Volvo 850 (1992-1996 J-P Registration) Service and Repair Manual (Haynes Manuals) 9781859602607, 1859602606

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Volvo 850 Service and Repair Manual John S. Mead Models covered

(326Q-240-2AB1)

All Volvo 850 models wkh 1984 ce, 2319 cc and 2435 cc petrol engnas

Printed by J H Hooyn .. & Co Ltd, SpIorkfOf'd, N. YlOOvtl. SomoI'Nt BA22 7JJ, Enllland

.... rigIrt...-.No - ' of Il>1o _

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.... _ Il1o ..., lorm 0< by ...,. "'un.. 0>I0ctr0n1c Of .... chan ... ｾＮ＠ lneludk>g phoIocopJto ... , ｾ＠ or by ..,. 1fIf _ _ _ ... _ . . .tem. _

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Ionlnwrillnglrom .... ｾ｟

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... P,obIk: . tiDo, Dato '"'""'" lor 1hio book "-11>0 _

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North America, Inc

861 La-.ce

DrIve, Newbury Par\, CaIiIcmia 9132{1, USA

Ｎ＠

EcIitIoouo Hayne. $.A. TOIl" Aurore - La D6f1WlS4l 2. 18 Place dos Rellet., 92075 PARIS LA DEFENSE Cede", France

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Publ!lhlng

Spa.rIdon:I, Nr Yeovil, Somerset BA22 7JJ. England

UI>rt or wint .. driving ,flQUir9J1enu;.

11>rtanc$ end the Supp/«nentaf Restraint $)'IIt""" and SOOfI Impact Protection S)'IIt"'" ofte,r 8g$r protaclion throughout the vehicle. Provided that '$gular s.eMcing is carried OUI In accoo:l8oce with the manufacturer's oses ate. are exposed to 'emperau..es III>cw 400"C. The rubber changes into a chamId or sticky sub$tancfI contaln;ng \toe acid. Onca Iotm&d. 1118 acid mma/ns dangerous for years. !f it

/he sJer tralliT

handle ｣ｬｯ＼ＺｾｷＢ＠ unlll the wh ....1 Is ,alsed clear 01 the ground. Unscrew me ｷｾ＠ bolts and """""8 tM wheel.

and !K'eW In Ihe Fit the spare ｷｴＮ･ｾ＠ bolto . Ughtly tighten the bolts with the wIIeeIb1en Ihe whtI&I bah. In tile sequence shown Ihen ,elil the wlleal lrimlhub CIlI>. Stow the P'JOCturG(I wI>eo!I and lools back In the luggage c:ompartmerrt

6

_I

and ,....,"'.. n,,,,,, In puollion. ｎＢｉｾ＠

II",t II",

wheel boilS should be slec\ened and tf>en ,etighte ned 10 Ihe specified lorejue al the opportunity.

Roadside repairs 0- 9

Identifying leaks Warning: Mosl .wtomo'lve 011. .tId fluids .... po/SDIIous. Wash ''''''' off sJc/II, IHtd cll.onge 0U1 of """'amln. teet clothing, wif,",'"

ｾ＠

c¥,...,.

The SIINIIII 01. fIlM INIdng

Puddles or 1l1li 11"'89'1 IIoor Of dn"", or otMous W_5 uoder lhe bon""t or ｾ＠ 1I>a car, suggesl D leak thai need!! lnvestiga1ir41. ｾ＠ can 1()m(II"'- be d ifficult to deCidf wJ\8l'll the teak Is comlng trom, ospodIIty H 1M ""gl"" bay '- v.y 6rty ｾＮｬ･｡ｫｨｧ＠ oil or ｾｵｩ､＠ can 81'10 be blown .......,0. by lhe passage 01 air under the car, gMrog • lalle imp"""ion o! wha'" the prabIem liM.

.&....,.

Sump oil

Oil from filter

Gearbox oil

Brake fluid

Power steering fluid

I

•

_

MIN

trom !he ｣ｍｬｯＢＬｾｓｭ･＠ -

-

prowfdt •

disIj,,,tIIwIy

coIounId. /I".., help 10 .... !he c¥ canlluIl'y _ 10 p.Irlt If _ _ _ ｾ＠

ＢＮＬｾｉＧ＠

lid ｉｯｾ＠ ItM ...... /hal .."". ..... rN)' MIy

I()UItOe 01",. ｾ｟ｪ＠

occur wItHe rtHt ｾ＠

• """""""

•

,•

•

ａｮｴｪｦｲ･ｺ

］ｾＺＭＬ｟＠

,•

Towing WMn all 81511 tails. you may find )'OUrsell haW>\I to get a tow home ｾ＠ Of o! CO!O'lIe yOU ...,. bo t.eIp\'Ig ....-..t>ody . . . Long.d""""'" *"""""'Y should Qr11y M done by a garage or tnaIecoroo 100 diluted. and will

traeza durhg cold _t'-. On ..., eccounl usa cooIanl anllfrene In I/le washal" systam _ this cooId disct>/OUr 01" damage pain-*.

When topping-up the reservoir, .. washe< ftuid mlar illiocatad 1 compartmllfll bo right·hand oogIna 2 SCfe8I1wash 'flCommanded on the . (the 'eservoir Its..tl ia Tlla q)Oted In CIlaptet 12.

If mg and ＧｾｩＸ｢ｬ＠ ........ic. life. Thl. Is 8 compr.nen.lve plan, .., maintaining .ome itemf, but not OChers 81 tile sptI(:IfIed MfVk: .. Interv. wm not pl angina wi" be

kepi In ｾ＠ good!UW'Olng c:ooodltiol .. lflii work wII "- " ••• iIecL !he need tor ＭＧ､ｾｩ｡ｮｴｉ＠ 2 It Is poulble thallh«e will "- 8OI'f!I1h* wf*1 !he .ngN Is !UW'OIng pooIIy .... 10 Ite lack of ｾ＠ ""'""I.......,.;e. ThIs hI_ mo:n IlIjj out liN following openttioIt....fer to liN precautions g/"en In "Ssf.1)' f lral l- at the beginning of tIt/I manuel, a l'ld follow tMIII implicitly. Patrol Is a highly deng..-ou, and ｾｯＯ｡ｴｩｬ･＠ l/quld, and rIIa p ... cautlons nace,..1)' "'hili handling It cannot be .,.,....,... " " . 10 ChacI< alilual hoses lor detariol'atlon and challng. Ched< especlslly lor cracks in _ wtlere the hoN bends, and also just bel,," finings. well sa w!>aM a hose attaches 10 \lit

ili.

remove the roadwlleoels. 3 Look through the inspection window in the calip .... and cl\eck thallh .. thickness of the fridioo ｾｮｩｧ＠

mat"";'" 00 each oIlhe pads is nOt 1"9 than the recommended minimum th ickness given In the Specifications. It any ooe 01 the brake padS has worn down 10. 0or iI delectM! Int".,.all)l. and renewal is

.....,

5 Grap the ｾ＠ at IhtI 12 o'clock and 6 o'cIocI< positions, and 11)' to 'OCk It (SflI 1usIrriDn). IIfIl'J slight !r..... play may be fell. buI If Ihe movement il apprl!(:lBble. lunhe< inYII1lsatlon I=; necessary to determine the __ COfrtiroJe rocking the whee4 while an ISSIltanl depresses Ihe lootbrake. II Ihe ITICI'emenlis now elIminated or ｾｧｮｈｬ＼Ｚ｡ｴｹ＠ ｾ＠ " il l kIIIy \haIlhe wheel bearings arl .IUI. If the free play is SI,UelAdent with the Itx:Utrlike depresAd. \hen tt-e is wear In the gpension joints or mountings. • Now,.asp lhe wMeI althe 9 o·cIock and 3 o'dOt:t; positiooa. and Iry 10 rock H as before. kr; nIO'I'em8I1t lelt r.aw IT1IIY again be caused tit _ In !hi wheel beartngs or the steaing nd< fIXI end bDJjoints. " the outer track rod II1CI Is worn, the vlousl movement will be oIr>4gus. ｾ＠ the Inner Joint '" suspect. It can be !til II)' pIIIc",g 8 hand ove' the rack-and· f*Iio/t r\)bbllr g aller, and grlpplng th6 track om. WthI...tteei Is now rocked, movement will bt fell al the Inner Joint il wea' has token

-

7 !»"tog a ｾ＠

Soidng lor splits, trICks Of cootaminatlon of lhe rubber.

8 With the vehicle standing on Its wheels. have an llSaiSlant tum the 8t""';ng wheel back·aneHor\t1. Hbout an eighlh oIatum e8Ch way. There ahould be very lillie, II any. ioSl movem""t between tha s teering wheel and roadwheals. II this Is not tile case, closely ob$.ervll the joints and mountings previously check the steering de&crlbed, bulln ｡､ｾｩｯＮ＠ column uniyersal Joints tor wear. and alllO chedc the rack-and-pinioo sleering gear itself. 9 The aHiciency 01 the shock absOfber may be checked by bouncing the car at each front comer. Generally speaking, the body will return to ita normal pesillon and stop all... being d&pressed. tilt rises and returns on II ,&bound, tha shock absorber 18 probllbly suspect. Eltr. but e xcessive _ Ytould be obvious. Che(;k the condition ot !h" shock abso,ba,. as

--.

7 DriYflhaft gaiter check

1 With thOl vehiel" raised and securely supponed on axle stands (see "Jooldng and ve/liod in Chep\9I' 7B.

"........

8 Check Ilia performal'lCe 01 tile engine. transmlsaion and drtveline. Q Chock thai the engine S!8t\S ｣ｯｲ･ｴｾＬ＠ both when cold and hot 10 Usten for any unusual noises from Ihe Mlgine and lr'an3tnIssion. 11 Make sure that the eoglne ruos smoothly when Idling. and that there Is no hltsi!a!ion when accehomllng. 12 On ｭ｡ｮｵｾＱ＠ tranamlnTon models, check that all gears can be engaged smoothly without noise, and that 1t1e gear lever action .. no\ al.>normalty ｾ｡ｧｵ･＠ or "notchy"'. 13 On automatic Il'8l\Sl\"Osslon mocIeUI, make sure that the drive seems smooth w ithout l.xs Of eng .... speed "fIare·ups· , Check that all the gear positions can be S&IecIed with the vehicle at rest.

Clutch 14 Check Ihat the ｣ｴｕｉｃｾ＠ peda l moves smoothly and easily through its fullt ..v"'. and that lhe dutch itMIIf functions correctly. with 1\(\ tr"ee 01 "ip 1)1' drag. If the movement Is uneven or SI illin places. check the system components with refflnln"" topping·up. 7 Add the fluid a little al a time. and keap ctlecking the ｬ･ ｾ･ｬ＠ as ｰｲ･ｾ ｩｯｵ ｳｬｹ＠ described until it is COfTeCt. The diff..."""" betw-. the "MIN" and "MAX" marks on the ､ ｩｰｳｴ｣ ｾ＠ 15 appmdmalety (1.5 litre. 6 If the vehlcla has oot been drtven and the engl"" aod transmission are COld. carry out the procedures In paragraphs 3 to 7. but use lI\e side oj the dipstick marked "COlD". 9 The need for ragular topping'up of the which transmission fluid indicales a ｬ･｡ｾＮ＠ should 1M found and rectified without delay. 10 Tht condition of the nuid Should a!:so be ｣ｨ･ｾ､＠ ak)ng with the level. ｾＡｨ･＠ fluid at !he end 01 the dipstick Is bla.:k or a dar1I reddish · brown colour. or If it has a bYrneett at thl c.anksh'rt pulley end of tile engi .....

21 ,5 Square hole In Ｎ

ｵＮ

ｬ ｬｉｯｴｹ､Ｇｨ＼･｢ｾ＠

Wlrnln", Be ......,.. c.r.ful , .nd weer protec tive "'0"" to m inimise the risk of tH.rnln" fOIN hlnth on hoi ｾｉ＠ ..

A

21 Auxiliary drlvebelt check and

nmn"'",

H lIN fII'git>e lIN rK .... l!y bHn 3 UW>g en inspection Igttt or I emalllIIIc1ric torch, and totaMg the engine wilen necessary with • I1M-""'" I pplied to the craokshafl ｰｴｊｬｾｹ＠ nul. ch-.c:k th. whOle length of the drMobeIt lor aacks, SIIpIRIion 01 tIw..-, and tom or wom nt... Also check lor "lying and gIalng, which gIWs the drIYebeIt I shiny appearanc.. 90th P;!es 01 the drwebeh should '-Insptoc:ted , which means y ou will hive to twist the drlvebelt to check !he ｵｾ

Ｎ＠

Use your IInge .. to telll the

tanaioIlflI'I. Ihen relllll;nany with Ihe specified coolant mixture. 1 tf only clean. soli waler and good-quamy antlffeele has been used. amlllle coolant IIa'!; been renewed et the specified ,ntervaIB. the above procedure wID be sufficient to kll8!l lhe syst"", clean for a considerable length 01 time. II. however. the system has been neglectlld . a more thorougft operation will be requwed. as fOllOwS. 8 Forsl drain the coolant. then disconneclthe .adiator lOp and boltom hoses. Inaetl a garden hose Into the lOP hOBe. and allow wet .... to circulate !hf'Ough the radiator ｾ＠ runs clean from the bottom outlet. 9 To flush the engine. ramove IIIe thermostat (see Chapter 3). Insen the ga.den hose Into Ihe thermostat housing. and allow wat ... to circulate unti l il IUns clear Irom the bottom

untn

1':'_..,,,

"'2 Every 20 000 miles or 2 years

-.

ｾＮ＠ N• .tIer. I'HSOtIebIe f*Iod. no. _,. 11K1 doee nQI run clear, the radi .. lo.- ahouId be nuOlhed with II ｾ＠ propriollary cleaning

iO In stlltm eases at contamination,

_·"".hil'l(l

of 'he r.dlalo.- may be necessary. To do Ims, .1ImO .... Ih. radiator ( _ Chapter 3), Invart R. IIrld lnMI1 the Q&fden ' - inlo _ bonom outlet. Cootnue ｾ＠

urrI" cu WilIer rvns from ItMIIly u • luI rlMO >

••

.

"•

..''. .."

"

25.11 Pull of! the HT lead. by gripping the rubber boot, not the lead Itself

25.3 Remove the sperl< plug cover

ｾ＠

• "••

"

"

2 ｾ＠

pUg removDl 8f'od reflt1ing requi ...... a socket, with an ･ ｾｴ ＦｮＤｬｯ＠ which 1*1 be IU'IIIKI try a mtchot hancHe or similar . ThiI $OCket 13iined with a ｮＬＯｾ＠ ｳｬＢｾ･Ｎ＠ to

'fill< ｾ＠

prOlll;I !he po !he sparIc pItIg hoIoI. You wiN also need a ..... ljpeleeler btade, 10 ctIeck and adjust the

J

.,..

--

I(I1II:. plug elet.:lfode gap. and D torque wnnch te lOp 04 the pIugt; . . light. and \hilt the plug extllf\Or

aurllICes and thr&acIs .... cleao. 13 On lnlltalling the spark plugs. first cMck IhIIl the cylind .. hNd thrNd and lailing 1IU1_ are u clean as possible: use. cINn f8!I wrapped around a ｾｮｬ｢ｲｵＤｨ＠ to wipe clean lhe _ling surf,c.. Enl",e thaI the

spark plug thr •• d.... cleln and dty ti'>en ｾＡｨ･ｭ＠ In by haod wI\eIw possible. T.... _ care to enter ｾ＠ plug IIvMds QQrT«:tIy. I. When each ｾ＠ plug it started con'ecItt on n. threads, _ _ ndown I.O'ItIIt just __ lightly. Ih\In tighten It to the sp«:lfled torque ........mHtting. 15 Reconn«:1 the HT 1Nd, In their COffeel 0I'der, usine • twisting motkNl on the boot unlil Mit Im.y Milled. I'InaJly, (alii the GP:>rk

.... -.

11', 011 ... dIfflcun 10 InMn ｰｊｵｾ＠ ｴｰ｡ｾ＠ Into tMIr ttoIH wIthout_""-ding

,,,.,,,. To

POId Ｇｾ＠

po ..JbJllty, fit.

of fIIbbe .. fire.

d !he Ｙｖ｡ｰｯｲ･ｾｶ＠ omisslon control syslems requires reglllar checking, and even Ihen, Ihe components of this syslem require minimal attention. D&tails of these checks wiH be fouoo in Cllapt"'" 48. Should H be ful' IlIat the other systems are not /unClionlng correclly, the advice of a deale' sI>ould be """9I1t.

29 Timing belt renewal . , 992Jg disn"tMtl&d aa described

.. ｾＮｴ＠ ｾ＠ PItt 9. any preliminary dismantling ｾ＠

can ". ignored.

Moll lI1..t, whf\e ｾ＠ may be po!Isible pI!yIicaIy 10 0'iIIIhau1 ｾＦｭｳ＠ such as the pjIIonIcortIIldlng rod ｵｳ･ｭｾｪｬｓ＠ while the .,gInI Ie In the ear. such tuks ara oot IIMJIIIy carried out as separate operaTions. ｾＬＭＮｉ＠ additional procedures (not to .....,... Ina cleaning ot componenb and ｾ＠ havtI 10 be carried out FOf lhls _ , all such tuloOI build up dumg S"CCl • • stroll • • Indlcatas leaking valves or I blown head

•

gaskaC (a cr,..;ked haad could also be the causa). Dflposlts on tha und..-sklaa 0 1 the valva I\aads can also cautetow compression , 8 II the preuura In wrt cylinder Is law. carry out the IoIIowing last 10 IsoIata the ClUte. Introduca a taupoonlul of dean oil Into lhat cylinder Ihrou-gh it, 1j)IIrl< ptug hole, and repeat 1hfI teat. .., II the addition of oH lemporarily lrnprova IhII ｾ＠ 1hIIIndicat... that bar. or piston w..... hi raapoMibie to< lhe ｾ＠ toes. No ｾ＠ suggall$ that I..klng or bumt valv". or a blown head gasket. mIIV be to bI&'nIi. 10 A tow........, from two adjKMt cylindets Is almost certainty du. 10 lhe t>ead gaslr.et t>aWIg blown _ _ _ tNm; IhII pr..-.ca 01 coolant In the ..... 011 .... CO'Iftrm thIa. , I 11 """ cytO\der ill aDDut 20 percenl iower lhan the others and the qna has , .tighHy rough k*, I worn urnthIh Iaba could be IhII

_,op"""

•.

_"' __

ｾ＠

12 If the compression •• adlng Is ..........atty high, tna comt:>ustion CI'IImbers .... probably coated with carbon deposits. II thl, I, Iha case, lhe cylinder IIaad thould bI! ."""WId and dacartIonised . 13 On completion 01 !he teat, raIiI plugs and raconnact lhelgnition 'Y"em end tuallnjectort.

the..,..,..

3 Timing bet!: - removal and

refitting

Removal I DIscoool8Cl the batlaly nI9ItiW lead. 2 Ra!no'4 IhII auxIIIIry drIYebaIt lIS ｾ＠

-.

InChapter ' . 3 un the cooling system a)q)aMio11M probably lak.. two Of three ｾ＠ urotiI )'IlU are SU'" that the ITIIlI'k5 are

- -.... ....,,' . -... --.

••

""

I' Undo the timing bell tensionllr upper ｾ＠ boIIlIIId stackO!l' the lower on. (see

1lullrali0ll). Move lhe tansioner aS$embly ＮＬｾｫ＠

Illey

"''',, -

...iu to Ifee It Irem the lensk>ner

U fIIrnQVI 111" ｾｉｏｕＸｹ＠ slackened IWIIbntr lower bolt and remove the . . . . On _ rnodeIo tIlere fs a plastic ｾ＠ sh8j)8d spacer coil .... fitted to the IOIlI:A 1M 101'18ionef. Cnllecl thl, collar Of 111111) which win fall out at this stage ,se"

:k(ll

ｾｉ＠

:811

" Iblo Ihe bo/t$ and lin off the timing

,'"'

14 M.t Ihe ｾ＠ dlreMI and lower the car to the g.ound. TIghten the wheel botta In a diagonal ｾ＠ 10 the spedIIed torque, 2fI Relit the 11"*'0 belt Ironl COlIer lind the two IuaI pipe ciampi:.

w......

3. '8

...-_.....

211 Re'il the .park plug cover and cooling

ｌ ｯ｣ｉｴｨ･ｭｰｲｳｍ､ｾＱＮｩｮｧ＠

• 2.0 mm dIIImttt.. twist drill

lorce oil b41tw.... tile inlerna! chambeg facti. 8 Clean the SNI seat. E-amln.. the shaft -'1"11 face I... Won antemg the gap betWEiflr'l the pistons and borM. - - . D ｾｴｬ･＠ g,ease In lile gap. After cleaning IiNK:h pbton, lIM a small brush 10 1iI1!rec.s 01 grease and eert>on !rom the gap, lhen wipe away the wIIh a cIe/Wl.-g. Clean .. tile pistons in thl sarrtI wWJ. 13 Check lilt mating Ilri.- 01 the ｾ＠ block and tile cyIioder head fOf niclce. deep .c"'ch .. and Olher df,maga. If alighi. Ihlt)l maV be r8fllOVed carefully with a file. bull! nClIISive , machining mev be lhe onlV liIIematiVfI to _iii. 14 11 warpage 01 lile cylinder head gasket Si.H1_ '- OW$p&CIed, UN a atralght-edoge 10 check it tor distortion. Re* to P.-I 01 .,. CI\ajlI&'" .-&ary.

'*"""'"

,.,1Iit1dat

e

RefittIng 15 Com"..,...,.,. refitmg b)I piecing a new head gasket on the cyIindoIr block. Make sure it Is

1ht right Wf-y UIl; it should be """"ed TOP.

I

ＬＺｾ＠

-.

.ＮＺＭ［Ｌｾ Ｎｾ＠

onwards. but do not Ie Ihis stege. 22 R.t!I the Inlet and em.m

Ｚ＠

I

"

in Cllapter 3.

B Crankshaft oN .... - renewal

Front seal

""""',.

1 Remove lhe liming be" as " '......, '

2. The cranksllef! Iprocklt mUll I» I tallonary while centre al&ckened . li the

"I

2A-1 2

Engine in-car repair procedures

ImJJJectlon B On manual tra nsmission models, II Ihe

IlywhlHll's clulch mallng Burlac_ ｾ＠ dlHlj>ly Of OTherwise damaged, Ihe nywhlHll musl be re""wed. However. It may be possible to have i] surlaca·ground; 3""k the advlca of a Volvo deal.... or anglne rllCondilioning specialist II Iha ring gear is badly worn 0( has miss ing teath. flywh ....1 renewal wiH aI'so be oecessatY. 9 On models equipped with 8U10mallc transmISSion , check the torque converter dnveplale carefully lor signs of distortioo . look lor any hairline cracks arouod the boll hollIS or radlallng outwards from the centre. and inspect the ring gear I",,]h for signs of wear or chipping. " any signs 01 w""r or damage llIe found. !he ckIvepIat. muSI be renewed.

scored. crac ked

II Conlin"" rafilling by .""e lSing Iho removal op ....tlon •. Apply thread locking compound \0 the .-1IywheaI .etainlr>g DOlts ｲｾ＠ "'" already pre-coaled) and tlghlan them to !he speclfoed torque. 12 Refit the dutch as described in Cl\ap1ar 6, and Ihe 1fat\$fOloWon DS described In Chap· lar 7A. Drivep]ale (models with automatic transmission) 13 Proceed as dasclibed above for manual transmission modelS but Ignoring any ralerenc&s to clUlch. Refit the ｴｲ｡ｮｳｭｾ＠ as described In Chapter 7B.

mounUng 10

'"

joint will be damaged.

Refitting 7 Rafol by ",versing iha removal tighl8nlng all fastenings to ｾ torque.

11 Engine mountings - removal

and relitting

Refitting Flywheellmodela with manual transmission) 10 Clean the matfnQ surlaces of !he IIywhN and crankshaft. Remove any f9IT1ainlng k>cking compound from the Ihmads of lhe crankshaft holes, usio9 the cormc:t-stza lap. H avrulable. If a au/re ble rap I. no' ."./labla. cur two slors Inlo ,he 'hrNd. of _ or "'" old rlywhe.' bon. and u.e ,,,. bon 10 twmo"" 'h. Ｏｯ｣ ｾ ＧｮｬＱ＠ compound rram the 'htWds.

ｨＧｾ

Ｂﾷ ＧＺＢｭ］Ｍ

'"

Removal 1 All the Individual anglne mountir>g5 can be renewed with the englnaltraosmlsslon iflslall6d. 2 Disconnecl the battery

negative 18aCI.

3 Ascertain which compone nts Bra ｬｩ ｾ｡ ｬｹ＠ 10 Impede removal end ramove. or move aside as necessary, wilh re'erenca to the re lavam Chapler. of th"-' manual. 4 Atta ch a suitable li/ting equipment to Ihe enllioe 0' POslllon a jack. with protacllve wooden block undor the sump or transmission as necessary.

］ＧＭ

Ｍｬ＠

(M8:3OHrn)

\ 1.5 Ez1g1na1l.ansml"slon mounting detalla (relet to SpecJficll rlonr lor latas1lorque HItIngsl

c

El ...., ",::::1 Ｇ＠

c

Chapter 2 Part B: Engine removal and overhaul procedures Contents re!iItOl ｾＮ＠

.......•. 12

()riIN/I- removal and Inspecflon . ClfI* ｴＺｬ｣ｫｉｲ｡ｯｾ＠ - cleaning and Inspection . ｾ＠ held • dismantling. cleaning. inspection and reassembly .• &ogiIt II1CI ｾｯｮ＠ - ,emoval, aeparatioo aod ｲｾｊｦｩｴｮｧ＠ £t9'II. WtIII SUfI-UP after ovemaL>l and reassembly • . ....••. &9M 0'/IrtIIIIl- preliminary InfotmaUon . Ef9i1oO'o'tlllU. raassembly &eQO.lIlI'Ce . . .. , . . . . . • •. . .•..•

8 9 5

3 16 • 11

Engin$ltmnsmiaslon removal _ preparation and precautions _. 2 ｾ＠ Information . . ..... , ........ , ... ...... .... . . Main and big-eod be\Uings - inspec1;oo and SC 0.19 mm mllX

ｾ＠

(doll. , • . . ｾ＠ jcunaI dwneter:

SWdII'!I , •..•. ,. LnOnIte .,..

64.981 to 65 .000 mm 64.75Omm

. ...... , •.• .

... ｾ＠

n.o:vVng cIe8rangeu- with their ｾＬＮ［ｮｧ＠ bolts. SC18W$ etc wilt save time arid avoid COI1Iusk>n when the oogioe is mlillad. Clean tne engine compartment and englnftftransml"lon belOfe beginning the removal procedure: tnis ｷｾ Ｑ＠ help ｶｬｳｩ｢ｾ＠ and help to keep too",ciean .

•

28-4

Engine removal and overhaul procedures

The help 01 en uslstant should ｾ＠ available: Ihere are cerlain Instances when ontO pereon cannot ....!ely perlorm all of I he op ....ations required to remove Ihe engine from the vehicle. Safety Is of prima ry impol1allCO, CII!l'iOtring lila potential hazards Involved In this kind of operation. A second person should always be in attendance to oNer help ... an emerger.cy. If thla is the first lime you have removed an engl"" . advice and aid from !IOmeoM more experienced would also be benefi(:laI . Plan Ihe operation ahead 01 time. Belore starting wor1< . obtain (or arran"" for the hire of) all 01 the lools and equipment you will need . Access to the following ｾ･ｭｳ＠ will allOw tha task of removing and refitting the englnel1ransmlssion to be complet ed ....Iely and with relative ease' an engine holst · rated in ･ｾ ｣ｮｳ＠ 01 the combined weight of t he engine/transmission . a heaV\l -duty trollay ladd on Ihe bulkhead . NOlO thai new nuts and bOlts win be required for refJlling. on the 8 Undo the earth lead relalnlng ｢ｯｾ＠ bulkhead . adjacent 10 tha steady bar bulkhead brackBI. Righi-hand drive models g

ｒ･ｾ＠

lhe pedal position sw itch on Ihe front of the brake vacuum servo unit. 10 Release all the brake pipes leading 10 lhe master cyflnder from their retaining c lips on

ｾＭ

Ｎ＠

tt Remove the brake mastar cyflnder from the servo una as described In Chapter 9. bill w ithout disconnecting any of the hYusing. 'M 34 Undo the Bteerlng ｰｵＢ ｾ ｭ ｾ Ｌ ｾ mounting baH and, then slac ken Ihe

""'"

'" the pump ｰｵｾ ｡ｹ＠ and two the pump. Leave the pump engine ｾ＠ reedy to be lifted out.

Ｚ Ｚ［

Ｌ ｟ Ｎ［＠

Engine removal and overhaul procedures

28-5

bill! end lor 8deQ11at. ｾ｡ｮ｣＠ • . Ens...re tllat lhe lilting l1li' Is . ... tMotanllal, and sac .....ety .nac:n.d to !hoi ang;n.. 53 Lift ofllhe aI. conditioning compressor (wh... IppHcebl.1 and piece It on th. wb/Jame. Do ｾ＠ dilconnect the .lfrIgerani

....

54 lift 011 the 00i!i

sl-r.g pump and ｾ＠

ｾ＠

to

aide.

55 ChIck Ihat no w\rM, hosa flC hove been OVfIt1ookad. Rai.. the anglr.e/t.ansmls.slon I nd .... nlpul" . It to cleat In adj ...... t compooenta. Take QrHI cera no! to ｾ＠ the .adlalo, .. the engln. Is baing

m.nOMlv. ed; .litTIOvl lhe .ngln. mounting brack", from the transmisaion N Ihis provide mora cIHfloc.. When aufficient height 'xlsts, lift ｾ＠ over the In:InI panel, cleat of 11M engine bay and lower It to the ground.

wi.

....,

SepartltlOll

r CrIoII'If ｾ＠

10 ｾ＠

sensor

ｾ＠

,-I At ｷｲｾ＠ ＮｾＬ＠

CO,"*fOj

1I ReYIrsJng IIghI .wlfCh , .. CamshaIt posIfJotI..-.scv 1$ ""'"" air /fowltlt.lc. 16RPMsamor

""'fej"......ｾＱｴｉｦＸ＠

• ｾ＠ poJiIiotI MIlKV" • 'fICI.n.tydoM, l.ci< up 11M In:Int of 11M • Ind tufIj)OfI ｾ＠ on ull ,lands (SM Ｎｾ＠ WKJ ｾ＠ wworT,. Removl lhe II:rflpOl ..... I::I . !nMlU&I

IflMmluJon mod9I.I /Ch8p18f 6). j} F/ywI!eaIIdt1'tap,ra {Chaptet- 2AJ. Ir) Oil fiIrer ｩｃｉ｡ｰｬｦｴＢＧ ｾ＠ I} Dipsrick, tube and bnlcker. Note: "'-1Wl"IOYing II-.. ...... ｾ＠ btom Ihe *",""" I»Y dosoI attvmon 10 dellib Itwt """Y be I!eIpIrA 00" i-r>pOI1anr d:Jrfng ｲ･ｾ Ｎ＠ Nora rile IItlJr>g pos/fioN of g.IIsJrets. seal•• bolls and ohIr - . . iMrIIa. II YOIJ are obtaining • - short· eng'ne

-..rs.

(cylinder bIockIcrankc:ase. Cfankshall. pi5l0r0s and connotcting rods .. M$IIIIbIed). then !he cylinder head . l1m1ng bel! (together with tenllOnll. with a bIoo:k of wood at IJIC/I ...cj to give ｾ＠ for the ........t...... 21 \fICa 0/ (!hi appropriate gradoIIj valve-grinding compound on the ...t lace. and pr... a auocllon grinding 1001 onto the vallll head. With I a.!!I' ro!ary acllon, grind the valve I'>Md 10 It. '''1. Iitllng lhe valve oce.stonally 10 redlalrit>utl ,he griooing

s.-w.

COfTIPOIXI(I. using paraffin Of a suitable $OMIf1I. bel,,", Ｎｾ＠ of the cylinder head.

Valve componenta 211 ElUIml"" tllft valll& spring. 10. alg'" of d&maoe and d/scoIorIt >on. and Ils.o meuurl thl lr free langll> by compa.I"Il IIcl> oll hl ,xistlrog springs with a n&W component. 3D Stand each spring on • Hat .ul'fICl. and check It lot $QUareneM. H any 01 tI>II apringe a" damaged. distorted. or 1>&11. Iofot IMIr ｾＮ＠ obtIjn • complete MI 01 new apringe. Ills normal to fit MW aprings _ III matler 01 co.ne if a major YIIIflIIuI1s being carrier;I out. 31 AeMw the lIaMI stem oil ..... 0I1heir apparent eo .... refit the cyllond .. dHCril:lld In PM '" 01 thII ChIpW. 6 Sump and Intennedlata MCtIOfl • rtrTlOval

,",,,,,

'egard"

Re8U8mbly 32 ()I the stem 01 001 veMI ..,ct Ins«! ｾ＠ lrMo Ita go.Ade thin 11th s.pritlg lower _to 33 The new v,,"'e stem oil seals ahouId ｾ＠ suppled 'oo'itt1 a pIas1k: fining ..... 10 protlCl IIIe SIll! when • Is ritIed !MIt' !hoi v..... If not. wnop • thin piect 01 potyfh6ne around !he """'" stem IIIoIWIg It to elC1end about 10,...., _ t h e «ld of the veMI stem. 34 Wilt! l he fitting sleeve, or potytI'IoIM In plica wound the 1iIMI. fit the ........ tem 011 Mal. pushing ｾ＠ orno the """'" guIc» _ I . _ it wKI go with a s.uita ble socke t or pilei 01 tube. Once the SMt Ia sealed. ramo... lhe protac1lvl ...... Of poIyIhene•

•

• Engine removal and overhaul procedures

7.10 Removing piston rings with 11M help 011_

I CaoIfI.Iy tap \lie Intermediate section trIM

"*lG I

0( hide malleI. UI1 olf the w::tion complete with cranlOOatt . . meItI be8I'n\I shells. H any 01 the ｳｨ･ｾＹ＠

",bber

ｾ＠

..... .. -,..-. -... .

r.t1ll\'1d on !he oraokshaft. !ransler \hem IIIh1J I;O'f8Cllocatlons In \he Inl\lg shell. Not& .... _ baits .... be ｾ＠ for raassetrt>Iy. I F\IIiI "" ｾ＠ rod IlIKI piston up and GIlrJh_. Ro!c:ov. tI>a other half beBrIr>g "fIlialDoM. I IWllIhe cop to the connecllng rod. the CO'IICI way round. 80 that tl>ey do not get

...

7 Checl< to see H u-e is 8/"1 atI"OW 00 the top 01 the piston wt1Ich shOIAd be ponr.g toward the tming bell end 01 the eogno. Hng arrow can be "..,. rtl8l«I. ｾ＠ di'ection man< yoo.rseII. 8 W;thoul rotating the crankshaft. repeat the rods operations on lhe remaining ｣ｯｮｦｉＸｃｾｧ＠ and pI$tOO5.

Inspection 9 Balore the Insp&CIlon process can be carried out, the plslon/connectlng rod assemblle$ must be cteaned. and lhe oriQinai piston rIngII removed from the pistons 10 carefully expand the old rlngs and remove them from the top 01 the pislonS . The use 01 two Of Itvee old l eeler blades will be halpfuf In preventing tha rings d,opping Inlo emply grooves 1_ Illustr.tlon). Ba cara/ul not to scnotch the pislonS with the enQ ｾ＠ ring accordj"fJ/y

(arrowed)

lor each

2B

-

28- 14

Engine removal and overhaul procedures

mkldlellng II bev.lled and tIwI ｾＢＮ＠ mllSl lactl downward. 1IIIheugh the radIIIlor matr\lt '" 8Nis1lld by a two-apeed

eMIetrIc: I..... w!lic:h '" COI'I1rOI8d by the ｾ＠ ｾｳｹｴ＠ .... ECU. A I h _ '" fitted 10 c:ootroI coolant flow ttwough the ｾｯｲＮ＠ WIW1Ihe engO'le '" cold. the ｾＱＸ＠ YI""- ......... closed 100 I,..t I .... coolanl flow wttlch occur. 11 notmIII Of*&ting lemperat.... Ihrough the .....,or malttlt lit ＱｮｴｾＮＺｉ＠ At, the coolanl w ...... up, the Ih8fmoelll ...,... . ,artl to opetl and allows !he _ " I flow ttwough the radlalor 10 .-.me.

a

n.. eogl". t_p"'a lura wit! Ｎｉｷｾ＠ bt malnlained at a constanl Ie.&! (accorolng to t.... thermostat ratlng) wtlala _ the Imb*!1

,_.

air 1....pead in delllil '" Section t .

3.2

Cooling. healing and air conditioning systems

Precautions w .rning' 00 not a".mpf 10 r8fI'10V. 1/•• eApans/on Ｇ｡ｮｾ＠ fIIt.r • cap. or to dis turl) .ny part of Ih. cooling system, w/lil9 It 0' 1/•• "."goln. /$ hot. lIS til .... Is • .,.". flTHl ｲｬｳｾ＠ of .c./dlng. If Ih. eApansJon lank fill., cap musl be remov.d before the ."fiJln• •nd red/alo, have fully cooled do ... n rev." t"oUfiJh this Is not ,e! removai. Ensure ... blato-. locating pegs engage with the ..." ct tho radiator 11$ the shroud Is refitted

• ｃｯ＼｡ｮｴ

5 Radiator - removal and

Testing

_....

＠ｾ HIN

Ｚ［ ｾ＠ ...Ｚ Ｎｾ＠ .... ;;;.... :;;;;;;.. Ｚ［ ｟ ［ ＢＧＱｾ＠

- testing, removal and refttIi'Ig

ＢＧｫ｡ｾ＠

Is tha ,....on for _ ..antlng to ".","WI Ilia radlaltN, baa, In ",lnd Ihat ",11101' "'ab ""n often ba c....J u&Insr a tIIdIaIor SNJant wftJt _

Removal 1 Drain the cooling svstem (see Chapter I). 2 Remove the radiator cooling fan as dMCribed In Section 4. 3 Undo the retaining bolt each side . ｲ･ｾ｡ｳ＠ the clips and f&IT\O\ItI the splash guard under the radiator Is- Ulustnltlonej. 4 0Isc0nnect the top and bottom hoses. from the radiator_ S On cara equipped with elr conditioning . uotlo the condenser upper mounting bojt on each 8Ide. Secure the condens« to the upper body panel with atring Of wire to rtltaln it In position. 1h&n uotlo the two 10_ bolts I .... Illu.tratIonj. 8 On automatic transmission models. disconnect the fluid cool." IIn85 from tha radiator left-hand slde tank. Be prepared for fluid ｡ｰｬ ｬ ｾ･ Ｎ＠ Plug or cap the I;""" to keep dirt

1 TllfI cooIantlemperalure

"",,501'

Is located

in the Iharmostat housing and is used by both the engin" management syslem and the Instrument panel temperature gauge fo supply an engine tempernture source signal. 2 In the event of 8 faun ... tho sansor or III lOSS of sIgr1al due to poor electrical COM9C\kIns a fault code will be logged In Ihe eng ine managemerJ1 system fCU which can be reed out .ia the diagnostic unit In the englna compar1ment. Refe' to Chapter 4A. or Chapter 58. for further Information on fauH code read 0U1. . ._ - / 3 $houkl a fault code be logged, a cll/elul • check should be made of the sensor wi ring , -" ,,_ . and the wiring connector. Apart from testing by substiMIon with a new ｵｮｾＮ＠ lutther checks require the use of Volvo tnst "'Iu1pm&l'lt and should be ""trusted to " dealer.

I

Removal

M

4 Partially drain the cooling system (see Chapter I ) to below the level 01 the sen""r unil. Slacken the clip and diaconnecl the redlator tOJ> hose al the thermostat housing. 5 Dlaconnect the wiring at the adlacent connector then unacrtlw the sensor from ils location In Ih" Ih"rmostat housing (IH

7 Whertl mted. disconnect the engine 011

lIIustnitionj.

S.S Left_hand elr conditioning ｾ tower moIII'1t\ng boH (...-owed) ｟＠

I

-

3.4

Cooling, heating and air conditioning systems

1.3 n.r.. of 1M M ven coolanl pump retaining botta (1t1'ugh1y dean 811 traces 01 old g!I$Ie IhennostBt

Refitting

watar. heal the water untH the temperature corresponds with Ihe tempeflture marking stamped on the therrnc>stat. e Suspend the {closedl thermostat on a length 01 ｾｴｲｩｮｧ＠ In me water and check that ma.>clmum openWIg oxx:ur8 within two minutes • 1 Remove the thermostat and allow ｾ＠ to cool down; check mat ｾ＠ cIo&ea fuRy. 8 If the m!ll'TTl!!ltat daM not open and close as described. or WH sticka in IIitI.- pOSitiotl. " must be rMlIIWeol.

Manual climate controllY'tf/II 1

On

rn(I&Is

equipped with

control system. the heater may Blono. or in conjunction with a controlled air conditioning ｵｮｾ＠ . houIlngs and heater

....-

2 The heater is of the IrMh air Ｇｾ［Ｌ＠ mrough • grille in Iront of the w

Its way to the various _." ••••• proportion of ＧＢｾＺ［Ｌ＠ ＺＭ［ＮｾＢ＠ heater matrilment detail. a l the healer unit

1

18 Undo the fo"r .crews securing tha glovebox compartment snd the lour &CraWl! securing the glovet>ox lid Il!nges. Remove ItItI ｧｉｯｶ･｢ ｾ＠ and lid from tha lacle. 18 Working through the glovebox aparlura. disconnect ItItI fan motor wil'itIQ connactor. 20 Rernovalhll cable duct from the Ian motor and tha two wiring COewm

fllIIt ItIJ:U/lIy (compntssotj drlvebelt ;s _ _ _ In Chlpler I , but m/ other

......".. Ｌｾ｣･ｰｴ＠ t""SII described be/ow . . III ."trusted 10 /I Volvo dell/II' 0' /II, ｾ＠ fP"C1aI131. If n_SSIII)', llui . . - - can be unboltlld lind moved _1'IItJoo! QilConnectilti 1M fl/rrlgeret1I ..... .,.. ｾ＠ IIlo!I drfYebIIIt. ..,. 0/ IIlo!I ｾｯｭｰｬＢＧｓ＠ used In IhfJ ｾＡｩｯｮ＠ IkJe 01 the S)'3/11m are moo _." an tquJppBd with manulll cllmale ...,... Rotter ro Secllon 10 for procedUfl/S II/IIIIg III Ihf".,. /an motor. h6ater mafliJt,

-'1'1'*-.

-

CIICroI pane/ and ECU t AImoYI I .... rId!o

."

3- 7

as deacribed In Chap-

11 .8 EJectronIc cllmtIlP88NI, . . IldiCltOl$ thaI there is a fault In Iha ""'"' ... to Section 12 Wthis Is the case. • • On complMicn. !wHCh olf the ｉ ｧｮｾｫｬ＠ . . IIIsflvlead In Its IIokIer and refit the unit

-...._.

/tha"dItJonlng Nillay and power

41 tkIdo 1M screws snd r","ove the ｾ＠ proofing panels Irom under the ｾﾫｉ＠ tr.1eft and righi-hand sides. • I/rIdC the lour SCr"WS securing the

fM'X'l compartment ,00 the four SCrews

IICI.IhQ t!w \jIoIteboX lid hinges. Remove the

fOoIOO> .-.did from !he facia.

• The tNy ｾ＠ oow be removed by pulll"i .",Ift! out oIlhe hQId ... base.

.. o;.canoecl

th. power stage w iring ccmec:tG' by depressing the catches on tna

--.._lhe_. IdInI \lUIIIIt 011.

• ｾ＠

_.....

....... .

, CEO

..... .... ""'" ..,. ｾ＠

..

too.

"'" ..... ｾ＠

."" ....

...

IIIs!8l8ln'ng SCrew 8o'\d

• AIfit by ｾ＠

remove Ihe

the removal operatlons.

......"'or

• TIl. lOOter teMOr fs C(lmbined w"h the ...,.. BIarm system dide aOO Is located

.,tlpollt.fllCla covw. • e..tuIy prise up the sentOr uSIng a ....-.Iriv... m"oo und8f Its base at the

• 1lisconneC' the wiring connector and

• ReIiI; by ｾ＠

'""

Inltlon

.ECU

the removal operations.

..

,-, n.

........... .... ｾ＠

1I1mo ｾ＠

Shor , _... air

the "REC· and "AC OFF" warning lights on the ｣ｯｮｾ＠ panel. the on-board diagnostics can be used to Initial ly plnJXl!nl any problem areas without the us. 01 special test equipment. Once thl, has been dOne controllault eodes

S Given In the accompanying table (shown ｯｶ･ｲｾ｡ｦｬ＠ are the possible elae codes have been deleted. switch 011 \he ignition, locate the ftyIaad In ｾｳ＠ holder and rem the unit CO\I9nI. II Once the location 01 a fault has been establiShed Irom the fault code read·oul. Invllllilgations can be concentrated In that area. In many instances. the lault may be nothing more serious Ihan a corroded • trapped Or loose w iring connad release the front &doe of the boot carpel. Remove the support panel under the carpet. Ur.do the backrest catch, ,eIease the fasteners IlIId ....".,.,., the boot &ide trVn panel 3 On Esr are mod-els. und" the retaining screws trom [hi! luogage compartmeot fronl IIDa panel. Pull the panel \(I the release the front mournings aOO ....".,.,., the panel. 4 Undo the nuts and 'emove the Keen cov",s o"ar Iha 1",,1 pump and Mnder unit. The sender Ｑｘｉｾ＠ Is beoeath the 00_ nearest the front of the car !_ IMuslr8tlonl. 5 Trace the w iring 100' the $Mlder unit. whict1 runs across the top of the fuel tank to the fuel pumP. thefl out to the group of ｣ｯｮ･ｬｾ＠ adjacent to the $hc>ck ab!:Klrtler upper mountrlg. Disconnect the ItIIe\tarIt conoectOO', raIo;ase any cable-lies. then feed !tie wiring back and tIvQoql the . . . . . alit aperIl.nI '" the 1Ioor. 15 Unscrew the sender unit plastic ,etalnlng nut using a w ide opening pair of grips , _ lllustnllloe6d and ｴＮｮｾ＠ base. then .... !he jac k to)ust take the weight 01 the

..

7 Undo the tank reta;mng straps and carefully lower the jack and tan k slightly. When aufflclent clearance exists, dls.cormect the ｾ ･ｮｴ＠ hoses leading to the front 01 the car , The fIoS8I bfttw"" tile tank and Mer tube can be left In place. and t ank. and ram0V9 the 8 Low er the ｪ｡｣ｾ＠ tank from under the car. g If tho tank is eontll/Tlillaled Willi sediment or and the water. remove the gauge sender ｵｮｾ＠ fuel pump as des.cribed previously. and d ls.connect the ventilation hOS89 and fil lar tube. Swill the tank out with clean tuel. The tank is moulded fmm a synthetic material and If d.maged. k shouW be...........ed. Howav",. In cerlaln eases It may be poss ible 10 have small '-ks or minor d amage repaired. Seek the advice of a dealer or suitable specialist c:oocemIng tank repair. 10 If a new tank is to be filled. transfer all the components from the old tank to Ihe n"",. Always . _ the fliler tube seal and the seals and pla stic nuts securing the fuel pump and gauge MOder urn!. 0J1t;e lI&I!l, they may IIOf seat and seal properly on a new tank.

ReflHlng 11 Refitting Is a revl!fS8l of removal bearing in mind the following points: .,t LocafB the tanIt. in posifion end lighten tIM! rear s".. mounlk>gs. AJsh the tanIt. /otWafrj end cetI/fe the fuel gauge sencMr unit end fuel pwnp plasrk; nuts wlf/l t8$p1Ct to their 8CC'8$!I ho/e$ It1 the fIoor_ Now fighten the front strap mounfings. b) Lubricate the filler neck seals and 8Ilswe tJwt they era proper1y 1oc819d. Make sure thBt the drain rub compiefion. refill the 18IIJ< with fuel end ched< exIliIusllvely lor signs o/Ieakage before drMng the car OIl the road.

8 Fuel injection systems -

general intoonalion Bosch LH3.2·Jetronlc system The Bosch LH3.2-Jetronic system Is filled to Ihe non·turbocharged 20·v uNe engines. excepl for some versions of the 85254 S MIg i"" which lJIiiise lhe MOIronic 4.3 system described let ... in this Section . LH3.2·Jetronic Is a microprocessor· controlled fuej In)ectlon system, designed to meet stringent emission control legisl allon whilst still provid ing excellent engine performance and fUIII !lCQnomy. This Is achieved by cootlnuousiy monitoring the anglnll using vartous S8tlsors. whose d.ta Is Input 10 the system's electronic control unit (EeU). Based 00 Ihls Intormetlon. the ECU program and memory then determine Ihe axect amount of fuel net, aloogaldll IN Mndscre&n washer resarvolr liller ｾ＠ illustration) . The diagnostic unil cooslttl It 1WO modul.... mounted side by side. "filth I plastic oover over each. Uk off IhIl COVIIfSn note that the two rnodulas are marl each digit.

11.3 Ins«! the 1IyInd Into SO(:ket \2) 01 module fuel system fault codn

!AI to ,.,.,..I t-

••• ••

Fuel system .... !he ItyINd In$llfled, switCh on the Ｌ＠ｾ Pfess the lesl bution on top oj . . . . ,1. once, lor about one second, then

. . land walt lor the LED to nash, As the lID""'" copy down the leuR code. Now ... \hi DU1ton again and copy down the ..... code, Wthere Is one. ConUnue unUI

-

No IauI! detected

aI outstoe voltage range EGA temperatlll"e seosor &!gnal lIbsMt or faulty

Turbo boost poesIIure too hlgh Turbo boost pres"""' reduced by automatic transmission ECU 4-3-2 High temperature In ECU modulo bOle 4-3-3 Rear knock sanaor signal absant Or faulty 4-3-5 Heated oxygen senaor response slow 4_4_2' I\ir pump relay signal at-11 or faulty loog term !vel mhdure too rieh at ｾ＠ 5-1-1 5-1-:1 SOort term tuet ｭｩｾｴｵｲ･Ｎ＠ too rich 5.'-3 Excas8Iv9Iy high lemper8.11.re In ECU fTIIl(,),gen sensor heating faulty 5-2-3 to 12 'IoIts Signal kI EOJ rnocUII bole oooIing !art ｾ＠ 5.2-4 Transmlssloo lorque control signal tautt:i 5-3-5 Turbo regu\IItor valve fault 5-4-1' EVAP valve taul! - Only appIIcfbIe Ie> enQ/I'Ies with c:ertain ｾ＠ oonvol ｾｴ＠ Chapter 48}.

r_

I

..

4A- S Fuel system ｌｈＳＮＲｾ＠

... -

,

1-1-\ 1-1-2 1-1-3 1-2-1 1-2-3 1-3-1

\-3-2 2_1_2 2-2-1

2-2-3 2-3-1

2-3-2 3-1-\ 4-1-1 5-1_1 5-1-2

S1*tem ....anlnll No lauH delacted ECUlauH Short I.." luel mlx1ure 100 weak MAf ｾ＠ slgnal a bsent 0< faulty COOIanllamperature sen&OI" signal absent or faulty Engi"IEI RPM signal from igrillon system absent 0< /aIIIy BII1tery voltage 100 low or 100 high

2 S lackllfl the hO"" dip outlet duct and , where c,ankcase vlIfltilalion hose

Refrtting Ｑ

codes cannot be delel&d until all ollhem have been displa.yed at least once, and the fYsl 008 is displayed again. Wrth the fIyIead still inserted in socket 2 oIlT1Odule A, switch on the ignition,

ptess tile tesl button and hold il down 10< approximately live seconds. Releasa the tesl bullon and afta, Ih'H seconds the LED wi ll ,;gill. When the LED lights. press ;v,d hold the test buIIon down 10< a I\WtIIer five seconds then reIease!t - the LED wUi go out. SwitCh off the ｾｩｯｮ＠ and check thai all the tauH codes ｾ＠ been delated by switching tile ｩｧｮｾｯ＠ on again (!lid pressing the lest bullon for one second code 1·1-1 should appear. If a code other than record the code !hen repeat the , - t - t ｾ＠ deleting procedure. When all the codes haVfl been daklted. switCh off the 19niIIon, locate the fIyIead In Its holder and relit the uri! cown. 9 Once the location of D ｦ｡ｵｾ＠ has ｾ＠ aslBblished lrom the faull code read-out. lrlvesIigations can be concentrated In that """'Go thrwgh the chooks carried out Pf8IIIousIy in case anything was missed Ihe lirst lima. Furth&!" delalled checking 01 the system

ｾ｟ＮＬ＠

Intake air temperature stlIIIII' (Fenlx 5.2)

aI Idle

Short term IUIII mlxl1xe' 100 fIch

ｾＢｭＬ＠

In the:'

ｾ＠

Idle . . control valve signal ｾ ｢･ｮｴ＠ 0< faulty Long term IIJei m\xIure too fleh In part·1oad stage Long lerm fuel mixture 100 WNk at Idle Vehicle speed sensor (apeedome\ef) signal absent ThrQt1je po$ItlOn aGn$Or 3ignal abM"tt

8 0rI0II aI the fauH CodM have been reoor tile manufacturer's sc/!edd o!le Induct .... head runs \ust above the drilled flywheel periphery. IIlow tllto ECU to comput e -nol", speed and crank.tlloft poaItiorl. M the cr..l pedal Ia r"'..-:t. the d iaptwagm spring ｣ｾ＠ tile pr...1H plale. driven plate 100 IIywhMI fltmIy logeth .... DrIve ,. II ... , mlll.cl through Ihl frIellon wrlaee , of Ihe ｉｾｨＧＢ＠

and pl'esw'e plate to the IlnInos 01 \lit driven plate and 1M to the IransmIssion Input Ihatt..

When tile clutch pedll fa deprul.cI, the It lrantmilted hyCIran_ ｾｉＧＢ＠ .nd rIO repair Of -"tIJ 0/ lhe cylincMr Is posaibIe. In lhe ...... of. ｾ＠ system /au/I. or WI)' sign rI ｾ＠ IUd JeaIg eIi!M and r...... tIM ... c.IItlIM from the ｴ Ｎｾ＠ brlck-'I

18 Allach

Ih, OUI.... cables 10 ltol tranamission brackets and !he Inner cables 10 the solector Ie ...... Nol. that Ito. On 50 that the retalnlng eirelip Iock!Ilnio plac" In the dif!erenhal gear. ToghlElll Bli routs and bolts to the specified torque with ret .... ence to Chap' ..... 8 , 9 and 10 as appl icable. Ensure that the ASS S!lflSOr, an(! $&r1sor location In Ih.. sl .....ing knuckle, are perfeclly clean

3

ａ｡ｲｾ＠

by 'everslng the 'emoval operations.

4 Wipe clean th" area around tho fUlerJlMi plug and I>'lSCreW the plug from tho Cf;$i!g 5 Fill the Imnsmlsslon through the tiller pbJ orifice with the correct type of 011 '-"'IIi til cI begins \0 run out 01 the orifice. 6 Relit the IlIlerl\eVel plug. and l igIttan I securely. Lower I he vehicle to the gnlOl'ld. drive n lor e short dislanc;e, til&n chtc:II b leaks. 7 Dispose oIlhe old ｯｾ＠ safety In acnIdulld poroofing pan ..1 from under the . . on 1M left-hand !IIde.

..

18 M ov. the transmission ..lect or lever rearward one poSition to R (R.verse) (".. lIIustrlltlon) . 19 Wilhout moving the "",lector cable or transmlsslon "",lect or rever position. locale the Inner cable on Ihe "",lector lev" and ｰｯｳｾｫ＾ｮ＠ the oute!" cable bracket on the transmlasion studs. Secur. the bracket with the nuts. and where applicable the washers and tighten tho nuts to tile speclfied torq\!ll. 20 ｒ･ｦｾ＠ the locking clip and washer seco.rlng the cable 10 the tranamlssion seIec:Ior lever. 21 Check the Ildjustment by moving the gear SfIIector lev ... lnalda the car to the N (nevtra/l poIIition. WlIhoot toucl\ing the k:>cIKk the transmission fluid level as

o..cribed IrI Chapter 1 on completlon.

Noll: Ao'.NfiiT*l1S musf be mIIde to suppor1 fit Jt9r>e from above /0 allow the wbfrem& II/iedtllldled on the iefI-hand side. 7h& basi "'YJo qIpOI1 t/I& engiII& Is with a bar mstjng it Ihf bOIlnel channels with l1li ad/ustable ｉｯｴｾｲ･Ｏｹ＠ placed. Trolley 1«1"OOlem . 12 If Ihe lault canoot bEl easily cured in this way. further detailed checking of the system componenls will requi!'9 !he use SO.'• . 0 0 _ Iocalion fn tINt steering 1 sid&, to expose each ball In tum track. Examlne the balls for • !hi top 01 ｾｳ＠ e w it. taking great eara not to dam&1ng nulS .. .. ... . ...... " . "' Rigid pipe unions ｆｬ･

ｾ ｬ｢･＠

hoM unions

ｾ＠

25

.... .... . .. .. .

ASS W'heeI sensor mounting bolts •..•.. . .. . ... . ..... ,. ASS feU mounting bOIlS .. ......... . .. .... . .. .

RoOOwMeI bOlts . , .

"'" "" ,"

• . .. .. .. . . . ..•.. " .

. . ... . . . •.•

'" Ignition and lIelect lirat gear (marul

1 Generallnformatlon

The brake pedal operates disc brakes on all tour wheels by means of a dual circuli hydrau lic system wTth servo essistance. The handbrake operates 5efl'I{ate drum brakes on the rear wheels by means of cables. An IIIltiloci, braking system (ABS). incorporating an on,board fault ｾ｡ｧｮｯｳ ｩ ｳ＠ lacUity. is fitted 10 all models. and Is described in fur1h .... detail i" Sectkln t9. The hydrauliC system is spilt into twa circulls. 50 that in the event of !ailura 01 one circuit. the other will still provide adequate and braking power (although pedal ｴｲ｡ｶｾ＠ ellon m8y increase). An a xle·spllt syslem is --..es the Iront employed in which one ｣ｩｲｵｾ＠ brakes and the other clrcurt the rear brakes. A pressure reducing valve Is incorpoc"ated Inlo the brake hydraulic circuit to redOOe hydraulic fluid pressure 10 the raw brakes under S9V"'" braking conditions. The brake """'" is 01 the direct-acting type, being interposed betwe&n the brake pedar and the masler cyli1\Oef , The servo magnifies the eHort applied by the driver. It Is "acwmoperated. the vacuum being derived from the inlet manitold. Instrument panel wamingl lghts alert the driver to low fiuld lev&l by means of a ｬ･ｶ ｾ＠ sensor In the master cylinder leservoir, Other warning Ｑｾｨｳ＠ remind when the llartdbrake Is applied. and Micale the presence 01 a fault in the ASS system. Note: When 511n'icing any perf of the system. worlr CMtlfully end methodically: also obseIve sc/upJ,J!ous c/eallliness when ovethaui/ng any parr of the hydraulic system. Always renew oompooenlS (Ill 8!I th"t Is being handled. Hydraulic fluid Is .Iso an e fleclive paint stripper, and will "tI..:k plutlca; If "flY Is spilt, it s/lould be washed oft ImmedI"tely, uslflg copious qllanlllils of CIa.fI w" t...... Finally, it If hygroscopic (It al»or/J$ tlKlislure from lhe ,,/rl. The mortI moisture Is absorbed by the fluid, thll iow ..r Its blJlllng point becomllS, IlIadlng 10 " dangetOlIS lou of braklflg under h"rd ...... Old fluid may be cootlJlOl/rSllled and unfit for further u .... Whllit topp/flfl-11P or renewing Ille /luld, alw"ys use t h" rec",.,m.fldod ty"", and ensure Ille t it comes from a

_u. . .

freshly-opened .....1ed contaJ.,..,..

General I The coU1ad. with no k in ks Or Iwists. and that Ihey lire secured In tile clips or brack .. ts p.ovlded. Original equipment fteolble hoses have white lines along their Ieogth which clearly show II Ihe hose i. twisted . 7 After mting. bleed tile hydraulic system as described In Section 2, wash oft any spill ""Id. and check carefully lor ftuld 1001et, mak e

(Section 4), ｾｮ､ｯ＠

II fII th8 pad, IItId shitM into the)aw3 of thll llIipIr with the frlclton ｳｾ ｲｬ｡｣ＸＱ＠ towards the

'"""'toe

" Insert the upper pad retaining pin together antl-rattle spring and tap the retaining .. Lty P>Qma. Fll the tow ... pad retalrWIg pin • tho HOM ｷｾｹ Ｎ＠ making sute thai Ih.. pin . . . 11"181" Ille tongue 01 the spring ( _ ....,.llo"s). 11 Pump the brake pedal sev ..ral tlm.s to IInl IN _ peds UP 10 the discs. II IllipUt trle op«811ons on the 01"'" rear

...

8.5 Ren remo\le !he d isc

own marII as an aid to rerMing. Remove thl! 9pIgot pin which I>oIds the disc to the hub (and also the bolt on early models) and lill 011 thl! disc (_Illustrations).

you'

Reffttlng 7 Ensure that the hub IItId disc mating ｦｾ＠ are spotlessty clean. Clean ruslprooflng compound off a new disc with methylated spirit and a rag. e locat.. Ihe disc em the hub with the Ot'ie ntation marks aligned and refit the relalning spigot pin (and bolt. where appllcabkl). 9 Rem the bdbraka ""bIe to the suspenskm ann .

.1_

16.7a Twlsl lha guide (arrowed) back and forth ".

18.5b ••• and undo the support bracket o.crew (arrowed)

16.7b ••• 10 ,ateaselt from the stub axle

16.7c Slide the IIlMr ""bit and piece'" 01 the .. xpander aIeeve

Braking system

........"""",

12 With Illfl braka pedal relaased. unSCrew Iha swltch until tllfl stop Iight8 Illuminate. Screw the switch blw::k In ｵｮｴｾ＠ the slop IIgms just go out. then lighl ..... 1116 locknut. 13 Check that the wiring Is not twisted. !hen refit I"" panels removlld for access.

lll11ndb1ekelever· removal

later type (self-adJu sting) switch

I AIrncMI the centre console as deoortbed 10

()IIp!e< II. I OisI;oI1nect tile wiring connector from the ｾｴｮｫ･＠ warning I9rt swilch. I Undo tII\I "'....nJng light switCh mounting baMa'Id ｾ＠ theswllch. ' lJrIijo the three bolls s8eeguaro (where fined) I:eIea\!l the stMriog coII..mn. 1 Depress !he brake pedal slightly Ihen push tie $I"" ｾ Ｌ＠ switch towards tha pedal to

• • f8flIOV8

..... Ihe IockinO I NlIhII ｾ＠

51_.

iocklllo IINva towards the switch as ｾ＠ wtn go. the swllch ｾ､･＠

118 far

I ｾ＠

retalnlng catches I'd withdraw the Iwltcll from the pedal indltl. Discoonect the wlrlng comector end _Ihe .witch.

-""

is futy e>c IIY'IM 10 facilitate fault Ilndlng and system ｉ ｾ＠ The diagnostic sysl\Wll Is a featlA 01 hAaS (ECU) which ｾ＠ eleclronits d/m;rlbed /n this Chap till" are secured by .wlS and DOlls tJghrltll...:/ by the a"glfHlghle"lng mf!Jlhod. 17lese partlcul8r nuts and bolts are Indic:etfJd in the "Tcvque wrench sttttings" of the $pecIfIcark:>n$. W'- any of lhasa fIls tlll"llngs lire disturbed. II Is ""mialtllal new nuts

sac'*'"

TN i odepoo !dent !root sospens.ion Is 01 the IIIr::I'IIerI SIM type tnc;orporating coli _ s and Integral 181ncoplc sllock Dorben. The slruta are located by _ _ o;>:;ntroi arms which are attoohed to tit MlnI subIrame oAa rubber t:.usMs at their trds SlId Incorporalll a balljo1flt at ｴｨ･ ｾ＠ o.I/J ond!I. The sl-r.g knuckles wt1k:h carry .. IkIIl bear ings. braka calipers and thll IltlldiK auemblles. are bQ.t!1Id to the IIIc:Phorsoo .strulJ;, and connotCtlld to the conlfOl arms through Iha balljolnll. A Iront .,okoII bar II lilted 10 all modllis and Is ｾ＠ to the "ublfama and to the ｾ＠ ,!ruts WI link Bm"IS. TN ..... _peosIon is 01 eemI·independenl 'DIIIl Unk" Iype. consisting 01 two l;ngI!UdiMl ' '''Iling arms and Integrated _ _ arms. The fON/ard end 01 aach ,.". arm Is attached to the underbody via n:IibIr mountlOOS ｷｨ ｩｾ＠ each transverse arm • Ｂｾ＠ !o tI1fI QPIXIllte trtIlling arm .Iso '/IOJIjI' rubber mounting. A colt a.pMg sod 1IPIfI!e telescopic shock absorber are .ned on each trailing arm. A rear anII-roll .. iJ _ to III modeII. Fower-ll5Slsted rack and pinion steMng Is IIaed as standard equipment. Pow,"," IIIiJIaIICfI is derived !rom a hyt!rauIk: pump. bIt-driYer1 from tI1fI crankshaft pulley.

"*

and/or IxIils are arwaY3 used when refitting. Sa/Mocking nuts lire also used In """'Y 8fMS and Ihese should also be ntneWBd, par1k:uIerIy If reslstlJflCe c.nnol be filii wfHm Ifle locking portion pases over the boil ex stud thread.

2 front hub carrier and

bearing - removal and refitting

L-_ _ _ _ _ _ ｾ＠

Hot,,: The hub bearing Is a sealed. prelId/vsl9d and pre-lubrlcel9d. double-row btlll type. and Is Imended 10 lasl illft car's entire servica Hff! wlthoul maintenance ex attanlion. 1ha bCIfJIIng is conlajn\ld w/fhkI the hub CJJ1T/tJr which Is in tum bolted 10 the stMrlng 1InucIde. The hub carrier. hub flange and bearing are serviced as " complele as!lembly and lliese compo""",, cannot be dismant1&d or renewed indiv/duaIIy. Note' On pre-I995 models, the supportj. Remove the appropriate I ron!

-.

5 Remove lhe praviously slackened ､ｲｉｶ･ｳｾＸｦｴ＠ r\llalning nul. 011 &arty models with a Slaked drlv&Shafl nul, di=ard ltJa nul and obtain a new one for relining, On ..I ... models the nut Is se/f·/ocking and can be re·used. a Remove the ASS wheel sensor from the steering knuckle and reI..asa the sensor wiring !rom thll suspensioo .strut brack"'. 1 Undo the two botts securing tha brake calipllr brackat 10 the steering knuckle. Note that new bolls w ill bll ".qulred lor r"tltling. S lldll the caliper assembly . complete with bralge I Chapter 8. Secllon 2). c) Lubricate the tJ>road. of IIlfJ CV joint and

tllrough the specified angle. using an angle tightening gauoe. If tho nut js of the staked type. lock the nul afler tighlening by lapping the nul flange Inlo the CV {oint groove using a chiS«. Ensure 11>81 tria ABS sensor. and sensor IocIItiotJ In tIl.B stoorlnQ 1Irlvckfe. IIIlI perfectty clean belom refitting.

3 Front stMring knucIde removal and refitting

Roflttlng 13 Prior to refitting, ｲ･ｭｏｾ＠ all traces of metal adhesive. rust, 011 and dirt from the splines and threads Of the driveshatt out.... CV joint and the hub carner mating surtace on the steering knuckle. 14 Locate the hub carrier assembly on the Sl&erlng knUCkle. Rant tho new bolls and lighten them progressively. in a diagonal saqu,,"ce . IIrsl to the specified torqu e settings using a torque wrench . then through the specified angle using an angle tightening

2. 12 Hub carrie< retaining bott, (arrowed) . 5t-'"9 knuo;ido shown ramoved lor clltrity

Hot e: From tria 1994 mod9I year onwards. Ihe d'-amaler of Ihe suspension st",t to ｳ ｴ ｡･ｲｬｮｾ＠ knuckle retaining bolt holes WItS mCrNSfld from 12.1 mm 10 13.0 mm to Imp't"'e camber angle adJustment tolal1lflCas during manufaclu"". This laler type s teefing knuckle Is now the only vetSion catrled by Volvo partS stockIsts. II tha steering Mudd. is 10 be renewed, II w,"" 8100 be nectISS8/)' to obtain a camber ed/uslmtHIt /cI1 from your dealerconsisting of spacer sleeves for /he sleering knuckl. boll holes. In all cases. j t will be necessary to have Iha fronl CIImb.r angle cllocktld and adJusted on complelion. It i! recommended that you COflsult YorJr Volvo d&aJer concerning the evalJability of pam, and the implicalions 01 flll$ moriillcation beforo P' ooeedio 19·

steering InlCk rod eod balljOOI fI'tIm lh&-"; knuckII! using a baiIjoIm sep;lIo.I8J hils ｾ＠ .I", H $1:1 hom 12. I mm 10 13.0 mm to /mproWI C8II!ber ang1/18 dealer consIsling of spsck the real whe/lls then iack up the fronl 011h8 car and support ｾ＠ on axle Stands (see ".Jacking and vehicle suppott"j. Remove the approprIata front 'oadwheel. 2 Ramova tha ASS wheel . " nso, I,om lh" slooring knucIoc/C absoIb8r mUIinv>Q /WI.

In Section 4.

2 Frt the Spring comprasaors to calch at least ｳｩｾ＠ colis or the spring. Ensu •• thai th. compres5Ofs used a.e 01 a type that incorporate a method lor positively locking them to lhe spring (usually by a !1m,," clamp bolt). Any other type mey slip 011 or slide roulld the Sjl. 'ng as they ara IIghtaned. Tighten the compressors unlll the lOad I. taken 011 the spring seats. 3 USIIl!! Volvo 1001 999 5467. ullscra... lhe strul moun1ing nul ...hile holdlllg the protruding pofIlon 01 the piston rod "";th too 999 5468. Remove the nut and special washer (see Mluatretlona). 4 Using 1001 999 5469, unscr.... th • • hock absorber retaining nut while holding the

5.58 Remove !he e.hock absorbw ret**'I

nut ... protruding portion 01 the piston rod ｾ＠ IIXI 999 5468. 5 Remove the &hock abSOfber r.\8b*.g l1li. upper mounl ing and spring seat. foIo:IwtII '" the sprtng. bump stop and gaitlf (1M IllulItraUons). 6 Reroo\ arm and the area IIround the conlrol arm mounHngs . Inspect the arm tor any signs 01 crac ks damage or distortion and carmul!y checl< the inner pivot bushes for signs ot ＹｷｾｬｉｮｧＬ＠ cracluI or delerioration 0 1 tho rubber. It ｾｴ ｨ･ｲ＠ bush requires .enewal. the woli< should be enl"",ted 10 a VoNo dealer. A ｾｹ､ｲ｡ｵｬｩ｣＠ pre$S and 8I.Illabie spacers are required to remave and .mlt the ｢ｕＵｾ･ｓ＠ and a settlnl! gauge Is needed for accurate positIonl"ll of the bushes In the arm. 5 The condition ｯｬｴｾ･＠ control arm ball)t>nl ｣ｾ･ ｫ ･､ Ｌ＠ On the aluminium should also ｾ＠ conlrol arm the balljolnt can be renewed separately ｾ＠ wam (..ae Section 7). On the steel control Irm the baliloint lind aim a", one assembly and If wear Is detected. the complete contro! arm musl be renewed.

Refitting II Locate the ann In Its mountirlgs sod ｲｾ＠ the new mounllng bolts and nuts. Tighten tha nuts /Ingar tight only at this stage . Final tighlenlog Is carried out with lhe car Iow_ and on Its ｾＵＮ＠

7 Front suspension control ann balljoint - removal and

refitting

AemCkl&. 1111"1 balljoint Is tight. spread the Ilol In tile IIteerin9 k nuckle with a chIsel or IqoI serawdriver. Take care not to damage lie ｢｡ｉｾｯｩｮｴ＠ dust cover during and after ｾＮ＠

S l/IIdO the two IlII1er mounling nuts,

ｾ＠

'S ｾ＠

e.3a Control

9tTTI

front I........ mounting •••

••• and raar Inner mounting

,o-a

Suspension and steering torque ullng a torque w rench, then I,-,"her, through the specified Ingll, USing an angle tightening gaug8. Tighten the InMf nu t firs!. then the centre. then the OUleIICifled totque. :II On rig!11·hend drive models, refit Ihe --.; gear crash guard nul snd the ,.... 0

.........

11 RIIit I!Ie S1-"'II gear ftuid

"pot retairting

12 On early models. relil Ihe splssh guard

.... 1heeng;n..

-

:tI RefiI

me antl-roll bar connecting links on

..:II Iide 10 lhe brackets on the suspensk:>n M

ｦ｜･ｲｾ＠

the road .... hG9ls. 10....... the car and

.,., me wI\eBI bolts In s diagonal seqoonce

10.5 BtlIh backplete, handbMlh shoe end ....bte attachtne-rlts at ｾ＠ ,tub exl,

lllhespoclfied torqve.

ＮｾＬ＠

I Rear hub "-109* - renewal

Nole: On pre-199S models. lhe 0 rtNJsed. Note ....lIen ｾ＠ 1/181 thIIfe at8 different torQue stJttings

.and by an M2C $elf· locking nut

1lI!he twO I)p8S. , The ...... hub booringa cannot be r _ ....1Id tIII*IIi/y and ara supplied ....i\h the ....... flub aacompl&te assembly. I A-:noye \he brake disc ss de-scri\)&d In CIw!IW 9, lap off the hob C8!' then undo the IIutl out. Withdraw Iha hub and bearing ...-.bI\I from lhe Slub a.>l. I rom inS ide Iha IU>l9age compartmenl or boot. S To 'emove Ihe upper mounllng. undo Ihe cenlre relaining nul while counlemolding Ihe piston rod. S Check the concljtion 01 the ｓｨｏｃｾ＠ absorber and upper mounting and ranew Bny components as necessary.

Refitting 10 Retitling Is a reversal 01 removal. tlghtani"ll all nuts af'ld ｢ｯｾｳ＠ to the ｾｩｬ ｩ ･､＠ torques and. whe.e applicable Ihroogh Ihe s.pacffiad an91e. 12 Rear coil spring - removal and refitting

Removal

ｾ＠

ｾ＠

'"

lhe nut to Ihe lower mounting and l ighten to ttle SpeCified IOfqUEl. 7 RaiS'l lhe craning arm by means 01 the jack and engage \he upper end 01 the spring In its fOC9SlI in the body. 8 Rem the shoclc absorber mountings using a rlIYersa1 01 removal aod tlghlermg all ｮ ｵｬ ｾ＠ aod bolts to lhe s-pecijiad IOfque. 13 Rear anti-roll bar - removal and rsfitting

8 Locate th" bump slop, spring and upper Soaal, and the Iowar mounting In position. Relit

this stage. II Again using new componenta, lOOMIyil the Inner transverse arm mounting bolt Mel nut. Align the datum mark made on .!IIIIO'IIi, than tighten the inner mountll19 t.rII wfficlenlly to hold the posl\lon. t o Fit the new outer mounting boll arK! rill then tighten both nuts to the apecified ｾ＠ ll8ing a torque wr.".,;h. lhen funher. IIvfAVl the specified angle. using an angle tigtifril

,..,.

Removal 1 Chock the lront wheels then jack up the rear 01 the veh icle and support ｾ＠ on axle stands (see -JlJcking and vehicle suppoII1. 2 Remove th" exhau st silencer left-hand rubber mounting and lie up the silance. as high as possible using a cable-tie or similar. 3 l()(;ate the right-hand Ｑｲ Ｘ ｮｾｶ｡ｲｳ･＠ arm mounl ing nuls on the lufl-hand trailing arm IhefI undo the Og nut 'II, and aUgnment mark made lor ｾＱｉｴｮｧ＠ 121

It right"" the anti-roll b!Ir·to-t...swww_ mounting null to the ｳＭｰ･｣ｾｩ｡､＠ torqlll. NOlI tll/hlen the anti-roil bar-to-iralilng .", _ \1/ the specified toer mounting. then lower the C8I" to the grW1I1

,4 Rear auspenaion aueriIIy removal

and refittIng

ｾ＠ ｾ＠

Removal 1 Remove both filar bralw tile underlrame is usually cleaned of large accumulations automatically and \his Is

a I100d time lor Inspection. Per\odjcally. exCoctywOrk. repair II vary DImple. lightly rub lhe arll of the K'/lItch with a painl'NOll< renovalOf, 01 , vety line cutting paste. 10 rIITIO¥I 100M p.aIot from the acra\Ctl. and 10 cieer !he IUffOUnd"'ll bOCIywOJl< Of wu polish. Rinsa the a,ea with clean waler. Apply tOUM-up paim 10 the ICflIIteh UIlng • line pllm DrUsh: cominue 10 apply line Iay.a Of paint until the SI.lrfacl 01 the paint In the IICfDleh is I.vel wilh tM ......oundlng palnlworir.. Allow Itt. new paint at lenl two weeIeeI1 of IMIiDnale, ABS. poIypropylant). Damage 01 a lias IIfIot.- oat... (abrasions. minor mocks etc) can be "'fI"II1Id by the DIY owner using I two-part ｡ｰｯｾｹ＠ fill ... repeIr .... teril!L Once m,xedln aq ...... propor'lions . lhis is used In Iimbt fashion IQ the bodywork filler used on metal panaII.. The r...... Is I,I:IUIIIy cured in Iwenly 10 thirty minullS. ready for sanding and painting. II lhe owne. 1$ renewing a complele componell' twr.eI\, or H he I\u repaIr«I ｾ＠ with epoxy filler. he will be left wIItl IhI problem 01 finding • ｬｉｕｾ｡｢＠ paint for 1inIs.tq which III compatibIa willi the ｾ＠ 01 plastic used.. At on. lime !he usa of • universal paint was not possible DWW1!I to the complex ""'lI" 0/ plaabc& enoountered In body ..... ,IpDI ... ｾ＠

ｾ＠

.

S lsndaro paints. generally spealtirlg. will nol bond 10 pllStlC or rubber utlsfactorily . However. H ill now poaIiIM 10 Obtain a ptastic body partS fiflishing kit vmich corWsts 01 II IQprimer lreatment. a prima< and CDIOurad lOP COllt. FIA nstructIons ... normally supplied with a kit. but bB!IIIcaIy the methOd 01 use ;. 10 IllS! IIPJlIy the pre·primer IQ lhe cornponan\ concemad and _ It 10 dry lor up 10 30 minutes.. Then !he pTner Ie ｾ＠ and left 10 dry for IIIbcut ., hc:Io.r bekn 5n'*I applying the special coIoufed lop coat. The ,esult Is • correctly 0CII0ur.,;I 00fTIPC:W*" - . . 11>11 paint

will flex with the plastic or rubbe. necessary 10 a-k completely the alig"",,,,1 of the body &hell .truct.... Due to the principle 01 construction. the strength _ shape of the whole can be aIIIctad by....-.age 10. part . In such Instancea. the M"IiceI of a Volvo egan! wiIh sp I r 1 chIICIdng JIgI . . . ｾ Ｎ＠ " I body Is left mlllligned. It Is lirel 01 aI dengaroI.II AI the car will not handle proptrIy arid secondly ..........., s l , _ wtI be impoeed on Ihe s leering. engine and I.ansmluion. ca using .bnorm.1 wear or complete lallurl. Tyre _may also bee>«;OSSiva.

11

.

11- 4

Bodywork and fittings

2

=::;;;::\\ 6.88 Bonnet adjustment details 2

Hinge rIactor antI-elockwlse to disconnect

• Bonnet kM:tF; - removal and ref!ttir.g

Removal t ()pef1 the bonnet and mark the posWoo ot hborlnel bel< and lock mounIing bme lower fIOge 01 tM panel down to dNr the tailgate then push It lorwsrds by IIIikInIl it sharply on 8;ich side. Catch the ,.... as It>e UpPIIr retainers come free. I IIefTIapter (2). 7 Disconnect the link rods at the lock cylinder and lIXIee bacl\fesl1OWlr'd1M aide of tha Car arod at the &arne Un'll lilt ｾ＠ ,.a. illustration) . Remev8 CIIfIIldt of !lit bec kr1lst Ihan ramo"a the olher side.,1110 _ way.

""""".

IS Fold tha cushion forward and PIA !til ｾ＠ catches upward. S Fold tha cushion back almosl ｾ＠ !he.."., than 11ft up 10 ramo ..... 1 If lhe back'"t Is haaled . dlSOCllll'*l h wiIin9 at lhe conoectors. 8 Remova Iha slda padding and seat belt anchoraga ratainlng boilll In "" floor, Ramo\Ie lhe anchoragrIs. e Relea" tha catch and fold tha batk!tII forward very s'Oghtly. ' 10 ReI'llO\l& \he clip securing the bIckrtII mounting to the wheel arch D)' pressing IIr1 ｾ＠ the bottom with a !I(lI8Wdriver and _ . '41 with a sooond sorawdriver 1_ ｈｉｾ＠ 11 Pres. the backr8ll1 III \ItICI PIA ｾ＠ up Ina oullll' mounllng. Uf1 the backrest up II1Il DI,I of thecar.

,-3-, ,-3-, '-3-3

undo"

...

Refitting Ie,

All mode" 12 Relit by reversing the ,emovaI opIIfIIior&

Bodywork and fittings

c..."." - FItter to eaIIIer Secttom of this Chapter IIf Jf»Cmc prcx;ed/J,," covering door lind

lII9a/IIi'lkIrior ｴｲｩｭｾＮ＠

tIterlor trim panel. - general I IlIt Inlerior I rim panels are secured using Iilher $(lrews or , various Iypes of trim usually sluds or e Ironl edpe, th&n remove Ihe ｾｲ･ＦＱ＠

6 Remove the parcel shelf as described In S&cllon 27. then remove the side bac kresl padding by pulling" cut and lifImg up. 7 Remove the rear SlIal

padd ing by

as describe' In

SecIJon 26.

Headlining 17 The headlining II clipped to Ille roof and can be Ｂｾｨ､ｲ｡ｷｮ＠ only once all fmlngs such Ill! grab handles, sun visors. sunroof rof fitted), fuced window gleas , and reltUed trim panels have been removed and tile relevanl sealing alr!p:oJ have !!eM prir;ed clear. IS Nole that h&OOlfning removal and refitting requires considet-abIe skIfI and expee parcel !Ih8/f. 9 Undo the relainlng bolts securing the Inania (eel IlSsembliea and Ihe lowe, anchorages and buckles on eech side and In II>e Centf8. 10 Feed Ihe belts through tile apertures In the parcel shelf and remove them from the ｾＬ＠

Rear sear belts - Estate models 11 Access to the buckles and Hoor anchorages I. gained by tipping the seat CUShion foe!rlm.

!tie centre &eal ben

Removal , Di5cOl1nee covotr panel l\andbrake Jewr ｾｯ

ｷ＠

the

."

29.6 A aieaM tI>e !jIIIar lever gailer from II!o

..,...

ＬｾＢＧ＠

•• ".

30 Facia - removal and rafltting

'

ｉｾＮ＠

side

Mote! For access to ffIe IIlstnomelll ｾ＠ ft1 roIat(ld componer!lS II Is ｾ＠ kI _ the fad8 top oover. If fha comp.Iefe fldllllD be romoV9(1 !he top co_ ｾＮＢ＠ be left i1 pilot end romovad as ..., aSS8mbly wiltl rile fIIciL

w'"

--

"" "" ••• .,..

Fa cia top C411er 29.7 Undo the two ""' .. WI In the rear

storage compar1ment

out

the ashtray light bulbholde, and remove the comparlmeot. 4 Ur.Oo the two SConnec:t the I0I«l) from IhfI dfcuit ｾｳ＠ . . t ... componenls wnch dIft.N co.nerrt from a circuit. sudI as bulbs. motors. II8atlng ..........ts. fII(:)• Ie RfIrncMIthe r-..nt fUM from the and COOl!IfICI • dfcuit lesl ... 01' YDltmetef to the lute oonnecticns. 17 Switch on the ｾｵ ｩｴ Ｎ＠ bfIaMg in mind ttIIt some circuits ..eli .... only when the 9nltlon s witch Is moved 10 a particular posltlon. either by 18 II voltage II present ｾ ｮ､ ｬｃＸＱＦ､＠ I.... testef bulb light ing Of S ｶｯｾｭ･ ｬ･ｲ＠ reading, U applic,bls). this means Ihat thflfe Is ,

!he c;omponent n'IOUnIIng _

!he DOd\' _

p¥I o. Ｑｨｉｾ＠

clr"ult. ' - - or CCI'IOCIII! mounll. CIIn t..... efof. _ _ . . . . . ,. ｾ＠ ' - - . ranging ffom IOIaI ...... d. c l...u'l. to • puuUng ｾ＠ partk:uIar. Ｑｩｧｨ ｾ Ｑ＠ may ..... 1III'nI)' ｾ＠ when ...om. clrt;uh INring !he ...,... .... poin1la In opwation). motcn t-CI ｾ＠ IIII*n or 1"- radtotlOf "ooIlng '.n molor)!NY"" -'owly. and t"- oper.11on 01 001 h.". In .ppll"'IIy·......etal.-l IIIect GIl lnollllr. NOI. Ihl! on mal'\)' mit.... wtI slrapl ... lINd btoIwean c.tIIn c:0fIIPCII'III'II SlK:h as lhe ..,glneltt,,..,.mlssloft ...., !!'II body . utU,lly wh ... thef. I, no IIIItll-too metal c:onllCl bttw ..... compOtltOllS. dill ｾ＠ n,xIbII rubber rnourlUngs. etc. 2., To cl>tek wh.lher I c:ompootlll" property aal1hed. dlsc:onnacl !he betleryll'lCl conntc;t 01 lead ot an onnvn... 1(1 • kl'II:IOfI ｾ＠ aal1h point. CoMIcI the oltllr INldI\l the wire or earth comectlon t*ng test«!.The resl,lIn". ,•• dlng ShOUld be zwo: Knot. checI< the IJ diIgIoIIIe unit 0lIl of it11 ｾ＠ and p/IJca ilto ooe . .

7 Open thlt bonnet. Tum the approprlato plastk; OO'J"" on !he r..... of the ｾ＠ IftIlIIIfI. clockwise and 11ft off (SH ｾＱｕＡｬ ｴｲ｡ｉｯｮＩＮ＠ 6 Press the sprlng-I(lacled retaining cfjp fMI lhe bulb 10 "" rnmoved ar>d mo .. ｾ＠ asllk Withdraw the bulb from the light uM and unpJug the connector (Ifttt Miustmionl. 9 When fittlng the new bulb. do not toucI1 "" glass (paragraph 2). Maklt sure that the . . on the bulb flange engage with the sIm;, ""

"""". front

direction Indlcator/fronl side IIgIt

t o Open the bonnet and reIeaM the ｾ＠ spmg which sec:ures the Iloht I.fIIt ., poaiIi;n 000 withdraw the light unit (_ lIustratiosled to a VolYO dealer. In practice It will be very dlfficutt for lIlyona unsidlled In Ihls wonr.. Or without the necessary tools 10 carry OUI the Job without n.MWIg the upholstery.

Seat heater .wftcM. Reter 10 Sectlog ･ｾ｣ｰｴｬｯ｡ｭ＠ strength. In ｡､ｾｩｯｮ＠ 10 the body reiI ,fooc","",,1 o f the SIPS s)'!Ilem, certain models may be fitted wlth a SIPS bag for both fronl passengefS. The SIPS bag is an allbag localed In a cushion module In the side of \he Iroot seat. The unit Is trtgg.,..ed via liS own Ind ividual 9flnSOf In the event of a lIevere side Impact. The SIPS b ag Is Inflated by IWO gas generalo.... which cause the bag to break open tha mOdule cover. rtp open the seal upholstery seam. and inflate to its lull volume towanj \he door.

PrecauUons Warn/nil' Tha .. ra Irand/Ing oJ tha SRS componMt. ｾ＠ • tha usa 01 Volvo SpKII/ aqulpment. Any ｡ｴｾ＠ ID dlsmant/a th a alrtJsg module, SIPS ｾ＠ cr..h sensora, confact ,..aI, ..., bolt l ansloners or any _ _ "'tad 01

.&. 1

..,/IIn,

compOnent. whhovt this ｾｵＯｰｭ｡ｮ＠ tha spaclallsl *nWledQa ｾ＠

tnd 10 UN'

Corr.cfly, could ,...ull In - . - . p&nOfIrI Injury _ndror m"ffunctlon or tha 1)'11..... For I lIIs .....on tha only procacW'" ｣ｯｾ＠ In this manual relating 10 ilia SRS componants a... thosa which ... aOso/vtely eS/lflntJal to atI/IbJa _ /0.11 gained 10 01".,. components or Q'SIarM. /I Is /mperellva IMt any other WOtt ｾ＠ tha SRS componenlS Is entrusted 10 • VoM:> dealer.

Key to wiring diagrams

,

Wire c olours

'"G'

BOo'

Gm,

, ""., "" W

,'" '.Ow Ｌｾ＠

"G' "" G_ Ｎｾ＠

OR

-

'" """"

Fuse no

Circuits protected

Fuse no

Circuits protected

1 1/1

LH 3.2 ｍ ｵｾｬｰｯｲ｜＠ IueIlniection Ｈ ｍｆ ｾＮ＠ EZ 12"9 K Dlstnbutor ｉｧｮｾｩｯ＠ (DQ MoIronIc 4.3 SFI.

11/21

Low beam. lelt (Acr$ BacI. Remote-controled central iocklrxJlafaom Data ｬｩｮ ｾ＠ connector (DlC} A (17/7) + X..-ail (1518) Power seat, Beam width COll/ml, TaUgate wast\I'wiflI Windshield wiperlWasI1er, Hom, Headlighl wiperfwasher Ashtray lighting. InSlrumonI and controIllg1tIng, Rheostat, Cigar light... W.."inQtion, Power surro::of.

Automatic transmission

""

".

Fenix 5.2 fuel and ignition B)'\It\lm Maln relay, F...,ix 5.2 fuel system (MFQ F.... po;mP. Alarm E>fIW; IbiW) IQk>pMcaIt (kP1)

--

MiIibIr (rrQr) • 0,01 " 88.947 ,. ｍｩｉ｢ｴｾ＠

01 rna'tU'Y (mmHg) " 1.333

•

• 2.4\11 " 1.868 " 21.68

• •

" 0.868

• PoI.ncIt.!orce inchM

• 8.85

•

'"

•

• 0.401 ,. 1nf;:hM of water (InHzO) • 0.535 .. 10ches of _er (WiA . 0.0311 .. Pounds·force per sq.,arelnch (psi; 1bIf....: Ib{IfI'I

ｾ＠ oIlT'OIO'CUI)' ｾ＠ Inchw of WIlIer (lnH,O)

,• ,

•

Torque (moment of force) Pounds·too:. lner.e. ｾ｢ｉ＠

in: Ib r.) Pounds-/orce inf;hes Qb1 In: Ib r.) Poun 32

o.gr.. Celsius ｾ＠

Ceutigo ... ; 'C) .

iF · 32).0.5&

I

• Buying spare parts Spare parts are available from many sources, Including m8ke tile

ear

01'

oper.!lon eflk;lenUy and 10 a proIesslonal tlanderd 01 woOOnanahop.

JOint mating faces and gaskets When sepa.. tin9 component. II lhelr 0TIBting laces. _

"'-'-

01' ｾ＠

.mllar ｾＡｉ＠ lnIo !;he ro;nt beIweM the ｉｾ＠ '" order 10 prj.- them apar1. Tl'OI c.n CIIuse seven! damage whlch """,III 10 011 leaks. cooIanl leak •. etc upon 1'8QHmbIy. Separatior> Is ........-y ec:hlevOld by lapping eIoog the ro;nt with • soIt·13ced I'IImmW In order 10 brNk Ihe ...... ｾ Ｎ＠ note II\a1 Ihis method mly not be suitable wne... dowels HAl used for Wl OipOO .,.a location. When:> • gasket II used be'-l tn. mltll'lg I.e... 0I1wo compOI'I8nls. a ............ must be 1in0ld on rNSSembIy; til ｾ＠ dry unless otherwise staled in the repair ｾ･Ｎ＠ l.1aQ SI.Q thai tile mating laces ... clean a">d dry. willi II _ of ok! ｾＮｳ＠ When dNI'lInga jotnt lace. UN • toolllllhich IIlII'lIokeI\IlO _ and ...-.ova any w.. or 01' dIrnage II'Ie nicQ IO'ith atl Q/j'I.... or III'le fife. Make lu ... ttlat tapped holes are cle8nOld wlttl a pipe ct_. and keep them /fee 01 jOOliI'lg eompourld. If this Is being UNd. uriass speciI\ctIIIy 1nswct0ld o\heo .IM. Enawe that all orifices. ｾ＠ 01' pipee ... dear. _ blow through !hem, prelerlbly using comptMHd • .

1_.

011 seals Oil seal. can be ｾ＠ by out with a wide ftal ·bl8dOld ｾ＠ similar ｾｴ＠ "".UippIng _ . an:! _

ｾ＠

tnem

or

AIWmaIIYeIy. • .......to. of be acrewed Into Ihot

UMd".

x:nrwI .....,.

ｾ＠

for ..... or

tome ......... deIIIce In order to pUllhot _1raI. ｾ＠ an 01 1611 II; .......,.,..;I from its wDflotoogh underItanding 01 !lit proeldufM described, ....... .ttlmp! 10 bypna the ｾ＠ 01 any speciIII I0OI wt.en lilt pocedauI, and $pecJIII. Newcomefs to Pf&ctlcal mechanics s.hould Itar1 off w ith thfI M&lntllnand m/tIo(" rfIpIit lilt Included in ""'"' IItt • I comprllhensiYll HI 01 lOCketS. Although \tiMe are expensive, they wilt be found invaluabl. at they are to versalile • part icularly If various ､ ｲｬｾ＠ art Included In tile HI. We rllCOlllmend the haH· lneh squar..d ..... type, at this can b, used with most proprietary torque .....1tIChes. ThIIIDcIs in lhlllitt wII ｾ＠ need 10 be supplemenled by 100II fn:m \he Spec:ilillt

_.,

o

ro covet ｾ＠

Soc/uItJ (01" bo.r ｾ＠ prlWious Mat ｾ＠

TM! aockenJ raIchM tkWe (fat" use wiItI

o ｾ＠ a &l8nskln p;.c.. 250 mm (fo( uM with ｾＮＢＬ＠ o I.kJ/'.'ersa/ joint (fo( uae wlrfI soc/celS} o TDI"QIJfI wta'ICh ｾ＠ 11M with .1OCIl 'Y$t.m (Chapeers I, 4A and 58). Cl Tmino;J bell ir...... ,lICuy fin.d (QwIpter 2Aj. or associated ' o v-..... leak at the In6M ｾ＠ tc:/IaPIMIl. 4A and .t8). o EmIAIon eootroI syst.n raul! {CIIapler 48}. 011 pressure wamlng I/ght illuminated with e"glne runnIng

o o a

Low oil OWe! or

incor.-.ct ｯｩｉｾＮ＠

(Cheptflf 1).

Faulty 00 pressure sensor (C'-Pter 12). Worn ｾＮｯＯｏｉ＠ 011 po.mp (Chaplet 2A or 28). fCI\apI8r 31. HIgh.-.glnoo operating ｴｾ｟＠ D Oil pttISSUfI! rI!Iief...,... deI.cthIe (Chlopter 2A). Oil pick-up pipe strainer cIoQged (Chaplet 28),

a o

_nome

EngIne runs-on after swltchl"11 off

o o o

Engine management IY't ... lau11 (Chepters I, 4A end 56). E>cceulvfl carbon build-up In .ngIne (Chapter 2A or 28). 1II

Incorrect entllre&l. mixture. (Chapters 1 and 3).

t

I

I I

I

I ,

,I

Fuel and exhaust system E.II"cessl ve fuel consumptIon o

o o o

Unsympethetic driving .ty1I. Of acNerte COOI:Siticns.. Air dill ..... (oller ",,"*,1 dift,I or o;IcgglId (Chapter 1). engine management.ystem fl uh (Ch8pter 1. 4A and 58). lyres under·inflaIad rWeeidy checks,.

Fuel leakage and/or fuel odour

o

0amI0ged or corroded fuel \aniectionl fChapIer t).

1

E.II"ceuive no/•• or fumes from .maust system o D

o

l.&aldng • • h8U11t system or manlloid joint. (Chapt... 1, ard 48). l.e;ildng. eon-od..:I or dgblalla

o o

•

or Ｎｳｴｾ＠

o o

Wtlfflng ligM b\Jlb blOwn (Chaplilf 12). Broken. discoMect\ld, or loose wiring In warning I9'lI elrcuil !Cha¢_I2). "",""",tor h1t.11tV (ChIop1_ ｾ Ｎ＠

Ught. Inoperative

o o o o

o o

Bulb blown (Chapt .... 12). Corro.Ion of bulb or bulbholder contacts (Chapter 12). Blown " - (Chaptotr 12). FMMyrelay{Chaplotrl2}. Bn;okan. loose. or diIc:onnec1ed wiring (ChapIer 12). {Cl\aI:lIotr 12}. F....1tV ｾ＠

REF" ,

1i

Fault finding

Electrical system (continued) InstlUmant readings inaccurate or 8"atlc

f

InstnJmenl readings Increase with engine speed

Wlndureenlteilgate weshers Inoperative, or unsatisfBChNy In operation

o

One or more washer jets Inoperative

Faulty inslnlm",,' panel control components or circuitry Ｈｃ ｾ｡ｰｉ＠ ... 12).

Fuel or temptll'slute gauges give no reading

o

Faulty InstrlJlTl9f1! panel control compooenls or ｣ｩｲｵｾＱＧＩｉ＠

(Cha pter 12).

Faulty gauge sender unit (Chapten 3, 4/\ or 56). D Wiring opeo-drruil (Chapter 12).

D

o

Faulty 9!'(IQe (Chaptllr 12).

Fuel or lempenll:ure gauges glye continuous mulmum

reading o

o D o

Faulty ,nslnlment panel control comp0nent3 or circuitry (Chapter 12). Fautty gauge sender unit (Chapters 3, 4/\ or SB). Wiling shorI·clrcuit (Chapter 12), Faulty gauga (Chapter 12).

Hom Inoperative, or unsatisfactory In operation Hom falls to operate o

(Chapt .... 10). Faulty horn (Chapter 12).

Hom emits Intennittent or unsatisfac tory sound o Steering wheel cable connections loose, btoken or disconnected (Chapter 10).

D Hom

o

ｭｯｵｮｾｲＮｧｳ＠

loose (Chapter 12).

Faulty hom (Chapter 12).

Hom operates all the lime

o

a

w_

jet (Chapter 12). Disconnected, kinked or restricted ftuid I>OIW! (Chapter 121. Jnwtflcient nuld In wa.a- reservolr r weIIkIy checks,.

Blocked

Washer pump fails to operate

a a o a

Broken or disconnected wiring or COOIl&Cti0n3 (Chapter 12). Blown fuse (Chapter 12). F....1ty washer ｓ ｷ ｾ｣ｨ＠ (Chapter 12). Faulty washM pump (Chajlter 12).

Washer pump runs for some time before fluid Is emitted from Jets

o

Faulty on&-way valve In ftuid soppIy hose (Chapter 12).

Electrfc windows Inoperative, or unSBtI.racfory In operation Window glass will only move in one direction

Blown fuse (Chapter 12).

D St-mg """"' cable connections loose, brok&fl or disconn9cted D

a

a

a

Faulty swile.t0ll A nal....... 1IbrcuI minerai wtth gt-' heal ..... commonly uHd In ,he

BraIe area In tl>e system ｾ＠ a malfunction may b6located. Oisc brake A brake desjgn ｩｮ｣ｯｦｰｉｾｧ＠ a rotstirl{l disc onto which brake pads Ilf1I squeezed. The resumng lriction conVIll1S tl>e er\8IlIY 01 a moving vehicle into heal. Double-overhead cam (OOHCI An enoine lt1at uses two overhead cams.hafts. usually one lor tho tntake valves and one for the

exhausl valves. The belt(s) used to dnye accessories such as the ahemator, water pump. pow« steering pumP. air conc!itionIng compressor. etc , of! the e< ligtll - 12' 8 l>eadllght - 1206 heater control paneI- 12' 8 indicator - 12' 6, 12' 7 Inttrumem panIIIl!ght - 12'9 Interior IigIrt - 12' 8 ,,-,",be< plate light - 12' 8 ,••," light cluster - 12' 1 reversing 'ohl - 12·7 sidelight - 1206 stop-light- 12· 7, 12· a switch iRuminatlon - 12' 9 Bump ... - I l " l Buying apare pam and veNcia iderrtilicatlon numbers· AE!"3

cCables accelefator - 4A'3 bon"'" release - 11 ' 4 climate control aystem - 3' S Mndbrake - 9' 9 ealector aulomatic transmission - 7B' 3 Caliper (broka) - 906, 9'7 C,mshafta and tIIppel. - 2A' 8 drivebelt - 2A'4 oil seals - :lA' 6, :lA· a posiijon sensor - SB' 6 Capacities - 1' 1 Carbon c anlstar· 48' 6 C,.,.." .· 11 · 2,11 ' 15 Cetll lylic conv."er - 48' 3, 48'6 Cantre conaola - I "15 ｳｷｾ｣ｨ･＠ - 12' 4 Charging system - 5A' 3 Cigar UghlarHtumlnaUon bul b - 12' 9 Climate control s yatem - 3' 4 et seq CMch · 6" Of seq ch6ci'tI sensor (luellysltIfTI) 4A' 5,4A' 10

Cooling Ian (radiator) - 3' 2 Cooling, I>..,i"9 1",gl ... ttrenlmleslon)- 2A' 12

.,...saur.

,.".1

N Number plate RgM - 12· 10 Nu"-, ptate HgM bulb - 12. 8

, I

I

o011 -0' 18 chang. - 1' 5 ｦｩｾ

･ｲＭｉ

Ｇ ｓ＠

leaks· Oog, 106 level IeIlsor - 12. 5 PfHsura ..... sor - 12' 5 pump - 2A" l 0 11 ...Is - REF ' 4 lUIomatic transmission - 78' 5 camshaft - M06, M ' B crankshaft - M ' 10 manual tn",,,,,,ission· 7A·3 011 temperature sensor , (automallc t. ans miuJon) - 78'4 ' OPlln-clrcult {findinll) - 12' 2 Outsldcl t. mperstura ...... or - 12' 5 O...maul (engl..." - 28 ' 1 or seq Oxygan ... nso. · 48 . S

P Pad. (brake) - 9' 4, 9' 5 Palntwork damage · 11 ' 2 P.rcal shell (Saloon) - 1"'5 Pa rts - REF ' 3 Peda ls btak. - 9 ' 8 clutch · 6· '

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Index Plrton ring8 • 28 ' 13, 2B " 4 Plrtonlconnecllng rod assemblles 28' 9,28 '13,28 '1 4 Pintle eomp_nl$- 11 ' 3 Plug.-wal - \'1 .1 '1 2 Po_steering drivebelt - "1 0 NukI- 0' 12. 0' 16 pump-l0 '14 s)'Slem bleeding - 10' 14 Pnouure reduci"1l vatve(braking system!-

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Pt/netu...,. - 0' 9

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cooling Ian - 3' 2 grille paoel - 11"2 Radio aerial - 12' 13

R.dloI".....tt. pJooye. - 12" 2 Redlolcasselte unit _",I-theft lyetem -

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Rear hub ...emblylbearlngs - 10' 9 Rear light cluster - 12'9 b\II)5 - 12.7 Rear parcel ahel1 (Saloon) - 11.15

ReerMrt -11 ' 14 Rear.t>ock abaorbel - 10·9 RNor stub ..1to - 10'9 fleer ｾｮＧｬｯ＠ ....mbly - 10' 10 Rear window gl ••• - 11 ' \0 RecI' c ....tlon damper molar - 3'6 11818,. -12 ' 2.12 ' 3 •• conditioning system - 3' 9 IueIs)'$Iem - 4A·ij

Relea .. beari"1l (clutch)· 6' 4 Repair procedures - REF ' 4 RHI>I1Ir!n9 -11 ' 3 R....rslng Mght

bulb - 1207 swltch · 7A· 4 RoU bani - 10. 8. 10. \0 Rolor ann - 58 ' 5 ROI#Io.

m.lnt.,,,,,,,,. nd

procedures -

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9Chedulo · \ ' 2 RPM ...nsor - 58' 6 RPM sensor (au1omatlc transmission) • Ｌｾ＠

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Sender unlta coolant lemperature- 3. 3 fuel gaUQe - 4A'4 Service ... mlnder light (....ItIng) - 12' 4 SeI'VIcill1jl - see Routine maiII!&181lCe SeIvo unit (bnIklng system) - 9' B Shock ｡｢ＮｾＬ＠ (.... r! - 10' 9 Short-cIrcuit !finding) - 12'2 S1del1ght- 12' 9 SIdII "peatar Ught - 12' 7. 12' 9 SIdelight bulb - 12' 6 SIPS/alrbllillystem -12 ' 13 Slave cylinder (clutch) - 6' 3 Solar Ie&,.. - REF. 3 Vehlcl. $peIt(I senlot - 12' 5 V. ntil.9tion syst.m - 3· 1 II seq, 3'4 Venta - 3' 7

W Was he,, - 12· 10 fluid 1_1·0' 13 senSOl" 12. 6 WMer (coQ lant) pump - 3' 4 W.ekly cMlck. - 0' 10 Whealal1gnment -l0 · 1. 10· 16 W .... I clulnglng - 0' 6 Wheal sensorl (ABS) - 9'11 Window ",a.. - 11 ' B, 11 ' 10 Window mato"reg ...... to. - 11 ' 7 Wln