Haynes Volvo 240 Series 1976 thru 1993 Automotive Repair Manual [8 ed.] 1563921367, 9781563921360

Citation preview

T

97020

(270)

240 Series 1976 thru 1993 All

gasoline engine models

Automotive Repair Manual

Digitized by the Internet Archive in

2011

http://www.archive.org/details/volvo240seriesau00madd

%

Volvo 240 Series Automotive

A B

Repair

Manual

A B

by Rob Maddox

and John H Haynes Member

of the Guild of Motoring Writers

Models covered: All

gasoline engine models

1976 through 1993 (3B3

-

97020) (270)

/urrCMCnvi?

ACCeSSOHI-L ASSOCIATION

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, 861 Lawrence Drive

Newbury Park 91320 USA

California

Inc

^—

About Its

this

manual

purpose The purpose

of this

manual

is

to help

you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine mainteoffers diagnostic nance and servicing; and and repair procedures to follow when trouble it

occurs.

We

hope you use the manual

the work yourself. For

to tackle

many simpler

jobs,

doing it yourself may be quicker than arranging an appointment to get the vehicle into a

shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop

must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Section 3 and Step

(or

paragraph) 2 within

that Section.

Procedures, once described are not normally repeated.

When

make

Using the manual The manual

is

Each Chapter is divided into numbered Secwhich are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustrations,

tion captions pinpoint the pertinent Section

and the Step within that Section. That illustration 3.2

means

be given as Chapter and Section number. Cross references given without use of the word ''Chapter" apply to Sections and/or paragraphs in the same Chapter. For example,

is,

the illustration refers to

"see Section 8"

means

in

the

same

seat, facing forward.

Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

will

CAUTION provides a special procedure or special steps which must be taken while completing the is found. Not heeding a Caution can result in damage to the assembly

procedure where the Caution being worked on.

WARNING provides a special procedure or special steps which must be taken while completing the is found. Not heeding a Warning can result in personal injury.

procedure where the Warning

Acknowledgements We are grateful to Volvo North America Corporation tions. Technical writers

©

who

for assistance with technical information

and

certain illustra-

contributed to this project include Larry Warren and Mike Stubblefield.

Haynes North America,

Inc.

1977, 1978, 1981, 1984, 1986, 1988, 1990, 1994, 1998

With permission from J.H. Haynes & Co. Ltd.

A book

in

the Haynes Automotive Repair Manual Series

Printed

in

the U.S.A.

reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

All rights

ISBN

1

56392 136 7

Library of

Congress Catalog Card Number 94-73496

While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

99-320

Chapter.

References to the left or right side of the vehicle assume you are sitting in the driver's

provides information necessary to properly complete a procedure or information which

A Warning

neces-

will

divided into Chapters.

the procedure easier to understand.

A Caution

the text,

it's

sary to refer to another Chapter, the reference

NOTE A Note

in

0-3

Contents Introductory pages About this manual 240 Series numbers

Introduction to the Volvo

Vehicle identification Buying parts Maintenance techniques, tools and working

facilities

Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Safety

first

Troubleshooting

Chapter

0-2 0-4 0-5 0-6 0-6 0-12 0-12 0-13 0-14 0-15 0-16

1

Tune-up and routine maintenance

Chapter 2

Part

1-1

A

Engines

Chapter 2

2A-1

2A

2B-1

2B

B

Part

General engine overhaul procedures

Chapter 3 Cooling, heating and

Chapter 4

Part

air

conditioning systems

Chapter 4

3-1

A

Fuel and exhaust systems

engines

-

fuel injected

-

carbureted engines

4A

4B-1

4B

Chapter 5 Engine

electrical

systems

5-1

5

6-1

6

Chapter 6 Emissions and engine control systems

Part A Manual transmission

Chapter 7

Chapter 7

Part

7A-1

7A

7B-1

7B

B

Automatic transmission

Chapter 8 Clutch and driveline

8-1

8

9-1

9

Chapter 9 Brakes

Chapter 10 Suspension and steering systems

3

4A-1

B

Part

Fuel and exhaust systems

1

10-1

10

11-1

11

12-1

12

Chapter 11 Body

Chapter 12 Chassis

electrical

system

Wiring diagrams

12-19

Index

IND-1

IND

0-4

1981 model Volvo 245GL

Wagon

1988 model Volvo 240GL Sedan

Introduction to the Volvo 240 Series These models are available in 2- and 4door sedan and station wagon body styles. They are powered by single overhead cam inline four-cylinder engines. These engines feature carburetors on certain models and

tination.

mechanical or electronic fuel injection systems on others, depending on year and des-

solid rear axle

Transmissions are a five-speed

manual and three-speed automatic and some models are equipped with overdrive. The transmission is mounted to the back of the engine, and power is transmitted to the by a two-piece driveshaft. Power-assisted front and rear disc

brakes are standard equipment. The front suspension is MacPherson strut design, with the coil spring/shock absorber unit making up the upper suspension link. The rear suspension is made up of coil springs and conventional design shock absorbers with trailing

arms and a track bar

locating the axle.

0-5

Vehicle identification Vehicle Identification

Number

The Vehicle Identification Number (VIN) is located on the cowl in the engine compartment, on the passenger's side door pillar, and. on US and Canadian models, on a plate on top of the dash, just inside the windshield (see illustrations).

contains valuable infor-

It

numbers

mation such as where and when the vehicle was manufactured, the model year and the body style. This number can be used to cross-check the registration and license. On later models the number is etched on the glass and affixed to most body parts in

Engine

serial

The engine the

left

Vehicle identification plates (early models)

and model year designation

Type designation, serial number and part number of engine Type designation, sehal number and part number of

Final drive reduction ratio, part

transmission

of rear axle

in

Final drive reduction ratio, part

located on

Vehicle identification plates (later models)

front fender

code number for color and engine compartment inside right

Vehicle type designations, plate

is

(see illustration).

Type Type Type Type

-

number

side of the block, toward the front

accordance with federal law.

Type and model year designation and chassis number upholstery

number

serial

number and serial number of

designation,

designation, serial

number of engine number and part number of

transmission

Service plate (sedan) or

rear axle

maximum permitted load and color code

designation and part

in

-

number and serial number

below the rear window on the right side compartment (wagon)

the large storage

VOLVO

i

In

_l

* H'M 'i'i'i

'

"

addition to vehicle type designation plate, on US and Canadian Identification Number is located on the left

models the Vehicle

side of the dash, at the base of the windshield (later models) or

along the windshield

pillar (early

models)

The engine serial number is stamped on the left side of the cylinder block. The last three digits of the engine part number are displayed on a decal on the timing belt cover

0-6

Buying parts Replacement parts are available from sources, which generally fall into one of

many

two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast,

parts

such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply

new

or reconditioned

parts on an

exchange

basis,

amount

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: If the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

which can save

money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and a considerable

of

general accessories, have convenient hours,

charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are

Maintenance techniques, tools and working facilities Maintenance techniques

Most automotive machine shops can perform

removed from an assembly, should always

There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

this task,

as well as other repair procedures, such as the repair of threaded holes that

damaged washers

have been stripped Flat

be replaced exactly as removed. Replace any with new ones. Never use a lockwasher on any soft metal surface (such

out.

washers and lockwashers, when

'*%

^r%

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type,

Grade

1

as aluminum), thin sheet metal or

Grade 5

or 2

plastic.