General dimensions, weights and capacities 0-7 Capacities Engine oil - at oil and filter change: RST eM nye lo(alNee. Be Cs St STE Ma IR ey ea HEVANIKeUTIOMOlS esa metic llennrawenna) Sata uho. 0 Sate eNemmetm Sat | Haran PeONIG MmMOCESIS erent Cine ae emcee ar aiit. 2 1, LaatPR Sepmeemi eS ySaetayNN Amount required to raise oil level from dipstick MIN to MAX marks: rand. Oilitremodelsiy) Wiitvesnpensncans acca CoRR RN yao, MICO TINOC OS terme ier ole ENUCoenmanakee yf), 4.bh ema maya Si Cooling system (including expansion tank): IGA GPNtOR OBO) erent strane uy ptt coc Sc eeaN ge ROY ORMOG GION)meer ivaieynerem are een Ma aie:(0.03 SUN RRO eR oe ESI iter NR et ae ance Ae Tee cen Seatac e eyeyo NS! SL ae Ro amg,

B19: MOGeISMIpHOMOS2 sue ante aire canes ntsc dc o Renae etatoaranat: MOGEIS OM IG2 raat taiee tase eae e)Seon clonic: 1c heen ayaie BOO Sperry eden obey tiieien om eine See Sea eisai oeERED Dictees tae Automatic transmission: PrimMahyiG@aliCase i. crmcteias viseyea Cea ols oie Sessauce Maciel Craetis SECONGarViGealeCaSGu ry caietaiia cuntobsn siemed a aie ce ane Chete eaten Manual gearbox (total):

7.0 pints (4.0 litres) 8.8 pints (5.0 litres) 7.9 pints (4.5 litres)

1.8 pints (1.0 litre) 2.6 pints (1.5 litres) 9.2 pints (5.2 litres) 11.5 pints (6.5 litres) 14.1 pints (8.0 litres) 14.1 pints (8.0 litres) 12.3 pints (7.0 litres) 12.3 pints (7.0 litres) 1.0 pint (0.55 litre) 1.8 pints (1.0 litre)

Four-speed:

ModelStmtoOslGG4' awncine iret ean MeO ie yi Rloa dale eS eens MoGeISHNOM OSA man aettsserseaupsore sain stcasin wishes Mae Hees MS oRN RRS

3.7 pints (2.10 litres) 4.1 pints (2.35 litres)

Five-speed:

Pin Giatireatgas sarees sean Reena ea ome aR Re heals RNR eyes Plug at front: Woaelsin tO AOS: a iieanar nanan yn crustal Su nae Iman Modelsitrom=GSotom GSO wanves jaime iis ator oh cecil ieee Modelstrom=1OSo nd Wen cies eles Wishes sceherays Misrsatan Final drive unit: B14: MOGEISIUD TOMMOB2m on Mirae citecy accu ne eoceis card sausage Models rom OS2en iar r: abateeee del ermal cir Sie evel isteraees as BBR areacerreas orei meetlanicg nite J. aay a een tela eLocaly ede EEA aieManelRap apices dee

B19 and B200: ROUTES POSE RIVEG-SDECCiaacecehinhs Fuel tank:

Sesser aiesecess mchehartace es rake airseealcambio So mnat Eetians(elit ee tarts eer mcenemieni eee eaaree tay:a eral iri Be

SADISENICS Bs netowr oerae ra et cseree eRe hare Rt eee OOLSEMES teria sarc veer Hoh to eaaett ee Nae ec MONT Gea

a Gg rye HL ahaded

Weights

4.8 pints (2.70 litres)

6.2 pints (3.50 litres) 5.3 pints (3.0 litres) 4.9 pints (2.8 litres)

2.6 pints (1.45 litres) 2.4 pints (1.35 litres) 2.4 pints (1.35 litres) 2.6 pints (1.50 litres) 2.4 pints (1.35 litres) 9.9 gal (45 litres) 12.5 gal (67 litres)

3-door

4-door

5-door

2160 Ib (980 kg) 2152 Ib (976 kg) 2176 Ib (987 kg)

2072 Ib (940 kg) -

2216 Ib (1005 kg) 2196 Ib (996 kg) 2229 Ib (1011 kg)

2105 2099 2116 2209 2372 2425

Ib Ib Ib Ib |b Ib

(955 kg) (952 kg) (960 kg) (1002 kg) (1076 kg) (1100 kg)

2110 -

2160 Ib (980 kg) 2143 Ib (972 kg) 2172 Ib (985 kg)

3197 3131 3263 3395

Ib Ib Ib Ib

(1450 (1420 (1480 (1540

1984 2205 2205 2646

Ib (900 kg) Ib (1000 kg)

Kerb weight: B14 automatic:

MOGeISiID tO GOAN ae trian ft ss anne tna icatera cpatoravent eames Sans Modelsitromiil S84: to O86 ireces ses castere ole % witcecnts woe it febb tars Modelsiromil SaOatts crecentesrcnte tem eee rented B14 manual: Moclelsiimstod O84 saeco: io Meese ee tral eee sa nic ttedeueiere tee mie we Models fromntO845tO nl G86 ares cerente sara wise scapes bsp asceymeena ers NMOcelSHfOM |OSG ausectnetareacsdcovra etree. oenome sceamuns beeel toca BidA2 ieee PANS HOG BKC) hate earete sates atnree miata Cycle eaPaPicattyiel f ctievnaceBr Siandis200 (Carotinetton) ses. teetasrenacecs cdopercny cieremeverm cenWiens.whara arto Bigiand: B200fuelinjection) eywiken vaccine whiny ctlaise scrote Maximum permissible weight: BS PAE AUTOM Cie eyes sleepiaren slats eawls watsy ee rewarming eealae Bt Aamianiclleencanscespeenencncs |roman ince waechore awrePaleccierk janities aint EBAiteae ay eter eaten aoa ahs ucicueamne Uc iam eels ictal Rls Ma aias BAlStand B20 0Rite teat Sines, tee erase Pate Sue a wae epee ence a Trailer weight (maximum): Bo SeAULOMmatle ree ai, outers aves cau iene eceealia id eKgeben ee MAME allel a x aes Bil 4utmeanUallaaios antl ee Mon Gan roc nEC en Us aeaneati ce iNT ee FSAI ee ene ace aitc TePine iif g ara: Wem Ons [aad NAA ols etitiaay edge Bian coOneca ca wamestsyfatvetesenecos Mv eae ee site eobiariei coals Roof rack load (maximum): Bil ScAlOnmatietinre tat cdereeddande ot fig iw chanel ed ae can te Mada ah ce Barra lalltema celery ae itis ences steep ates aibieielarsbemajer sijalayareie: ¢)ace Ea ee en Aol ere UU atvit ssn RennCManeseI pa oleralayarendck eS ets

PimenAonai

ar ie ee

ire le site es cies caddis

kg) kg) kg) kg)

Ib (1000 kg) Ib (1200 kg)

99 Ib (45 kg) 110 Ib (50 kg) 110 Ib (50 kg)

132 Ib (60 kg)

Ib (957 kg)

2370 Ib (1075 kg) 2410 Ib (1093 kg)

2414 Ib (1095 kg) 2467 Ib (1119 kg)

os Routine Maintenance

For modifications, and information applicable to later models, see Supplement at end of manual Maintenance is essential for ensuring safety, and desirable for the purpose of getting the best in terms of performance and economy from your car. Over the years the need for periodic lubrication - oiling, greasing and so on - has been drastically reduced, if not totally eliminated. This has unfortunately tended to lead some owners to think that because no such action is required, components either no longer exist, or will last forever. This is certainly not the case; it is essential to

carry out regular visual examinations as comprehensively as possible in order to spot any possible defects at an early stage before they develop into major and expensive repairs. The following Routine Maintenance schedule periods are recommended service intervals only. Where the vehicle is operated under extreme conditions, or used mainly for stop-start type driving, the intervals may need to be reduced.

2 000 miles (20 000 km) or 12 months - whichever ¢ comes

transmission models) —

LJ Check vacuum servo¢ Renew servo airfilter ae Check cate

for wear

Check hydraulic hoses andcoe |

security— | Check steering gearforweal _ Check suspension for wear, \

/

damag dar

irst

Routine Maintenance

Every 24 000 miles (40 000 km) or 2 years - whichever comes first

Every 48 000 miles (80 000 km) or 4 years - whichever comes first

In addition to the 12 000 mile service

In addition to the 24 000 mile service

|_| Clean crankcase ventilation system hoses |_|] Check valve clearances (B19 and B200 models)

Check valve clearances (B172 models) Renew timing belt (B172, B19 and B200 models)

|_| Renew coolant |] Renew air filter — |_| Renew fuel filter(s)

[| Renew fluid (automatic models) [| Check propeller shaft joints for wear [_] Renew brake fluid

LJ

oe and ager frontwheel bearings

Under-bonnet view (360 GLEi model) 1 Washer reservoir 2 Fusebox

3 Front suspension strut upper mounting 4 Cooling system filler cap 5 Brake servo unit 6 Brake fluid reservoir filler cap

7 8 9 10 11

Ignition HT leads Heater air inlet Brake servo vacuum hose Inlet manifold Brake pressure-conscious reducing valve

12 13 14 15

Fuel filter (LE-Jetronic) Windscreen wiper motor Battery Fuel injection control relay (LE-Jetronic) 16 Airflow meter (LE-Jetronic) 17 Engine oil dipstick

18 19 20 21 22 23

Distributor Thermostat housing Vehicle identification plate Engine oil filler cap Exhaust manifold Air cleaner

o-9

o10 Routine Maintenance

Under-bonnet view (360 GLS with B200 engine) 1 2 3 4

Battery Headlamp rear cover Air cleaner Bonnet hinge

5 Radiator top hose 6 Distributor cap 7 Air cleaner warm air duct 8 Idle solenoid

9 10 11 12

Vehicle identification plate Cooling fan Engine oil filler cap Fusebox and relays

13 Washer reservoir 14 Front suspension strut upper mounting

15 Cooling system fillercap and expansion tank 16 Brake fluid reservoir fillercap 17 Exhaust manifold and warm

air shroud 18 Clutch cable 19 Heater intake 20 Brake vacuum servo hose

21 22 23 24

Crankcase ventilation hose Inlet manifold Starter motor Choke cable 25 Renix electronic ignition module 26 Windscreen wiper motor

Routine Maintenance

A

Under-bonnet view (340 GL 1.7 litre)

1 2 3 4 5 6 7

Air intake heating/ventilation Recirculation vacuum valve Windscreen wiper motor Suspension tower Heater blower motor Renix ignition control unit Coolant hose

8 Alternator 9 Drivebelt 10 Water pump

11 12 13 14

Timing belt cover Crankshaft pulley Thermo-electric cooling fan Fuel filter

15 16 17 18

Battery Fuel pump Carburettor Coolant expansion tank

19 Brake fluid reservoir 20 Brake vacuum servo unit

21 Fusebox 22 Distributor 23 Valve cover

24 Engine oil filler cap 25 Oil filter 26 Spark plug HT leads

oe11

oe12 Routine Maintenance

Typical front underbody view (360 GLEi model)

1 2 3 4 5

Anti-roll bar Engine sump Engine oil drain plug Track rod end Steering rod 6 Lower suspension arm 7 Brake caliper

8 Front radius arm 9 10 11 12 13 14 15 16 17 18

Typical rear underbody view (860 GLEi

model) Torque tube and propeller shaft Intermediate exhaust pipe Gearbox filler plug Rear roadspring

Handbrake cable 5th gear section of gearbox Transmission mounting Driveshaft De Dion rear axle OMANDOAAWN™ 10 Brake hydraulic line 11 Rear silencer 12 Rear tailpipe 13. Final drive unit 14 Rear shock absorber lower mounting 15 Fuel tank

16 Main section of gearbox 17 Gearbox drain plug 18 Fuel in-line filter (LE-Jetronic) 19 Crossmember/heat shield with fuel pump (LE-Jetronic)

Clutch housing Clutch cable adjusting nut Torque tube and propeller shaft Exhaust downpipe Intermediate exhaust pipe Brake hydraulic line Crossmember Anti-roll bar link Engine splash guards Front foglamp

Routine Maintenance

oe13

Front underbody view (340 GL 1.7 litre) Exhaust pipe

Front radius arm Front brake caliper Anti-roll bar attachment bolt Anti-roll bar Track rod end bush Coolant hose Front engine mountings OANDAAWNH™ Engine front bearer Engine oil drain plug Sump Engine earth strap Track rod Oil filter a ®MY-> OAK 0 Rear engine mounting attachment 16 Clutch housing

Rear underbody view (340 GL 1.7 litre)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Fuel tank Rear suspension road spring Shock absorber lower mounting Road spring front mounting Brake hydraulic lines Fuel lines Gearbox Gearbox drain plug Propeller shaft Exhaust pipe Halfshaft Final drive unit De Dion rear axle Silencer

o14 Roadside Repairs

Jacking and towing To change a roadwheel, remove the spare wheel and tool kit from the engine compartment or boot. Check that the handbrake is fully applied, then engage P (automatic transmission) or 1st (manual transmission). Two jacking points are provided on each side of the car. With the car on level ground, open up the jack and slide the lifting pad into the jacking point. Continue to open the jack until it.is in contact with the ground. On early models, remove the hub cap

or wheel nut caps. Using the brace, unscrew the wheel nuts half a turn. Raise the jack until the wheel is off the ground, then remove the wheel nuts and withdraw the wheel. On late models remove the hub cover. Fit the spare wheel using a reversal of the removal

procedure,

but

on

late

models

remember to fit the hub cover before fitting the nuts. When using atrolley jack, position the jack . under the four jacking points, the rear engine

bearer, or midway along the De Dion rear axle. Towing eyes are provided below the front and rear bumpers on the right-hand side; do not use these eyes for lifting the car. If being towed, select N (automatic transmission) or neutral (manual transmission) and remember that with the engine stopped, more effort will be required when depressing the footbrake pedal since the servo will be inoperative.

Tool kit with spare wheel removed (340 models)

Jacking up the car (note the early scissor

type jack)

Front towing eye

Rear towing eye

Roadside Repairs 015 PANS

Jump starting

Jump starting will get you out — of trouble, but you must correct whatever made the battery go _flatin thefi firstplace. There are

When jump-starting a car using a booster battery, observe the following precautions:

v Before connecting the booster a _. joe | = properly (alternator iho slack or broken, alternator wiring fault or Ze. itself faulty). 7

x, :the een, is being eee rom the battery in another vehicle,

en sia Buresne: me:ignitiends

)The Canina

the positive (+) terminal of the flat battery

Vv Make sure that the booster battery is the same voltage as the discharged one in the vehicle.

v

the two vehicles MUST NOT TOUCH each other.

Ensure that all electrical equipment

(lights, heater, wipers, etc) is

Make sure that the transmission is in

switched off

neutral (or PARK, in the case of automatic transmission).

:

YJ Connect the other end of the red lead to the positive (+) terminal of the booster battery. ="

3

Conhiact one id of the black jump lead to the negative (-) terminal of the booster battery

4

Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started.

i i I I

aieeeleeteeleeiaet

Make sure that the jump leads will not come into contact with the fan, drivebelts or other moving parts of the engine.

ee ae ee a ee

Soe =

ee

eee

ee ee ee ee ee ee eee eee

6

Start the engine using the booster battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection.

oi6 Roadside Repairs Tyre condition and pressure It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the front tyres wear out faster than the rears. Interchanging the tyres from front to rear ("rotating" the tyres) may result in more even wear. However, if this is completely effective, you may have the expense of replacing all four tyres at once! Remove any nails or stones embedded in the tread before they penetrate the tyre to cause deflation. If removal of a nail does reveal that

the tyre has been punctured, refit the nail so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Regularly check the tyres for damage in the form of cuts or bulges, especially in the sidewalls. Periodically remove the wheels, and clean any dirt or mud from the inside and outside surfaces. Examine the wheel rims for signs of rusting, corrosion or other damage. Light alloy wheels are easily damaged by "kerbing" whilst parking; steel wheels may also become dented or buckled. A new wheel

is very often the only way to overcome severe damage.

;

New tyres should be balanced when they are fitted, but it may become necessary to rebalance them as they wear, or if the balance

weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration, particularly at a certain speed (typically around 50 mph). If this vibration is felt only through the steering, then it is likely that just the front wheels need balancing. If, however, the vibration is felt through the whole car, the rear wheels could be out of balance. Wheel balancing should be carried out by a tyre dealer or garage.

=

Tread Depth - visual check

Tread Depth - manual check

TyrePressure Check

Alternatively, tread wear can be monitored with a simple, inexpensive device known as a tread depth indicator gauge.

Check the tyres pressures been used,

the tyre pressures regularly with cold. Do not adjust the tyre immediately after the vehicle has or an inaccurate setting will result.

Shoulder Wear

Centre Wear

Uneven

Wear

Underinflation (wear on both sides) Under-inflation will cause overheating of the

excessive wear, not to mention the danger of

Overinflation Over-inflation will cause rapid wear of the centre part of the tyre tread, coupled with reduced grip, harsher ride, and the danger of shock damage occurring in the tyre casing. Check and adjust pressures

sudden tyre failure due to heat build-up. Check and adjust pressures Incorrect wheel camber (wear on one side) Repair or renew suspension parts Hard cornering Reduce speed!

If you sometimes have to inflate your car’s tyres to the higher pressures specified for maximum load or sustained high speed, don’t forget to reduce the pressures to normal afterwards.

Front tyres may wear unevenly as a result of wheel misalignment. Most tyre dealers and garages can check and adjust the wheel alignment (or "tracking") for a modest charge. Incorrect camber or castor Repair or renew suspension parts Malfunctioning suspension Repair or renew suspension parts

The original tyres have tread wear safety bands (B), which will appear when the tread depth reaches approximately 1.6 mm. The band positions are indicated by a triangular mark on the tyre sidewall (A).

Tyre tread wear patterns

tyre, because the tyre will flex too much, and

the tread will not sit correctly on the road surface. This will cause a loss of grip and

Unbalanced wheel Balance tyres Incorrect toe setting Adjust front wheel alignment Note: The feathered edge of the tread which typifies toe wear is best checked by feel.

Roadside Repairs 0-17

Identifying leaks Puddles

obvious

on the garage floor or drive, or

wetness

under

the

bonnet

or

underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the

Warning: Most automotive oils

and fluids are poisonous. Wash them off skin, and change out of contaminated clothing, without delay.

:

HAYNES Aisel

:

lesan

clue to wiet’s oehig Some fluids are distinctively

coloured. It Ee may help to clean the car carefully and to park it over some clean paper overnight as an aid to locating the _ source ofthe leak. _ Remember leaks mayq only eee that somea Ae

problem lies.

| occur while the engine is running.

Sump oil -.

Oil from filter

Gearbox oil

...or from the base of the oil filter.

Gearbox oil can leak from the seals at the

—

Engine oil may leak from the drain plug...

inboard ends of the driveshafts.

Antifreeze

Brake fluid

Power steering fluid

Leaking antifreeze often leaves acrystalline

A leak occurring at a wheel is almost certainly brake fluid.

connectors on the steering rack.

deposit like this.

Power steering fluid may leak from the pipe

oig Recommended

Lubricants and Fluids

|.

Component or system Engine (1)

Lubricant type/specification Multigrade engine oil, viscosity SAE 10W/30 or 15W/40, to API SF

Transmission: Automatic (2) Manual (3) Final drive (4)

Hypoid gear oil, viscosity SAE 80W/90, to API GL4 or GL5 ATF type A, suffix A Hypoid gear oil, viscosity SAE 90, to API GL5

Braking system (5)

Hydraulic fluid to DOT 4

Carburettor dashpot (B19A models)

Automatic transmission fluid

Power-assisted steering

ATF type A, suffix A

104

Chapter 1 Engine For modifications, and information applicable to later models, see Supplement at end of manual

Contents Part A: B14 engine

Part B: B19 and B200 engines

Ancillary components - installation ................ 000. eeeeee 36 Ancillahy.components=Temoval’. sake c ake ere slos cw nes cans 7 Camshaft and followers - examination and renovation ........... 24 Camshaft and followers - installation ..............0 0c ecence 32 Camshaft and followers - removal ....... 0.0... 00cece cece eee 13 GOMPLESSIOMMES te ar Meer Tan a vuiene DateRange Slutak ay 127 Crankcase ventilation system - description and maintenance ...... 18 Crankshaft and main bearings - examination and renovation ...... 21 Crankshaft and main bearings - installation .................... 29 Crankshaft and main bearings - removal .............0.00e00ee 17 Crankshaft rear oil seal - renewal ........... 0cee eee eee eee ee 16 Cylinder head - decarbonising, valve grinding and renovation ..... 27 Cylinder|head =idismantling!: ssc Mactan ninse ghee neice Vine eee 9 Cylinder head - reassembly and installation................040. 35 Cvlincdemneacd TOM Ovals italyvein cc x wicuiscpadsowslerk wrels! aoaca wei iar axelelee 8 Cylinder liners and crankcase - examination and renovation....... 22 Engine - adjustment after overhaul ................0 0. eee eee 39 Engine dismantiing: (general). soe we te ke Pee ae 6 EMGiMmeuns tallattOne ate Sie. x 0c conde wleies 6 un Me nieer me aiee ae eyes37 Engine:= reassembly (general): 22 fas lie ht ntun w elem eens peers le 28 EMCMeerOImO Vallee scrnet es acon oaratlri son eis iteselet aimeemta gepete eaetims5 Examination and renovation - general .......... 00.00 ee eee eee 19 FAUT DCUMC EVOM GING Nste is6= a vite)s ccsa Sieliciate/arsatve voletewed See end of Chapter Flywheel - examination and renovation ...........0 00. ceeens 26 Rivwheeli=MStallatiOny witimusw cc ec-cyelensie + re eineuendidcteis a aces a abniet 30 IVA GI E=orSIMOVELsec sk asiamaceeisucsaise ec isatiee) a wilcpametteta neapa)agea)eilneta have 15 GONE ralCESCIIOHON tiie hstecsGrs seeinllee rantstestiiinirous Sime aes ie Silas be 1 Liners and pistons/connecting rods - installation ............... 31 Liners and pistons/connecting rods - removal .................- 14 Major operations only possible after removal of engine............ 4 Major operations possible with engine in car .................05. 3

Ancillary components - refitting Ancillary.components’= removal: is-.55 2c épcs « curs seen ne ays ee Camshaft and tappets - examination and renovation COmpressiontest isa 5 Os.somcig nrc ia.s, th a eth orcin ees eeennde oe Crankshaft: retina: cisters wists tera, Wis rtaatecagate cin einai emer Crankshaft and bearings - examination and renovation Crankshaft and intermediate shaft gears - refitting Cylinder bores and crankcase - examination and renovation ...... Cylinder head - decarbonising, valve grinding and renovation ..... Cylinder head and camshaft - dismantling ..................... Cylinder head and camshaft - reassembly ..............00.000-

Oil pump - examination and renovation ................0.0000, 20 GOilOumMpPs ana oiliilLeri= TEMOVAI ccrcpreietene eon alateietatojsreloa.s eevcimes coe11 OiliPUMpPsanasSUMPp)= INStAHALIOM! sie chee yetaqncsaymlee wecciateagatewlehe"aes 34 Pistons/connecting rod assemblies - examination and renovation . .23 FROULIMONIIGHILCMANGG) cele olececisceme w tyesqhiyecpimmle cecceyaine wie iciMicra a alela 4 2 SURI REMO ION Alanine ictal sas Jeneliaieparties igaroriepow) ayant aUala tae «sos 10 Timing cover, gears and chain - installation .................0.. 33 Timing cover, gears and chain - removal ................00000- 12 Timing gears and chain - examination and renovation ........... 25 Valve clearances - adjustment .......... 00. eee eee eee eee 38

54 56 47 67 Cylinder head and camshaft - refitting ..............2.8.200..- 68 DistbUtOr = remitting s.‘=© £ =° he = £ }so oOLo 1986-on

12¢45

12°46 Wiring diagrams

15

BL (B200)

16 17 18 19

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28

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Schematic diagram for all models, 1986-on (continued)

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26

Wiring diagrams

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12°47

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12°48 Wiring diagrams

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£ °ZS oO ay 1986- on (continued)

Wiring diagrams

(10A)

B 14

MT

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Supplementary diagram for 1986-on B14 models with automatic transmission

12°49

12°50 Wiring diagrams

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MOT Test Checks

erst

This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testable component is in borderline condition, the tester

has discretion in deciding whether to pass or fail it. The basis of such discretion is whether the tester would be happy for a close relative or friend to use the vehicle with the component in that condition. If the vehicle presented is clean and evidently well cared for, the tester may be more inclined to pass a borderline component than if tne vehicle is scruffy and apparently neglected. It has only been possible to summarise the test requirements here, based on the regulations in force at the time of printing. Test standards are becoming increasingly stringent, although there are some exemptions for older vehicles. For full details obtain a copy of the Haynes publication Pass the MOT! (available from stockists of Haynes manuals). An assistant will be needed to help carry out some of these checks.

The checks have been sub-divided into four

oe

as follows:

A;Checks cared out 2 Checks carried out ‘FROM THE DRIVER'S WITH THE VEHICLE o ON THE GROUND

3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN

4 Checks carried out on YOUR VEHICLE’S— EXHAUST EMISSION | SYSTEM . .

FROM THE ‘DRIVER'S EAT Handbrake (J Test the operation of the handbrake. Excessive travel (too many clicks) indicates incorrect brake or cable adjustment.

[1 Check

that the

handbrake

cannot

be

released by tapping the lever sideways. Check the security of the lever mountings.

] Check that the brake pedal is secure and in good condition. Check also for signs of fluid leaks on the pedal, floor or carpets, which would indicate failed seals in the brake master cylinder. LJ Check the servo unit (when applicable) by operating the brake pedal several times, then keeping the pedal depressed and starting the engine. As the engine starts, the pedal will move down slightly. If not, the vacuum hose or the servo itself may be faulty.

Footbrake LJ Depress the brake pedal and check that it does not creep down to the floor, indicating a master cylinder fault. Release the pedal, wait a few seconds, then depress it again. If the pedal travels nearly to the floor before firm resistance is felt, brake adjustment or repair is necessary. If the pedal feels spongy, there is air in the hydraulic system which must be removed by bleeding.

Steering wheel and column _({J Examine the steering wheel for fractures or looseness of the hub, spokes or rim. (1 Move the steering wheel from side to side and then up and down. Check that the steering wheel is not loose on the column, indicating wear or a loose retaining nut. Continue moving the steering wheel as before, but also turn it slightly from left to right. L] Check that the steering wheel is not loose on the column, and that there is no abnormal

movement of the steering wheel, indicating wear in the column support bearings or couplings.

Windscreen and mirrors L] The windscreen must be free of cracks or other significant damage within the driver’s field of view. (Small stone chips are acceptable.) Rear view mirrors must be secure, intact, and capable of being adjusted.

REFe2

MOT Test Checks Electrical equipment _] Switch

on

the

ignition

and

check

the

operation of the horn. [] Check the windscreen washers and wipers, examining the wiper blades; renew damaged or perished blades. Also check the operation of the stop-lights.

CJ Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the steering from lock to lock, and ensure that the hoses do not contact the wheel, tyre, or any part of the steering or suspension mechanism. With the brake pedal firmly depressed, check the hoses for bulges or leaks under pressure.

Seat belts and seats Note: The following checks are applicable to all seat belts, front and rear.

L] Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles. If applicable, check the retracting mechanism. Check the security of all seat belt mountings accessible from inside the vehicle. L] The front seats themselves must be securely attached and the backrests must lock in the upright position.

Doors L] Both front doors must be able to be opened and closed from outside and inside, and must latch securely when closed.

a Checkacarried out

Vehicle identification J Number plates must be in good condition, secure and legible, with letters. and numbers correctly spaced -— spacing at (A) should be twice that at (B).

LJ] Check the operation of the sidelights and number plate lights. The lenses and reflectors must be secure, clean and undamaged.

L] Check the operation and alignment of the headlights. The headlight reflectors must not be tarnished and the lenses must be undamaged. L] Switch on the ignition and check the operation of the direction indicators (including the instrument panel tell-tale) and the hazard warning lights. Operation of the sidelights and stop-lights must not affect the indicators -if it does, the cause is usually a bad earth at the rear light cluster. L] Check the operation of the rear foglight(s), including the warning light on the instrument panel or in the switch.

Footbrake L] Examine the master cylinder, brake pipes and servo unit for leaks, loose mountings, corrosion or other damage.

Steering and suspension [] Have your assistant turn the steering wheel from side to side slightly, up to the point where the steering gear just begins to transmit this movement to the roadwheels. Check for excessive free play between the steering wheel and the steering gear, indicating wear or insecurity of the steering column joints, the column-to-steering gear coupling, or the steering gear itself. L] Have your assistant turn the steering wheel more vigorously in each direction, so that the roadwheels just begin to turn. As this is done, examine all the steering joints, linkages, fittings and attachments. Renew = any component that shows signs of wear or damage. On vehicles with power steering, check the security and condition of the steering pump, drivebelt and hoses. L] Check that the vehicle is standing level, and at approximately the correct ride height.

Shock absorbers L] Depress each corner of the vehicle in turn, then release it. The vehicle should rise and

then settle in its normal position. If the vehicle continues to rise and fall, the shock absorber is defective. A shock absorber which has seized will also cause the vehicle to fail.

L] The VIN plate and/or homologation must be legible.

isan vension ——



4.4A Unscrewing single piston caliper guide

>

Fig. 8.4 Drive out the pins (arrowed) and take off the cross spring (1) - Series 1 Girling caliper (Sec 3) 8 Smear the surface of the pad backplates j-seize grease and insert the pads into the caliper (friction surface to disc). With Girling brakes, place the anti-squeal shims on the backplates the correct way up. 9 Refit the retaining pins and clips (Girfing). 10 Repeat on the opposite brake. 11 Apply the brake pedal hard two or three times to position the pads against the discs. 12 Fit the roadwheels and lower the car to the floor 18. Check the hydraulic fluid level and top up if necessary 14 Avoid harsh braking as far as possible for a few hundred miles to allow the new pads to bed in.

, ia

q

‘

aye] ( ( I

{

grams q-Yo

i

2

Volvo 340, 343, 345 & 360 models, including special/limited editions 1.4 litre (1397cc), 1.7 litre (1721cc) & 2.0 litre (1986cc) petrol engines Does NOT cover LPG conversion Haynes Publishing, Sparkford, Yeovil, Somerset BA22 7JJ England

,

I| 383 45°00715 ISBN 1 85960 231 2

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