Haynes Volvo 740 & 760 Owners Workshop Manual 1850105405, 9781850105404

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1982 to 1989 1986 cc. N )

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SUT - waythdrawe EDINBURGH CITY LIBRARIES Reference Department UNDER q THis Book MUST NOT BE REMOVED RTDEPA E RENC REFE ANY PRETEXT FROM THE ERS REND RULE THIS OF MENT. INFRINGEMENT ION. THE OFFENDER LIABLE TO PROSECUT

Before leaving the Library readers must return the books to one of the attendants at the issue desk, or they will be held responsible for them. Readers are required to take care of the or books. Writing or drawing with pen ng turni or book, a of part any on pencil down the leaves, or cutting or mutilating them, will be treated as serious damage. q CoNnvVERSATION IN THE REFERENCE DEPARTMENT IS ANNOYING TO STUDENTS, AND IS NOT PERMITTED

i

/

Accession.

Location.

Class.

:t

:

: CRICK

:

Volvo 740 & /60 Owners Workshop Manual Matthew

Minter

Models covered Volvo 740 GL and SE; 1986 cc Volvo 740 Base, GL, GLE, GLT, SE and Special; 2316 cc Volvo 740 Turbo and 760 Turbo; 2316 cc Volvo 760 GLE; 2849 cc Does not cover changes introduced for 1990 model year, or Diesel engine models

(1258-181)

pace KLMNO

DE Se

Ay

GE 5 — TS

Haynes ST IES THE BOOK

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ

Group England

Haynes Publications, 861 Lawrence Drive Newbury Park

California 91320

USA

Inc

EDINBURGH CITY LIBRARIES

Acknowledgements Thanks are due to the Champion Sparking Plug Company who supplied the illustrations showing the spark plug conditions and to Duckhams Oils who supplied lubrication data. Certain other illustrations are the copyright of AB Volvo, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and all those Sparkford who helped in the production of this manual.

people

at

© Haynes Publishing Group 1990 A book in the Haynes Owners Workshop

Manual

Series

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

All rights 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.

ISBN 1 85010 540 5 British Library Cataloguing in Publication Data Minter, Matthew, 7952Volvo 740 & 760 owners workshop manual.—2nd ed. 1. Cars. Maintenance & repair |. Title Il. Series

629.28722 ISBN 1-85010-540-5 —— eee Whilst every care is taken 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.

Contents

~ Page

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oa

Introduction to the Volvo 740 and. 760

5

General dimensions,

6

Jacking,

weights and capacities (a/so see Chapter 13, page 329)

towing and wheel changing

7

Buying spare parts and vehicle identification numbers

9

General repair procedures

11

Tools and working facilities

12

Safety first!

14

Routine maintenance (see a/so Chapter 13, page 329)

15

Recommended

21

lubricants and fluids

Conversion factors

22

Fault diagnosis

23

Chapter 1 Engine (a/so see Chapter 13, page 329)

27

Chapter 2 Cooling, heating and air conditioning systems (a/so see Chapter 13, page 329)

78

Chapter 3 Fuel and exhaust systems (a/so see Chapter 13, page 329)

96 142

Chapter 4 Ignition system (a/so see Chapter 13, page 329)

Si

ee

a

a

ee

eee

eee

ee

eee

Ee

eee

Chapter 5 Clutch

159

Chapter 6 Manual gearbox, overdrive and automatic transmission (a/so see Chapter

i a Chapter 7 Propeller shaft (a/so see Chapter

pis Ne

ie

a

eS

ee

165

13, page 329)

ee

ee 201

13, page 329)

ee

ee

ee

ee

ee

Chapter 8 Rear axle (a/so see Chapter 13, page 329)

206

Chapter 9 Braking system (also see Chapter 13, page 329)

210

Chapter 10 Steering and suspension (a/so see Chapter 13, page 329)

230

Chapter 11

Bodywork and fittings (also see Chapter 13, page 329)

Chapter 12 Electrical system (also see Chapter 13, page 329) Chapter 13 Supplement:

Revisions and information on later models

248 279 329

Cee Index

394

Voivo 760 Turbo

Volvo 740 Turbo

Saloon

Estate

About this manual [ts aim The aim 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 should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

[ts arrangement The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms

Introduction

top of the Volvo range; besides the solidity and attention to safety characteristic of the marque, they are luxuriously equipped. Engines available in the 760 range are a 2.8 litre V6

2.3 litre four-cylinder,

Whilst every care is taken 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.

Project vehicles The vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

to the Volvo 740 and 760

The Volvo 760 Saloon was introduced to the UK market in July 1982, followed by the 740 Saloon in October 1984. Estate versions became available for the 1986 model year. The models represent the

turbocharged

of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity.

both

with

and a fuel injection. The

turbocharged engine is also available in the 740 range, other options being the same engine without the turbo, with either fuel injection or a carburettor. Both manual and automatic transmissions are available throughout the range. The manual gearbox may be 5-speed, or 4-speed plus

overdrive. The automatic transmission fitted to UK models may be 4-speed, or 3-speed plus overdrive. Drive is taken to the rear wheels via a traditional live rear axle. A limited slip differential is available as an

optional extra. Braking is by discs all round, the handbrake acting on separate drums on the rear wheels. Anti-lock braking (ABS) is available on later models, sometimes in conjunction with electronic traction control (ETC). Together these two systems offer the best possible handling and safety characteristics on loose or slippery surfaces. Steering is power-assisted on all models.

Changes to the range in later model years include the introduction of a 2-litre fuel injected engine to the 740 range, and provision of independent rear suspension on later 760 Saloons. These and other changes are covered in Chapter 13 of the manual. The home mechanic will find the vehicles well-constructed and pleasant to work on, provided that tools and facilities appropriate to the vehicle are available.

General dimensions, weights and capacities For modifications, and information applicable to later models, see Supplement at end of manual Dimensions MuineelbaSe messi

Overallengtites Overatlawicdtiimenect. tacksenemeters

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2.770 4.785 1.760 1.460 1.430

m m m m m

(9ft 1.1 in) (15 ft 8.4 in) (5 ft 9.3 in) (4 ft 9.5 in) (4 ft 8.3 in)

Weights Kerb weight (depending on equipment):

TAO rd epee est SC TAOG) ic c8h oretae takBO ee RTE

ak Bo ov cL ae ase oak ees oo vtac ea nchandhcess ated, Oy eee ee REE ea EE DE

1270 to 1460 kg (2800 to 3219 Ib) 1330 to 1500 kg (2932 to 3307 Ib) See type designation plate (under bonnet)

Capacities (approx) Engine oil (drain and refill, including filter change):

B23 (B23 Oise

eee

dir ccaiathoncousthvas ten Meee

Rares Oe,

BQ SMEs sre neet ee neee nant Sratclt. Sant ahe rien

ieee

Cooling system:

B28 2S Opener Merce ais cer essa DAS) Gk « Sencar CBEcy Ee ERIE eed EEE

SR OR

aL

ss eee

Re AS aa LO

Manual gearbox: M4G6x(42speediplus: overdrive), :.ccevcctectsaceusveenesetiesvssececasnvcletasinececs. W472 =S Peed) tees ciate ey: a:snssvccae eed eerie be a ate eee Automatic transmission (drain and refill): Pade chose se eae otc Gates SAE yer My eo Rg Sot plete ie AR

3.85 litres (6.8 pints) — plus 0.6 litre (1 pint) for Turbo oil cooler if drained 6.5 litres (11.4 pints) 9.5 litres (16.7 pints) 10.0 litres (17.6 pints) 60 or 82 litres (13.2 or 18.0 gallons) depending on model and year 2.3 litres (4.0 pints) 1.3 litres (2.3 pints)

3.9 litres (6.9 pints) 2.0 litres (3.5 pints) 1.3 litres (2.3 pints) 1.6 litres (2.8 pints)

Jacking, towing and wheel changing Jacking Use the jack supplied with the vehicle only for wheel changing during roadside emergencies. For repair or maintenance, use a pillar jack or trolley jack under one of the jacking points. To raise both rear wheels it is permissible to jack up under the final drive casing, but use a block of wood as an insulator. To raise both front wheels, remove the engine undertray and place the jack below the centre of the front axle crossmember. , If the whole vehicle is being raised on a four-point workshop lift, place the lifting arms as shown in the illustration. If the front lifting arms are placed below the jacking points, the vehicle may become nose heavy. Never venture under a vehicle supported solely by a jack — always supplement the jack with axle stands. These may be placed under the jacking points, the rear axle tube or the front crossmember. Do not use four axle stands under the jacking points, however — as with the four-point light, the vehicle could become nose heavy. For many procedures, an alternative to jacking is to use ramps or to place the vehicle over a pit. Make sure that ramps and axle stands are adequately rated for the weight of the vehicle and in good condition.

occurred, the propeller shaft must be removed or the vehicle towed with its rear wheels off the ground. When being towed, insert the ignition key and turn it to position II. This will unlock the steering and allow lights and direction indicators to be used. If the engine is not running, greater effort will be required to operate steering and brakes.

Towing Towing eyes are provided at both front and rear of the vehicle (photos). The rear towing eye should be used only for emergency towing of another vehicle: for trailer towing a properly fitted towing bracket is required. Vehicles with automatic transmission must not be towed further than 20 miles (30 km) or faster than 12 mph (20 km/h). If these conditions cannot be met, or if transmission damage has already

Support points (arrowed) for a four-point lift, or when using four axle stands

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Fig 12.26 (cont'd) Supplementary wiring diagram for 1982 models.

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Fig. 13.43 Main wiring diagram for 1989 760 models (continued)

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Fig. 13.44 Supplementary wiring diagram for 1989 760 models

390

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391

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3515655

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Fig. 13.44 Supplementary wiring diagram for 1989 760 models (continued)

2:2

392 Key to Figs. 13.43 and 13.44. Not all items are fitted to all models; some-systems do not apply to UK Description

Coordinate

No

Battery 12V Ignition switch

D3 E3

Instrument connection (4-pole)

T5

84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 112 113 114 115 116 117 118 120 121 122 123 124 125 127 130 131 135 136 137 138

Ignition coil 12V Distributor Spark plug

D6, N5, P5 D5, R5 E5

Instrument connection (8-pole)

T5

Starter motor 800W

Q3

Alternator (incl. regulator)

04

Fusebox

B-K1

Instrument connection (12-pole)

“T5

High beam 60W Low beam 55W max Relay unit, 15 circuit Parking light 4CP/5W (USA: rear also) Hazard light 32CP/21W

A1, A6 Ai, A6 A1, A6, Li, L6 A1, A6

Instrument connection (18-pole)

T6

Tail light 4CP/5W. Brake light 32CP/21W Fog light 55W Numberplate lighting 4CP/5W Courtesy light Reading light, front 5W Reading light, front 5W Courtesy light 10W Reading light, rear 5W. Turn signal bulb 32 CP/21W

:

L2,L6 L1,L5,L6 Ai, A6,L1, L6 L4 W5 W5 W5 W5

V5, W5 A1, A6, B1, B6, L2, L6

Relay unit (30 circuit) Relay unit (21 circuit) Glove compartment light 2W

T4 T4 W4

Ashtray light, front 1.2W

13

Ashtray light, rear 1.2W

13

Sunroof switchlight 1.2W

13

Seat heater switch light, passenger 1.2W Gear selector light, auto. trans. 1.2W Instrument and panel lighting 1.2W Engine compartment light 15W Trunk light Door-open warning light Heater controls light Sun visor light

13 H3 W3 V5 V4, V5,W4, W5 H3 W4

Glove compartment light switch Seat belt lock light, driver 1.2W Seat belt lock light, passenger 1.2W Windscreen wiper switch

W4 J4 J3 B4

Headlight switch Turn signal/hazard lights/headlight switch Horn switch Heated rear window switch Seat heater switch, driver

B2 C4 A4 K2 J4

Seat heater switch, passenger Overdrive switch M46 Power window switch, driver, front Power window switch, passenger front Power window switch, driver, rear Power window switch, passenger, rear Power door mirror switch, driver Power door mirror switch, passenger Central lock linkage switch Sunroof switch Fog light switch, front/rear Brake light contact Parking brake switch Back-up light contact Start inhibitor switch, auto.trans Driver door switch Passenger door switch Door contact, rear Passenger seat contact Pressure sensor, turbocharger Overdrive contact (M46)

Positive terminal Fuse box light Thermal time-switch AC pressure sensor

J3 P6 X3 VS YS X5 X5 x5 W6 T6 B3 J5, R6, S5 G5 J6 E3 V3 X3 V4, X4 14 N3 P6, R6

E2 W4 04

U3

Description Coolant temperature sensor

Speedometer Tachometer Clock Engine temperature gauge

H4

F4

Indicator light, reat foglight

F5

Indicator lamp, service

F5 G4 H4 G4 H5 G5 H5 G5

Indicator lamp, brake failure Indicator lamp, washer level Indicator lamp, W/70/71 auto.trans. overdrive Indicator lamp, bulb failure Indicator lamp, glow plugs (diesel) Indicator lamp, battery charge Indicator lamp, trailer Indicator lamp, ABS Indicator lamp, left turn signal Indicator lamp, high beam Indicator lamp, right turn signal Indicator lamp, M46 overdrive Indicator lamp, front seat belts Indicator lamp, rear seat belts Bulb failure warning sensor (14-pole) Fasten seat belt light (USA) Windscreen wipers, intermittent relay Rear windscreen wiper, intermittent relay

G5 F5 H5 F5 H5 F5 F5 G5 G4 G5 G4 G5 H5 14 K5 14 B5 U6

Bulb failure warning sensor (9-pole)

C2

Flasher unit and switch, hazard lights Relay, temperature warning (Japan) Relay, M46 overdrive Relay, power windows and electric cooling fan

C4 R5 N6 ¥5

Relay, central lock

X6

Loudspeaker (4 ), driver door Loudspeaker (4 (), rear left Loudspeaker (4 ), right rear

Aerial Power aerial 3A Radio Motor Motor Motor Motor

(5A), (5A), (5A), (5A),

driver power window passenger power window driver power window, rear passenger power window, rear

Power mirror, driver side Power mirror, passenger side

Motor (13A), electric cooling fan

.

F5

Speed warning chime Panel lighting intensity (rheostat) Instrument lighting Indicator lamp, temperature warning Indicator lamp, oil pressure Indicator lamp, boost pressure (turbocharger) Indicator lamp, parking brake

Relay, auxiliary lights Relay, glow plugs (diesel) Relay, fan Relay, Motronic, LH-2.2 Relay, overdrive AW70/71 Relay, headlights Seat heater pad, driver 30/130W Seat heater pad, passenger 30/130W Seat heater backrest, driver Seat heater backrest, passenger Loudspeaker, instrument panel, left Loudspeaker, instrument panel, right Thermostat, driver seat Thermostat, passenger seat Loudspeaker (4 (), passenger door

140 141 142

G4, 24 H4 F4

Fuel gauge Indicator lamp, diagnosis

139

143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163

Coordinate Q2,P3;,P5, R3/S3;7V1

Motor Motor, Motor, Motor, Motor, Motor,

(1A), headlight wiper sunroof opening central lock, passenger door central lock, rear door, driver side central lock, rear door, passenger side central lock, trunk

Motor (3.5A), windscreen wiper

C3 $5 v2 N3, Q2, 3 Q6

C3 K4 K3 K4 K3 U2 U2 J4 J3 U1 U2 U2 U1

T2 U3 2

Y4 Y5 X5 X5

W5 Y5 W2

A2, A5 T6 Y6 W6 Y6 Y6 B4

393

Key to Figs. 13.43 to 13.44. Not all items are fitted to all models; some systems do not apply to the UK (continued) No

Description

164 166 167 170 176 178 182 185 186 187 188 195 195 196 197 198 199 200 201 207 208 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 231 233 238 240 241 242 243 244 245 246 247 248 251 252

Motor (2.6A), windscreen washer

Capacitor Suppressor resistor Thermo-element, catalytic converter Control unit, CIS Washer level sensor Fuel level sensor Charge air temperature sensor Air flow meter Lambdasond Cold start injector Solenoid valve, carburettor (alt) fuel valve (diesel) Idle valve Oil pressure sensor

Throttle switch Temperature sensor (diesel) AC compressor (3.9A)

Actuator solenoid, overdrive Horn (5A + 5A)

Glow plug (diesel) Tank pump Fuel pump (6.5A) Service socket Throttle switch, Motronic Crankshaft position sensor Engine RPM sensor Control unit, Motronic Control unit, LH-2.2 Knock sensor Test point, Lambdasond Test point, idle system Heated rear window 150W Cigarette lighter (7A)

Cigarette lighter light Thermostat, electric cooling fan Cruise control switch Control unit, cruise control Vacuum pump, cruise control Bridge connector, clutch pedal

Bridge connector, brake pedal

Relay, rear fog lights Turbocharger pressure sensor (turbo diesel) Motor, window washer, rear (2.6A) Switch, wiper/washer, rear Motor, wiper, rear

Power seat emergency stop Relay, power seat Control unit, adjustable power seat Power seat motor, fore-aft Power seat motor, up-down, front Power seat motor, up-down, rear Power seat motor, backrest tilt Kickdown inhibitor Control unit, ABS

Coordinate

No

Description

A2 D4 E4 R5 $3 FS R3 Q2 R1 N3, 04 E4 $5 $5 N4, 04, $3 G6 P3, P5, R3, R5 S5 U3 P6, R6 A3 $5 F3 N4, Q2, 04 E4 R1 Q1 Q1 Q1 N3, R3 N4, 04 N4, 04 P4, R4,S3 L2 13 12 W3 S4 T4 $5 R6, S5 $5 C3 S6 U6 U5 U5 V6 V6 V5 W6 W5 W5 W6 R6 T1

253 254 256 257 260 265 266 267 270 284 289 295 296 346 347 361 362 363 364 365 366 376 378 384 413 416 417 419 424 425 438 456 457 458 464 490 491 495 496 497 498 499 501 502 503 504 870 886 900 901 928 929 930 931

Hydraulic unit, ABS

Coordinate $3

Transient surge protector, ABS Sensor ABS, front left Sensor ABS, front right

$2 $1 $1

Control unit, EX-K ignition system Delay relay, heated rear window Delay relay, heated rear window and door mirrors Test point, EZ-K Speedometer sensor Air mass meter Power stage, DME Relay, gear shift indicator Control unit, DIM-DIP Roof light, trunk Door contact, rear Injector 1 Injector 2 Injector 3 Injector 4

Injector 5 Injector 6 Series resistance Ground, ABS Brake fluid level sensor Impulse generator, EZ-K HT lead sensor Service socket, EZ-K Power stage, EZ-K Solenoid valve, charge pressure limiter Temperature sensor, charge pressure limiter Seat heater contact Relay unit (30 circuit)

Relay unit, fuse box Relay unit (30 circuit), fuse box Relay, injectors Power aerial switch Dimmer Heater controls, ECC 130 Heater controls, ECC sensor Solenoid valve, ECC Servo motor, ECC heater Power unit, ECC Fan motor, ECC Ambient air temperature, ECC Sun heat sensor, ECC Inside air temperature sensor, ECC Clock switch Transfer box 1234705 Accessories Amplifier, radio SRS Ignition module, SRS Indicator lamp, SRS Safety circuit, SRS

N5, 04 K2 K3

_

Q5 S1 R4 R2 G5, R5 T3 W5 W5

P4, R2, R4 P4, R2, R4 P4, R2, R4 P4,R2, R4 R4 R4 P4,R2

$1 G5;S1 P5 N5 P5 N4, 04 S6 S6 : L3 J4

W4 W4 N3, 04, R2 U2 B3 YA W1 W1 vis X2 X2 V1 W1 V1 H3 P4, R4 H3 Wa ¢5 C5 H5 H5

Index A About this manual - 4 Accelerator cable removal, refitting and adjustment - 108 pedal removal and refitting - 109 Acknowledgements - 2 Advance systems (ignition) description and testing - 151 Aerial removal and refitting — 299 Air cleaner element renewal — 99, 344

removal and refitting - 100, 344 Air conditioning compressor drivebelt - 81 control panel removal and refitting — 88 fault diagnosis — 95 general description - 88 maintenance - 88 precautions — 88

Alternator brush renewal - 283 drivebelt - 81 precautions — 282 removal and refitting — 283 testing — 282

Antifreeze mixture — 80 Anti-lock braking system (ABS) bleeding — 362 caliper — 216 component removal and refitting - 224, 360, 361 control unit - 361 description - 225 fault tracing - 227 master cylinder — 220 modifications - 360 Anti-roll bar removal and refitting front - 241 rear — 245 Ashtray light bulb renewal - 291 Automatic choke adjustment - 121 Automatic climate control programmer removal and refitting - 94 sensors description - 92 testing, removal and refitting - 92 vacuum hose connections - 342 Automatic transmission fault diagnosis - 200 fluid level checking - 194 renewal — 194 gear selector — 194, 291 general description —- 192 kickdown cable - 195, 196 maintenance and inspection — 193 oil seals - 198 overdrive switch - 198 removal and refitting - 199 reversing light switch - 197

selector - 194, 291 specifications — 166, 335 starter inhibitor switch — 197

Auxiliary front light bulb renewal — 287 removal and refitting - 289 Auxiliary shaft examination and renovation — 51

refitting - 54 removal — 47 Axle see Rear axle or Final drive and driveshafts

B Ballast resistor testing, removal and refitting - 156 Battery

charging — 282 disconnection - 370 maintenance - 282 removal and refitting - 282 Bearings clutch release - 163 engine (in-line) crankshaft spigot - 43 main — 47, 48, 53

engine (V6) crankshaft spigot - 67 main - 71, 74, 341 halfshaft — 208 mainshaft (manual gearbox) - 356 propeller shaft — 204 roadwheel - 234, 239, 339, 362, 366 Bleeding hydraulic system brakes — 215, 362 clutch - 162 power steering - 234 Blower motors (heater) — 92

Bodywork and fittings - 248 et seq, 367 et seq Bodywork and fittings bonnet — 253, 255, 367 boot lid - 254 bumpers - 273, 274, 370

central locking - 263, 367 centre console - 271 damage repair major - 253 minor — 249

doors - 253, 256, 258, 259, 261, 262, 264, 367 engine undertray - 275 facia - 173 general description — 248 glovebox - 271, 370 grille - 275 head restraints - 266 locks — 238, 261, 262, 263, 367 maintenance bodywork and underframe - 248 upholstery and carpets — 249

Index

395

mirrors — 264, 372 rear console — 272 seat belts - 270

seats — 266, 267, 269, 270, 368, 370 spoiler —- 273

steering column trim — 271 sunroof - 276, 278 tailgate — 255, 259, 262 undertray - 275 weatherstrip — 264 wings - 276

windows - 259, 260, 368 windscreen — 259 Bonnet A light bulb renewal - 291 release cable removal and refitting - 255 removal and refitting - 253, 367 Boot lid lock removal and refitting - 262 removal and refitting — 254 Braking system — 210 et seq, 358 et seq Braking system ABS - 225, 227, 360, 361, 362 bleeding - 215, 362 caliper front - 216, 359

rear —- 217, 218, 359 disc

front - 218, 359 rear - 219

fault diagnosis - 227, 229 fluid level - 212, 358 general description - 211

handbrake - 214, 222, 224, 360 high level lights —- 371 hoses - 214 maintenance and inspection — 212, 339 master cylinder —- 219 pads front — 213, 358

rear — 214, 358, 359 pedal - 221 pipes - 214 pressure differential warning valve — 220 servo - 214, 222 specifications - 210, 335 stop-light switch — 224 vacuum pump - 222

Bulb failure warning system — 296 Bulb renewal ashtray light - 291 automatic transmission selector light — 291 auxiliary front light - 287 boot light - 290 brake light (high level) — 371 cigarette lighter illumination - 291 courtesy light - 290 day running light - 287 direction indicator — 287, 289 door edge marker light - 291 headlight - 287 instrument panel light - 291 load area light - 290 number plate light - 289 parking light - 287 rear light cluster - 287, 289 seat belt buckle light — 291 switch illumination — 291 under-bonnet light - 291 vanity mirror light - 372 Bumper removal and refitting buffers - 274 front — 273, 370 rear - 274 Bushes (independent rear suspension) renewal — 363

Cable accelerator — 108 clutch - 159 handbrake - 224 heater - 90 kickdown — 195, 196 sunroof - 278 throttle - 108

Caliper (brake) overhaul front - 216, 359 rear - 218, 359

removal and refitting front - 216 rear — 217, 359 Camshaft

in-line engine cover gasket - 339 drivebelt removal, refitting and tensioning — 38 examination and renovation - 51

oil feed - 339 removal and refitting - 40 V6 engine examination and renovation — 73 removal and refitting — 66 Carburettor fuel system adjustments - 100, 116, 121, 344 air cleaner — 99, 100

automatic choke adjustment - 121 carburettor description - 114, 344 overhaul - 117 removal and refitting - 116 EGR system - 346 fault diagnosis - 114, 122 fuel filter — 100 fuel pump - 105, 106 hot start valve - 122 idle speed adjustment - 100, 339 manifolds - 112, 113 Pulsair system — 344, 346 mixture adjustment — 100, 339 tamperproof screws - 99 Cassette player removal and refitting — 299, 374 Central locking components removal and refitting — 263, 368 Centre bearing (propeller shaft) renewal - 204 Choke adjustment - 121 Cigarette lighter bulb renewal - 291 removal and refitting - 299 Clutch — 159 et seq Clutch bleeding - 162 cable - 159 component inspection - 163 fault diagnosis —- 164 general description - 159 maintenance and inspection - 159, 163 master cylinder —- 160 pedal —- 160 release bearing - 163 removal and refitting —- 162 slave cylinder - 161 specifications — 159 Compression test in-line engine — 57 V6 engine - 77 Coil testing, removal and refitting — 156

Column (steering) removal and refitting - 237, 362

396

Index

ec

Connecting rods in-line engine examination and renovation - 50 removal and refitting - 44 V6 engine examination and renovation - 72, 341

refitting - 75 removal — 70

Console removal and refitting centre - 271 rear - 272

Console switch (rear) removal and refitting - 292 Constant idle speed system description - 102 adjustments — 102 Continuous injection system components removal and refitting - 128 control pressure regulator ventilation - 344 control unit overhaul — 129 description - 123

fault diagnosis - 114, 131 testing procedures — 124 Control arm general — 362 balljoint removal and refitting - 240 Control pressure regulator ventilation continuous injection system - 344 Control unit removal and refitting ABS - 361 ignition - 153,.354

Motronic —- 154 seat heater - 370 Conversion factors - 22

Coolant draining - 80, 342 filling - 80 flushing — 80, 342 level sensor — 85 Cooling, heating and air conditioning - 78 et seq, 342 et seq Cooling and heating system air conditioning - 88, 92, 94, 95

antifreeze mixture — 80 automatic climate control - 92, 94, 342 control cable - 90 control pane! - 88 coolant level sensor — 85

draining — 80, 342 drivebelts - 81 electric fan - 83 electronic climate control - 342, 344

fan - 82, 83 fault diagnosis - 94, 95 filling - 80 flushing - 80, 342 general description — 78, 86 maintenance and inspection - 79 matrix — 90 motors — 91,92

oil coolers — 86 radiator — 82 specifications - 78, 333 temperature gauge - 84, 85 thermostat - 84 thermoswitch - 83

viscous coupled fan - 82 water pump - 83, 342 water valve - 92

Courtesy light bulb renewal - 290 Crankcase ventilation system in-line engine — 37, 339 V6 engine - 60 Crankshaft in-line engine examination and renovation - 48 refitting - 53

removal - 47 spigot bearing removal and refitting - 43 V6 engine examination and renovation - 71 refitting - 74 removal and refitting - 70, 341 spigot bearing removal and refitting - 67 Cruise control - 111 Cylinder block and bores (in-line engine)

examination and renovation - 50 Cylinder block and liners (V6 engine) examination and renovation - 71 Cylinder head in-line engine decarbonising, valve grinding and renovation — 52 dismantling - 51 reassembly - 53 removal and refitting - 41 V6 engine 3 decarbonising, valve grinding and renovation - 73 dismantling - 73 reassembly - 73 removal and refitting - 63, 70, 76 Cylinder liners (V6 engine) examination and renovation - 71 identification - 341 refitting and checking protrusion — 73 removal - 71

D Damaged body repair major - 253 minor - 249 Day running lights bulb renewal - 287 removal and refitting - 289 Direction indicators bulb renewal - 287 fault tracing - 296 removal and refitting - 289 Discs (brake) inspection - 218 removal and refitting front - 218, 359 rear - 219 renewal - 359 Distributor

drive oil seal - 340 overhaul - 148 removal and refitting - 146, 354 Door adjustment - 367 edge marker bulb renewal - 291 handles - 261 interior trim - 256, 258, 367 latches - 261 locks - 261, 367 mirror — 264 removal and refitting - 253 switches - 292, 293 weatherstrip — 264 window - 259 window lift mechanism - 260, 293, 368 Drivebelts (accessory) removal, refitting and tensioning - 81 Driveplate in-line engine

examination removal and V6 engine examination removal and Driveshaft removal

and renovation - 51 refitting - 42 and renovation - 72 refitting - 66 and refitting - 357

Index

E EGR system description - 346 maintenance - 346 Electrical system - 279 et seq Electrical system aerial - 299 alternator - 282, 283 battery - 282, 370

brake lights (high level) - 371 bulb failure warning system — 296 bulbs - 286, 290, 371, 372 + cigarette lighter - 299 direction indicator fault tracing - 296 fault diagnosis — 296, 305

397 tappets — 51 undertray - 275 valves - 36, 52, 339

Engine (V6) bearings - 67, 70, 71, 74, 341 camshaft — 66, 73 compression test - 77 connecting rods - 70, 72, 75,341 connection to transmission - 76 crankcase ventilation system — 60 crankshaft - 66, 67, 70, 71, 74, 341 cylinder block - 71 cylinder heads - 63, 70, 73, 76 cylinder liners — 70, 71, 73, 341 dismantling - 61, 69 distributor drive oil seal - 340 driveplate — 66, 72

fuses — 294, 372

examination and renovation - 71, 341

general description — 281

fault diagnosis - 77 flywheel - 66, 72 general description - 58, 339 maintenance and inspection — 58, 339 management relays - 156 manifolds - 112, 113, 347 mountings - 67, 341 oil cooler - 340 oil filter - 58 oil level sensor - 77 oil pressure switch - 340 oil pump - 63, 71

headlights — 289, 290, 296, 298, 370, 371 heated rear window - 299 horn - 296 ignition/starter switch - 291 instrument cluster — 293, 372 interference suppression - 301

lights - 286, 289, 290 maintenance and inspection - 281

radio/cassette player - 299, 375 relays — 295, 373 specifications — 279, 337 speedometer - 294 starter motor — 283, 284

switches - 152, 191, 197, 198, 224, 291 to 293, 339, 340, 358, 372 wash/wipe - 296, 297, 298, 375 wiring diagrams - 307 to 328, 375 to 393 Electronic climate control control pump and control unit - 344 description —- 342 sensors — 344

Electronic traction control - 154 Engine - 27 et seq, 339 et seq Engine (in-line) auxiliary shaft - 47,51, 54 bearings - 43, 47, 48, 53 bores - 50 camshaft - 38, 40, 51, 339 compression test — 57 connecting rods - 44 connection to transmission — 55 crankcase ventilation system — 37, 339 crankshaft - 43, 47, 48, 53 cylinder block - 50 cylinder head - 40, 41, 51, 52, 53 dismantling — 39, 47 driveplate - 42, 51 examination and renovation — 48 fault diagnosis - 57 flywheel - 42, 51 general description - 34, 339 maintenance and inspection — 35, 339 management relays — 156 manifolds - 112, 113 mountings - 45 oil filter - 35 oil pressure switch - 339

oil pump — 44, 48 oil seal - 42 operations possible with engine installed — 39 pistons - 44 reassembly - 39, 54

refitting — 56 removal - 45, 46 separation from transmission — 46 specifications — 28, 330

start-up after overhaul — 56 sump - 43

oil seal - 66, 340

operations possible with engine installed — 60 pistons - 70, 72, 75, 341 reassembly - 61, 76 refitting - 76, 77

removal — 68, 69 rocker gear - 73 separation from transmission - 69 specifications - 31, 332 start-up after overhaul - 77 sump - 67

timing chains and sprockets — 61, 72 timing scale - 76 undertray - 275 valves — 59, 339 Exhaust system inspection and repair - 109 manifold - 113 removal and refitting — 110

Facia removal and refitting - 273 switches — 292 Fan removal and refitting electric - 83 thermoswitch - 83 viscous coupled - 82 Fault diagnosis automatic transmission - 200 braking system - 227, 229 clutch - 164 cooling system - 94 electrical system - 296, 305 engine in-line — 57 V6-77 fuel system - 114, 122 general — 23 heating and air conditioning — 95 ignition system — 158 manual gearbox - 192

398 ee

Index SSS

SSS

overdrive - 192 propeller shaft - 205 rear axle - 209 steering and suspension — 247 Final drive and driveshafts - 356 et seq Final drive and driveshafts description - 356 driveshaft removal and refitting - 357 final drive unit removal and refitting - 357 lower section removal and refitting - 365 maintenance and inspection — 339 oil level checking - 357 pinion oil seal renewal - 357 side oil seals renewal — 357 specifications - 335 Fixed glass removal and refitting - 259 Fluid automatic transmission level checking - 194 renewal - 194 braking system level checking - 212 level warning switch - 358 power steering level checking and bleeding - 234 Flywheel in-line engine examination and renovation — 51 ring gear renewal - 42 V6 engine examination and renovation - 72 removal and refitting - 66 ring gear renewal - 66 Flywheel sensors removal and refitting - 153, 354 Fuel and exhaust systems - 96 et seq, 344 et seq Fuel and exhaust systems air cleaner - 99, 100, 344 carburettor - 114 to 122, 344 constant idle speed system - 102, 344 continuous pressure regulator ventilation - 344 cruise control - 111 EGR system - 346 exhaust - 109, 110 exhaust manifold - 113 fault diagnosis - 114, 122, 131, 141 fuel filter - 100 fuel gauge - 107, 108, 346 fuel injection - 123 to 131, 135 to 141, 344, 348 to 353 fuel pumps - 105, 106, 346 fuel tanks - 104, 347 general description - 99, 348 hot start valve - 122 idle speed adjustment - 100, 339, 348 inlet manifold - 112, 347 maintenance and inspection - 99, 339 mixture adjustment - 100, 339, 344, 348 Pulsair system - 339, 344, 346 specifications - 96, 333 tamperproof adjustment:screws - 99 throttle cable - 108 throttle pedal - 109 turbocharger- 131 to 134, 353 unleaded fuel - 99, 344 Fuel filter renewal - 100 Fuel gauge senders removal, testing and refitting - 107, 346 testing - 108 Fuel injection systems air cleaner - 99, 100 constant idle speed - 102 continuous injection - 123 to 131, 344 control pressure regulator ventilation - 344 fault diagnosis - 114, 131 fuel filter -100 fuel pump - 105, 106

SS

SS

SSS

SS

SSS

SSS

idle speed adjustment - 100, 339, 348 LH-Jetronic - 348 to 353 mixture adjustment - 100, 339,.348 Motronic system - 135 to 141 tamperproof screws - 99 testing - 350 turbocharger - 131 to 134, 353 Fuel pump removal and refitting main pump - 106 tank pump - 105, 346

Fuel tank removal and refitting auxiliary tank - 104 main tank - 104, 347 Fuses (general) - 294, 372

G Gearbox see Manual gearbox Gear lever (manual gearbox) pullrod renewal - 190 removal and refitting - 189 Gear selector (automatic transmission) checking and adjustment - 194 General dimensions, weights and capacities — 6, 338

General repair procedures - 11 Glass removal and refitting door - 259 fixed - 259 tailgate - 259 windscreen - 259 Glovebox removal and refitting — 271, 370 Grille removal and refitting - 275

H Halfshaft, bearing and seals — 208 Handbrake adjustment - 214, 360 cables - 224, 360 shoes - 222, 360 warning switch - 224 Headlights beam alignment - 290 bulb renewal - 287 dismantling and reassembly - 371 removal and refitting - 289, 370 wash/wipe - 296, 297, 298 Head restraints removal and refitting - 266 Heated rear window - 299 Heated seats - 269 Heater see Cooling and heating system Horn removal and refitting - 296 push switch removal and refitting - 292 Hot start valve testing - 122 Hub carrier (independent rear suspension) removal and refitting - 366 Hydraulic pipes and hoses - 214

Hydraulic system bleeding brakes - 215 clutch - 162

Idle speed adjustment - 100, 339, 348 Ignition advance systems description and testing - 151 Ignition control unit removal and refitting - 153

SE

Index

399

SS

Ignition/starter switch

sie

removal and refitting - 291 Ignition system 143 et seg, 354

Ignition system advance systems - 151 ballast resistor - 156 coil - 156 control unit - 153, 154, 354

distributor - 146, 148, 340, 354 electronic traction control - 154 engine management relays — 156 fault diagnosis - 158 flywheel sensor - 153, 354 general description - 143, 354 knock sensor - 153, 354 maintenance and inspection - 144, 339 Motronic system — 156 power stage - 354 spark plugs - 144, 339 specifications - 142, 334 switch - 291 throttle position switch — 152

timing - 150 torque limiter system - 154 Ignition timing checking and adjustment - 150 Independent rear suspension axle member lower section - 365 bushes renewal - 363 description — 363 hub carrier - 366 lower link - 363 shock absorber - 366 specifications - 335 spring - 366 support arm - 365

track rod - 365 upper link - 365 wheel alignment - 363 wheel bearing - 366 Indicators see Direction indicators Inlet manifold removal and refitting - 112, 347 Input shaft (manual gearbox) dismantling - 175 reassembly - 176 Instrument cluster dismantling and reassembly - 293 removal and refitting -'293, 372 fuse renewal - 372 panel bulb renewal - 291

Intercooler removal and refitting —- 134 Interference suppression (radio) - 301 Introduction to the Volvo 740 and 760 - 5

J Jacking — 7

K Kickdown (automatic transmission) cable adjustment - 195 renewal - 196 marker adjustment - 196 Knock sensor (EZ-K system) general - 354

removal and refitting - 153

L Layshaft (manual gearbox) dismantling - 175 reassembly - 177 LH-Jetronic fuel injection system component removal and refitting - 352 description - 348 injector check - 349

idle speed adjustment - 348 mixture adjustment - 348 testing procedures — 350 Light bulbs see Bulbs Locks central locking - 263, 368 removal and refitting boot - 262 door - 261, 368 steering - 238 tailgate - 262 Lower link (independent rear suspension) removal and refitting - 363 Lubricants and fluids - 21

Main bearings in-line engine examination and renovation - 48

refitting - 53 removal - 47

V6 engine examination and renovation - 71 refitting - 74, 341

removal - 70, 341 Mainshaft (manual gearbox) bearings - 356 dismantling - 175 reassembly - 177 Maintenance and inspection see Routine maintenance Manual gearbox, overdrive and auto transmission - 165 et seq, 356 Manual gearbox component examination and renovation - 176

dismantling - 171, 174, 356 fault diagnosis - 192 gear lever - 189, 190 general description - 167 input shaft - 175, 176 layshaft - 175, 177 mainshaft - 175, 177, 356 maintenance and inspection - 170 oil seals - 170 reassembly - 179, 180, 356 removal and refitting - 170 reversing light switch - 191 specifications - 165, 335 Master cylinder overhaul brakes - 219 clutch - 160 removal and refitting brakes - 219 clutch - 160 Mirror (door) glass and motor removal and refitting - 264 removal and refitting - 264 switch - 293 Mixture adjustment - 100, 339, 344, 348 Motronic system component removal and refitting - 139

control unit removal and refitting - 154 description - 135

400

ES fault diagnosis - 114, 141 testing procedures - 137, 156 Mountings removal and refitting in-line engine — 45 V6 engine - 67, 341

N + Number plate light bulb renewal - 289

O

ae

ee

Index rec nn ROE

MAM

LATS Pew

Propeller shaft centre bearing - 204 fault diagnosis - 205 general description — 201 maintenance and inspection - 201 removal and refitting - 202, 356 rubber coupling - 202 specifications — 201 universal joints - 202 Pressure differential warning valve overhaul — 220 removal and refitting - 220 Pulsair system description - 344 maintenance - 346 Pump (steering)

Oil coolers removal and refitting - 86, 340 Oil filter renewal in-line engine - 35 V6 engine - 58 Oil level sensor (V6 engine) testing, removal and refitting — 77 Oil pump in-line engine examination and renovation — 48 removal and refitting - 44 V6 engine examination and renovation — 71 removal and refitting - 63 Oil pressure switch removal and refitting in-line engine — 339 V6 engine - 340 Oil seal renewal automatic transmission - 198 distributor drive - 340 engine in-line -"42 V6 - 66, 340 manual gearbox - 170 rear axle/final drive - 207, 357 Overdrive description - 182, 356 dismantling — 185 fault diagnosis - 192 overhaul - 188 reassembly - 189 removal and refitting - 185 switch removal and refitting - 191, 198

p Pads (brake) inspection and renewal

front - 213, 358 rear — 214, 358, 359 Panhard rod removal and refitting — 245 Parking lights bulb renewal - 287 Pedal removal and refitting accelerator- 109 brake - 221 clutch — 160 Pinion oil seal renewal - 207 Pistons in-line engine examination and renovation — 50 removal and refitting - 44 V6 engine examination and renovation - 72, 341 refitting - 75 removal - 70 Power stage (ignition) removal and refitting — 354 Power steering see Steering Propeller shaft - 201 et seq, 356

overhaul - 236 removal and refitting - 236

R Rack bellows (steering) renewal — 235 Radiator grille -— 275 removal and refitting - 82 Radio/cassette player aerial — 299 interference suppression - 301 removal and refitting - 299, 370, 375 Radius rod removal and refitting — 240 Rear axle — 206 et seq Rear axle see a/so Final drive and driveshafts bearing — 208 fault diagnosis - 209 general description —- 206 halfshaft - 208, 339 maintenance and inspection — 206 oil level checking — 207 oil seal renewal - 207 removal and refitting - 208 specifications — 206 Rear light cluster bulb renewal - 287, 289 removal and refitting - 289 Relays general - 295, 373 ignition/engine management — 156 Repair procedures - 11 Reversing light switch removal and refitting automatic transmission - 197 manual gearbox - 191 Roadwheels alignment — 234, 363 bearings checking and adjustment — 234, 339 removal, inspection and refitting — 239, 366 general care and maintenance — 245, 339 studs renewal - 245 Rocker gear (V6 engine) examination and renovation — 73 Routine maintenance automatic transmission — 193 bodywork and underframe - 248 braking system - 212, 339

clutch —- 159 cooling, heating and air conditioning - 79, 88 electrical system - 281, 282 engine in-line - 35, 339 V6 - 58, 339 final drive and driveshafts - 339 fuel and exhaust systems - 99, 339 general - 15 ignition system — 144, 339 maintenance intervals — 15, 339

Index

401

Ss?

manual gearbox and overdrive= 171 propeller shaft — 201 rear axle - 206 suspension and steering - 232, 339 upholstery and carpets — 249 Rubber coupling (propeller shaft)

removal and refitting - 202

S Safety first! — 14 Seat belts ; buckle light bulb renewal - 291 care and maintenance - 270 removal and refitting - 270 Seats adjuster control panel removal and refitting - 368 adjusters removal and refitting — 267, 368 heating control unit - 370 elements removal and refitting — 269 removal and refitting - 266 Self-levelling rear suspension — 245 Servo (brake) checking operation — 214, 339 overhaul - 222 removal and refitting - 222 vacuum pump - 222 Shock absorber (rear) removal and refitting - 244, 366

Shoes (handbrake) removal, inspection and refitting - 222 Slave cylinder overhaul clutch - 161 removal and refitting clutch - 161 Spark plugs removal, inspection and refitting - 144, 339 Spare parts - 9 Speedometer sender unit removal and refitting - 294 Spoiler removal and refitting - 273 Spring (rear suspension) removal and refitting - 244, 366 Starter inhibitor (automatic transmission) removal and refitting - 197 Starter motor overhaul - 284 removal and refitting - 284 testing - 283 Steering and suspension - 230 et seq, 362 et seq Steering bellows - 235 column removal and refitting - 237, 271, 362 column switches - 292, 372 fault diagnosis — 247

fluid - 234 general description - 231

lock - 238 maintenance and inspection - 232 overhaul - 236

pump drivebelt - 81 overhaul — 236 removal and refitting — 236 rack bellows — 235 removal and refitting — 235 roadwheel alignment — 234 bearings - 234, 239, 339

care and maintenance - 245, 339 studs — 245 specifications — 230, 335

track rod end - 235 wheel removal and refitting - 236 Stop-light switch - 224 Subframe and mountings (rear) removal and refitting - 244 Sunroof frame and cables removal and refitting - 278 motor removal and refitting - 276 removal and refitting - 276 Supplement: Revisions and information on later models - 328 et seq Supplement: Revisions and information on later models automatic transmission — 335

bodywork and fittings - 367 to 370 braking system — 335, 358 to 362 cooling and air conditioning systems - 333, 342 to 344 dimensions, weights and capacities — 338 electrical system — 337, 370 to 375 engine in-line engine - 330, 332, 339 V6 engine - 332, 333, 339 to 341 final drive and driveshafts — 356 to 358 fuel and exhaust systems — 333, 344 to 353

ignition system — 334, 354 to 355 manual gearbox — 335, 356 overdrive —- 335, 356 propeller shaft - 356

rear axle — 335 routine maintenance -— 339 steering and suspension — 335, 362 to 366

Suspension anti-roll bar - 241, 245

bushes — 243 control arm - 240, 362 fault diagnosis - 247 general description - 231 independent rear suspension - 363 to 366 maintenance and inspection — 232 Panhard rod - 245 radius rod - 240

rear subframe - 244 roadwheel alignment -— 234 bearings — 234, 239, 339 care and maintenance - 245, 339 studs - 245 self-levelling — 245 shock absorber - 244 specifications — 230, 335 spring - 244

strut - 241, 242, 362 subframe - 244 torque rods - 243 trailing arm - 244

Sump removal and refitting in-line engine — 43 V6 engine - 67 Support arm (independent rear suspension) removal and refitting - 365 Switches removal and refitting central locking — 368 console - 292 door - 293 facia panel - 292 handbrake warning - 224 horn push - 292 ignition/starter — 291 mirror control - 293 oil pressure — 339, 340 overdrive - 191, 198 rear console - 292 reversing light — 191, 197 starter inhibitor - 197 steering column - 292, 372 stop-light - 224 tailgate - 293 window - 293

402

Index

rr TT

T

Tailgate glass removal and refitting - 259 interior trim removal and refitting - 259 lock removal and refitting - 262 removal and refitting —- 255 switches - 293 wash/wipe - 296, 297, 298 Tamperproof adjustment screws (fuel system) — 99 Tappets examination and renovation - 51 Temperature gauge sender removal and refitting - 84 testing - 85 Thermostat removal, testing and refitting - 84 Thermoswitch (electric fan) removal and refitting - 83 Throttle cable.removal, refitting and adjustment - 108 pedal removal and refitting - 109 Throttle position switch adjustment - 152 Timing chain and sprockets (V6 engine) examination and renovation - 72 removal and refitting - 62 Timing (ignition) checking and adjustment — 150 Timing scale (V6 engine) checking and adjusting - 76 Tools and working facilities - 12 Torque rods removal and refitting - 243 Towing - 7 Track rod end removal and refitting - 234 Track rod (independent rear suspension) removal and refitting - 365 Traction control - 154 Trailing arm removal and refitting - 244 Turbocharger boost pressure checking and adjustment - 134 description - 131, 353 inspection and repair - 133 intercooler removal and refitting - 135 removal and refitting - 132 precautions -— 132 wastegate actuator inspection and renewal - 134 ‘Tyres general care and maintenance - 245 specifications - 230

U Undertray (engine) removal and refitting - 275

T

Universal joints (propeller shaft) overhaul - 202 Unleaded fuel - 99, 344 Upper link (independent rear suspension) removal and refitting - 365

V Vacuum pump (braking system) overhaul - 222 removal and refitting - 222 Valve clearances in-line engine - 36, 339 V6 engine - 59, 339 Vanity mirror light bulb renewal - 372 Vehicle identification numbers - 9 Viscous coupled fan removal and refitting - 83

W Wash/wipe - 296, 297, 298 Wastegate actuator inspection and renewal - 134 Water pump drivebelt - 81 removal and refitting - 83, 342 Water valve (heater)

removal and refitting - 92 Weatherstrip (door) removal and refitting - 264 Wheel changing - 7 Wheels see Roadwheels Window lift mechanism removal and refitting - 260 motor removal and refitting - 368 Window removal and refitting door - 259 fixed glass - 259 Windscreen removal and refitting - 259 wash/wipe - 296, 297, 375

Wing removal and refitting - 276 Wipers blades and arms - 297 motor and linkage - 297, 298, 375 Wiring diagrams - 307 to 328, 375 to 393

Working facilities — 12

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