Volvo 240, Manual (1) Service and Maintaince

SeruiceManual Section1 (17l
7,500Mile
Repairs MaintenanceService
1984
DL,GL
and maintenance GLE(Canadal
Turbo,Diesel
Contents
Opeation Page
lntroduction 1
Volvo7.500Mile MaintenanceServiceChart 2
7,500Mile MaintenanceServiceProcedures
Controls and lighting 1 18 10
I nc a r , . , , . . , , . . , , . , , , 41-A6 15
Exterior,..,,......... 81-83 1l
On lift
- Tires,wheels c1- c4 18
- Frontend D 1 -D l 0 19
-Brakes,,..,........ E 1 -E 4 22
- Powertransmission F1 F4 23
-Rearend........... G1-G2 24
E x h a u s ty s t e mD, i e s e. |. . . . . . . . . . . . . . . . . . . . H1 25
-Rearaxle,manualtransmission........... t1 t2 25
- Engineoil andfilter:
' G a s o l i neen g i n e s J 1 -J 2 26
' D i e s eel n g i n e J3-J4 21
Underhood:
- E n g i n ceo o l i n sg y s t e m. . . . . . . . . . . . . . . . . . . K 1 - K 2 28
F | u i d .s. . . . . . . . . . . . . . K3- K5 2A
- R e p l a c i nagu t o m a r li .ca n s m i s s i o f l nL r i d . . . . L 1 - 1 1 0 29
821and 823
- lMiscellaneous M 1 - M 3 33
- Adiustvalves N 1 - N 1 5 34
R e p l a c e t i m ignega rb e l t . . . . . . . . . . . . . . . . . . . 01-07 31
B2lNCanadai
- lMiscellaneous Pt-P15 39
- COemissions check 01-016 44
821F-Turbo: R] R16 49
B23F:................ S 1 _5 7 55
D24diesel:
- Miscellaneous al- a7 58
- Valve c l e a r a n caed j u s t m e r,t. , , , . , , . . , , . . h1-h12 60
ldlespeeds.......... cl c6 63
- S e t t i n eg n g i n e c o n t r o.l.s. . . . . . . . . . . . . . . . d1-d7 64
- Compression test el - e10 61
C h e c k i n g a d j u s ti n ; nj eg c t o ' s. . . . . . . . . . . . f1 f8 10
- R e p l a c i ntgi m i n gg e a rb e l l s . . . . . . . . . . . . . . 91 933 73
Road test a2
TP30600n
7500.08.83
Printedin U.S.A.
G,e!PJf,lE99!]ls!e elviee
- Chaft -
7,500 Mile 12,500km Maintenance

Service
lntroduction
Thesemaintenanceinstructionsare presentedin a "Work RelatedSequence".Stepby step proceduresare
designed in performing
to assistthe technician the tasksin an efficientand logicalmanner.
VolvoMaintenance
ServiceChan
The VolvoMaintenanceServiceproceduresare listedon the followingpages(seechart).They appearin
the sameorderas in the Warranties and MaintenanceRecords Manualsuooliedwith eachnewvehicle.
Thecertificates in the manualshouldbe signedby the ServiceManager, datedandstamped.
Thechart,aswellasthe operations insidethe manual,liststhe actualmileagewhenthe servace
insoectionshouldbe oerformed.
Greatcarehas beenexercisedto makethe charteasyto read.Groupingof mileageand servicesfacilitate
finding of intervalsfor the serviceoperations.
EMTSSTOTVS
Seruiceevery 7.500 miles : 12.500km
Emissions
ItemsmarkedEMISSIONS havebeen
determinedpartof emissionrelatedser- Seruiceat: IEMTSSTOTVS
vicemainlenance program. 15- 30- 45-60- 7' 90- t 05- t
Theseitemsreouireservicemaintenan- 2, 50- 7r, 0lr- 12, 150- t 75- 20O-t housand km
ce at mileageintervals
shownto ensure
trouble-freeoperation.
Seruice
at: lEMrSSrOlrS
30-60-90-12o-thou sand m
50- 10O-t 50-2(n-t housand km
Group17,7,500Mile MaintenanceService
- Chart -
Volvo7,500Mile (12,500km) MaintenanceServiceChart
Contlols and lighting

l Hazard warningflasher 10 Parking lights
2 Blower 11 Brakelights
3 Heatercontrols 12 Taillights
4 Reardemist Back-uplights
5 AIRCONDcontrol 't4 Reflectors and lenses
6 norn Fillwasherfluid
7 Turn signals Wiperblades
I Headlightsand LIGHTS switch 17 Wipercontrol
9 Instrumentpanellights 18 Washeriets
In car All items on this pageshould

Powerbrakefunction be inspectedal 7,500mile =
A2 Pressuretest brakesystem = 12,500km intervals:
A3 Parkingbrake miles km
Warninglights =
7,500 12,500
A5 Autotransshiftcontrol 15,000: 25,000
A6 Steering 22,500: 37,500
30,000= 50,000
Exterior- lubrication 37,500= 62,500
81 Hoodhinges 45,000: 75,000
82 Doorhinges
83 Trunklid 52,500: 87,500
60,000= 100,000
On lift 6 7 , 5 0 0 :1 1 2 , 5 0 0
Tires.wheels 75,000-- 125,000
C1 Tires 82,500 137,500
C2 Tire pressure 90,000= I50,500
C3 Wheelbearingplay 97,500= 162,500
C4 Wheelbearingnojse 105,000 = 175,000
Frontend 112,500 = 187,500
D 1 Frontshockabsorbers 120,000 = 200,000
D2 Frontsprings
D3 Steeringgear
D4 Steeringrack
D5 Controlarm bushings,
D6 Steeringrod play
strut O
D7 Ealltoints
D8 Steeringrod ends
D9 Controlarms
D 1 0 Stabilizer
barand links
- Chart-
ooos.,,S
oBg"oB .r"l€l$
k.
"ss"-"te
*t1)'-s*'e= S*"".S .Sg{'"'
,.d"e"S o8.8o8miles
",88"",8{)rd'bo'
r"*r'O' "S"s"S
ooA f,' Eba'6'
Brakes
aaa oaa aaa aoa E1 Brakehoses
aoa aaa aoa aaa E2 Brakelines
aoa aao aoa aaa E3 Parkingbrake
OaOaaa:,1 Wheelbrakes
Powertransmission
aoa aaa aoa aaa Fl Clutchplay
aoa aaa aaa aaa F2 B2lFTurboand B23F:
clutchnegativeplay
aoa aaa aao aaa F3 Autotrans:shiftcontrol
aao aaa ooa aaa F4 Propeller
shaft
Rearend
aaa aaa aaa oaa c1 Rearshockabsorbers
aoa aaa aoa aaa G2 Rearsuspension
Exhaustsystem
aaaaoaHl 821-Turbo
aaaaaaH2 B23F
aaaaaaH3 D24diesel
Fluids
aaa aaa ooa aaa t1 Rearaxle EMtSStONS
aoa aao aaa aaa t2 lvl46manualtransmission EMtSSTONS
Engineoil andfilter:
aaa aaa aaa oaa J1-J2 Gasoline engines EMtSStONS
INOTE:Turbointervals!)
aaa oaa aao oaa J3-J4 Dieselengine EMtSStONS
Enginecoolingsystem:
oaa aaa oaa aaa K1 Checkanti-freeze
a a a K2 Replace coolant
Fl!ids:
aaa aaa aaa aaa K3 Brakefluid level
aaa aoa aaa aoa K4 Powersteeringgear
oaa aao aaa aaa K5 Battery
Automatictransmission
a a a a L1-L10 Replace
fluid EMtSSTONS
aaa aaa aaa aaa L t1 Checkoil level
821and 823(all)
aaa aaa aaa aaa M1 Autotrans:adjustkickdowncable
aaa aoa aaa aoa M2 Enginecontrols
aoa M3 Drivebelttension EMtSStONS
oaaa N1-N15 Adjustvalves EMtSStONS
aa 01-07 Replacetiminggearbelt
3
-r
- Chaft-
.sss&",S oS.,SoS "SS."}S .s"l€l$rm

6 *o'E ${}bo
S'g'a' ,""-'s'.{r
,//// r4
^sos"s os",Bos
//4// ,r,
oB.sosmles
o)
"Bos",sp$ioY
-".Al"g- *:a-'A
"r*p:+ B21l'lcanada
aaa aao aaa aaa Pl Exhaustsystem
aaa oaa aaa aaa P2 Damperoil level
aoa aaa aao aaa P3 Chokecontrol
aoa aaa aaa aaa P4 Breakerpoints,rotoretc
aoa aaa aao aaa P5 Dwellangle
aaa aao aaa aaa P6 Pulsair
a ao a aaPT Positivecrankkcase ventilation
a O' a aaPs Replacesparkplugs
a aa a aaPg Lubricatedistributor
a aa a aaP10 ChecUadjust timing
a aa a a a Pll EGRvalveoperation
aaa P12 Cleanfuel pumpstrainer
aaa P13 Replace airfiltercartridge
aoa P14 Checkcentrifugal advance
aaa P15 Checkfuel lines
aaaaaa 01-O16 COemissions check
821F-Turbo
aaa aaa aoa aaa Rl Tightennuts,exhaustpipeto turbo
oaa aaa aaa aaa R2 Checkturboseal
aaa aoa aaa aaa R3 Torqueclampscrews
Checkof turbo system:
aoa aaa oaa aaa R4-R5 Connectinstrument
aaa aaa oaa aaa R6 Checktimingretard
aaa aao oaa aaa R7 Checkfull loadenrichment system
aoa aao aaa aaa R8 Checkoverloadprotectionswitch
aoaaaa R9 Lubricatedistributor
aaa R10 Replace airtiltercanridge EMtSStONS
aaa R11 Replace sparkplugs EMtSSTONS
aaa R 1 2 - R 1 3Replace oxygensensor,
resetlight EMtSStONS
a R14 Replace fuelfilter
a R15 Positivecrankcase ventilation
aaaaaa same:adverse conditions
a R16 Replace fueltankfilter
- Chart -
",s
:.9',$
I'r
,"Bss:?soB"8o&t.
os,"soB
l' .rs8,9 A'*o'S
"""^t": S$-!"'
,J,/ / t ////4 4////
)"s
tod"i^o
.,r",
so l",o'0'f'
ii-:$ E8'6
? ( !\,'
.u":':-""
4,.s.j.%lo!s B23F
a a asl Replace air filtercartridge EMtSStONS
O a os2 Replace sparkplugs EMtSStONS
a a a s3-s4 Replaceoxygensensor,
resetlight EMtSStONS
a Replace fuelfilter
a Positivecrankcaseventilation
a aaa a - same;adverse conditions
a Replace fueltanktilter
D24diesel
oaa aaa aaa aaa Draincondensate
a aaaaa Positivecrankcaseventilation
oaa a3 Coolingsystempressurecheck EMtSStONS
aaa a4 Replacing airIiltercartridge EMtSSIONS
aoa a5 Replace fuelfilter EMtSStONS
aaa a6 Checkluel lines EMTSStONS
oaa a7 Drivebelt tension EMtSStONS
o aaaoo b1-h12 Valveclearanceadjustment EMtSStONS
aaa c1-dj Enginecontrols EMtSStONS
Maintenance
servicesat 75,000mile intervals:
a e'l-el0 Compressiontest
a f1-f8 Checking/adjustinginjectors
a g1-933 Replacing timinggearbelts
5
- Chart -
Roadtest
_----
I
Item Adjust
Engine
l Startingability
l Fastidle(coldengine)
3 ldle(warmengine)
4 No stallson acceleration
or deceleration
5 No noisefrom engine
6 Normalwarm up
7 Normalengineoperation
8 Normalacceleration
o
I Leaks
10 Reinstallhardwareremovedat Jactory
Elestrical
l Staner/alternator
operation
2
3 lgnitionandsteeringlock
4 Instruments,
controllights
Drivetrain
l Clutchadjustment
2 Clutchoperation
Manualtransmission
Correctoperation
- Chaft -
Automatictransmission
1__ Gearseloctorplay
o3 Starteroperationonly in P and N
Runto normaloperating
No slippageat stallspeed
temperature
5 Upshift
6 No slippageduringshifting
1 Kickdown
8 Upshiftwith kickdown
Gearselectorin 2, downshiftand braking
10 Gearselectorin 1, downshiftand brakino
11 Parkpositionoperation
12 Driveshaftsand bearingnoises
Biakes
1 Powerassist
No pullwhenbrakinghard
3 Pedalpulsatlon
"Spongy"brakepedal
Parkingbrake
Steering
1 Correctsteering
2 Stoeringwheel positionand return
Steeringwheeleffort
Steeringlooseness
5 Powersteeringlunction
Serines
and wheels
I No suspension noises
2 Rearaxletight
3 Tireunbalance
Bodyand equipment
't
__ Accessoryoperation
Heaterand heatercontrols
Speednoises
Body noises
Visibledefects
Cleansteeringwheeletc
Notefaultsdetected
Checkoff
Remedyfaults
7
- Chaft -
Servicesbeyond90,000milqq - '150.0QQ
!m
The seruicechartslist mileageup to 90.000milos= 150,000km. Spaceand readabilitysetsa limit.
On the following page is a list that goesto 300,000miles = 500,000km. lt crossreferencesactual
mileagewhena serviceshouldbe performedandwhat intervalservices shouldbe pedormedatthat
mileage.
8
Gtoup 1/, /.500 Mile Mdinlenance Service
- Chart -
Services at the
ftileagesindicated
below - --------- --- includeserviceoperat;onsperformedat theseinteryals.
7,500 15,000 22.54O 30,000 45,000 60,000 75,000

12,500 25,000 37,500 50,000 75,000 100,000 125,000
7,500= 1 2 , 5 0 0 ..:t
15,000= 25,000 ;ii;i1.1.!:t:r
;tii:ii iiii,I
22,500= 37,500 ' L l,... ,-. .t
30,000= 50,000 rji.rl!.Ii;ririii[jii;j]**f:-rr::1,:],::r.e.ll-,lrtlii,!.:19,.!-!l9,r9t
i?li:?ll
37,500= 62,500 :: l
45,000= 75,000 iii::.Nni:i::r!!t!rr!ir!!r!*t.!!i:air!rtiiaii:iiil!rlr.!!!a1ir!rarllr!:arlir!r!rarriiiiii-lil:l
52,500= 87,500 t
60,000= 100,000 i.i:ii ararql::rir r:l.rr.::;::r.-l
ii.1,iai.ii.li; i:r;i.:iiiiri:rajiii;lirj!tiji,i;:;
ili.i; ili:i-:l*illilllll.Sliiiii.iil
67,500= 1 1 2 , 5 0 0 :.,f ,f i:::::r:rr:.:,..:a:.::!!
75,000, 125,000 a,fi;*+liii.ti+;i.r:i.rtl1:rf
iirlls'ri_iidix,r:--i
82,500: 137,500 '.-.l
90,000= 150,000 ;tllrl.|t:aiilliiiriliii:$r$:*l>11'f1'"Ll'"1'"!,r*i:r:lri3l;ilr:.1):ii*i:lll-:li.l;::r:r;11
97,500- 162,500 .,:|
105,000 = 175,000 :xri;I3{iri;i8i;li:.li::l ......
112,500 = 187,500 ::::a:r..,.,:.::..:..: ...1
120.000 = 200,000 t'.6''*.i46liiiij;l 'I,,1i:ril::1i1li1:;1.!li:::
i::iilr: niiii;l
):i::i;ji;i.ai!9ll: i:rl:li*l-:l::*i:::!li:li?l{irlllliii
127,500= 212,500 '1:!
135,000 : 225,000 idl$G).iq.$.ij.!.1;s.'e:)-!.LF.ll!-.:i9i*9-.ri9.)i!I,,q-16;diYiLl.F)i6[111;1!:1]lilrlrl:r1,:!.l|
142,500: 237,500 ',,:|
150,000 = 250,000 a;.ilila.:,i!!Eaia,jirji;i;l;*fiil?r1:illi;lirjijrii;1?:t.!.:isi4.itii;l>:)x*t?,lLlL)irl,+3
157,500 = 262,500 :-,1":1'1,::::: :" '.'r'.,"'!
165,000 : 275,000 iittlis,*rtn"tiT<t$ilrll
172,500= 247,500 .,,.
180,000 = 300,000 iri{fii;iri1i1;ti)tr:r,:::rf,i:i:::1ll:1:::lltlil)-1:l:ri:;l.l:riii.jili.lijiijilirji6i,iji6jtr]a.!.r,+r.llj$iltiijii;rl
187,500 : 312,500 t:tl
135,000 = 325,000 j,ili-ili;i,ij;l
,+:4*.i;i.tjii:
202,500- 337,500 .t;!:,r':1r'-i::.. r: . 1
210,000= 350,000 ilrllrirji-:ii:ll:l.jl
$tlli-jiilnii;ri;jiir,*r*i:;1;r.l;rir::.r11'!.:
2 1 7 , 5 0 0 : 362,500 ':l
225,000= 375,000 r.;ii:*,itii:i;::l::::::*ri!i!r.i;;;:::rl:f:::r1:;::l::r,:ri::::ll::::r;:r:l::rl::::l
232,500: 387,500 .l
240,000: 400,000 :]:li:G;ij.j!!l:]:1]::;x;.ji]!ll,!i:li]!:!]:]:::]l:::::1i]::l!!]i!.1j!iiiij:jij
247,500= 412,500 'f I
255,000= 425,000 I::li:I ::r::it::r;:i:ti:r;:N
262,500: 437,500 I
270,000= 450,000 iriril:li,.t.ljti:r;:rt:rr-: !t!rir:!]l:!!rrijriii:::1!r
t:r..I:!::!t!: n;;:::r!l:!rjr!iirl
277,500- 462,500 I
285,000= 475,000 l|;:lil ::ll::l::il-r::::::1I
292,500- 487,500 'l r'' r I
300,000= 500,000 iri:jli i.jiilii iliiiri;riif !!rli:
:-1r
l-rr
l:l;:
9
- Controlsand lighting-
Procedures
Controlsand lighting
Hazardwarningflasher.
Pressin switch.Checkthat all fourturn indicator
lightsand switchindicatorlight flash.Turn off
0l
@ I D n t,4l
l-!21l-ll EI
E
tl
@E Blower.
Turn on ignitionswitch.
Checkthat bloweris off with FANcontrolin posi'
tion Off and operatesin positions1-2-3-4.
Allow
blowerto runfor a briefperiodat maximumrpm
(position 4).
Heatercontrols,
Setall contfolsin positionswhereair flow vents
areclosed.Heatercontrolon COLD.
DepressDEFcontrol.Checkthat air is blowing
from delroster
Depress FLOOR
ventopenings.
control.Checkthat air is blowing
c
from floor vent openings.Also checkthat air is
blowingto rearseat.
Runengineuntilat normaloperating temperatu-
-11-
ry^E,
Checkthatairexitingventsis stillcold.Setheater
controlto WARIM. Checkthat heatedair nowexits
vents,
Checkthat air exitsfromall outletson instrument
panel.
Switchoff blower.
Check thatREC(recirculate)valve operates. Listen
to valvefunctioning whendepressing controt.
srop engrne.
10
- Controlsand lighting-
Checkelectricallyheatedrearwindow
(demist).
Actuate REARDEMISTswitch for rear window
heater.
Checkthat lightin switchcomeson.
Switchis a spring-back
type.SystemremainsON
for 1G-15
minutesunlesskeyis turnedOFF.
CheckAIRCONDcontrol.
Startengine.
ActuateAIR CONDswitch.Checkthat maonetic
clutchfunctions,
visuallyand by sound.
Switchengineoff.
Checkhorn.
Depress places.Check
horncontactsat alternate
at all points.
that hornoperates
Checkturn signals.
Check thatleftandrightfrontandrearturnindjca-
tor lightsaswellas indicatorlightson instrument
panelflash.Checkthat leverreturnsto neutral
afterturningsteering wheel.
11
Group 17,7,500Mile Maintenance Seyice
- Controls and lighting -
Checkheadlightsand LIGHTSswitch.
PlaceLIGHTS position.
switchin headlight Switch
between highandlow beams.Checkin highbeam
position
thatheadlightsandindicatorlightareon.
Checkin low beampositionthat low beamlights
areon andhighbeamindicatorlightis out.
Checkinstrumentpanellightsand lights
in gearshift control.
Mustbeaccomplished eitherin a darkened
areaor
by lookingdirectlyat lamplens(openingl
Switchon LIGHTS switch.Checkthatlightintensi-
ty increasesand decreasesby turning rheostat
first clockwise,then counterclockwise.
10Q
Checkparkinglights.
Checkthat all lightsareon.
0)
Qr
11
Checkbrakelights.
nonroc. hrrL6.6.lil
Checkthal brakelightscome on with light

pressureon peoar.
0r
12
- Controlsand lighting,
12
Checktail lights.
Checkthat all lightsare on.
Checkback-uplights.
Setshift selectorto reverse.
Checkthat bothlightsareon.
Checkrear reflectorsand lenses.

Check
thatreflectorsandlensesarenotdamaqed.
Fillwasherlluid reservoir.
Use cleanwaterand solvent,In belowfreezinq
conditions
usewashersolventanti-Ireeze
GtouQt17,7,500Mile MaintenanceService
- Controls and lighting -
16
Checkwiper blades.
Checkbladealignment.Checkthat bladesare not
damagedand a16free trom for€ign matter.
Wagons:checktail gatewip€rblade.
17
Checkwipers.
-[' Turn on ighitionk€y.
Switch on wipers. using WASHMIPEcontrol on
sto6ringcolumn.
Checkspoed.in first and secondposition.ptus
rmervatpostflon.
Checkwiperbladealignmentand parkDosition.
Forwagonmodels:Checktailgatewiper by actua-
tins REARA/VIPE/WASH.
18
Adiustwindshieldwasherdischarge
nozzles.
Washsrl'etsshouldhit windshield10-20cm {4-8"}
from upperedgeand approx.35 cm ('12")from
door pillar
Adjust nozzlesby inseninga needlein metal in-
sen and rotateinsert.
Forwagonmodels:Also checktailgatewindow
washeraltonm6nt.
14
Group17,7,500Mile MaintenanceSevice
- ln car -
In car
Se,rviceevery 7,500miles = 12,500km
A1
Checkpower braketunction,
Removevacuumby depressingbrakepedal 5
trmes,
Depressbrakepedal,start engine.
Pedalpositionshoulddropslightlyif powerbrake
l!nctions.
Pressuretest brake system.

Keepbrakepedaldeprcssed20 secondswith low
oeoalDressure.
Repeatwith high pedalpressurefor 5 seconds,
Pedalpositionmust not drop.A drop indicates
brakeIluid leakage
or boostervacuumleak.
A3
Checkparkingbrake.
Applyparkingbrake. Adjustif it is notlullyapplied
afterpulling10-11 notches.
Afteradjustment,adequatebrakingpowershould
beobtained afterpulling2-8notches, pullingforce
approx.65 lbs. Adjustthroughrear of parking
brakeconsole.
Checkthat catchis operatingcorrectly.
Checkthat indicatorlight on instrumentpanel
goeson. Release leverand checkthat lightis out
whenleveris in bottomposition.
Yokeshouldbe at rightanglesto parkingbrake
lever.
lf yokeis askew,use nuts at cableendsto adjust.
Thereshouldalwaysbe at least2 mm threadpro-
rruotnq,
15
-lncar-
44
r lI t ,t"z
[.nftEIEIddLl
Checkwarning lights.
Tuln ignitionkeyto drivingposition.Checkthat
warninglights for charging,oil pressure,butb
failureand brakefailurecome on. Stan enoine.
Checkthat lightsgo off.
tt tt
Automatictransmission.checkshift
control.
Clearance in position"D" towardoosition"N',
shall be the same as clearancein position"2,'
towardDosition"1".
ou0
Check steering.
Turnsteeringwheelbackand fonh with wheels
restingon ground.
Checksteeringwheelplaywith wheelspointing
straightforward.
Jackup frontendand placestandsundercontrol
armscloseto wheels.
0)
Turnsteeringwheelfully to right and left posi-
tions.Checksteeringeffortand steeringgearfor
play.
0
16
Group17,7,500Mile MaintenanceSeruice
- Exterior, lubication -
Exterior- lubrication
Seflice everv 7,5(n miles : 12.500km
B1
Lubricatehood hinges.
Useoil canand heaw oil.
..\
82
Lubricatedoor hinges,door stops and

strikerplates.
Lubricate door hingeswith heavyoil. Use door
wax to lubricatedoor stops.
Checkthat latcheslock in both outerand inner
posrtrons.
Checkthat door stops are in working order and
providepositivelockingin intermediateand outer
oostt|ons.
BiJ
Lubricatetrunk lid (tail gatefor wagons).

Lubricatelid/gatehinges.Use heavyoil.
17
- Tircs, wheels -
On lift
o
Tires,wheels
Seruiceevety 7.500miles : 12,500km
0;
Checktires.
Checktreaddepth.Minimumallowableis 1 mm
atrpressure arrpressure l=1/32"1.
too high Checkwear pattern.lt may indicateunbalance,
incorrect
camber, tirepressure,
toe-inor incorrect
Checkthattiresmountedon bothfrontand both t^
rearwheelsarethe same(radial,cross-ply,
tread, U
studded).
0r)
0r)
a t- == =-1. Checktires and tire pressure.

qca riro h16.."ra lrh6l
Generally:
Economy andmax5 personsin vehicle:use36psi
front and rear,
Comfortandmax3 personsin vehicle:use26 psi
front and 27-30psi rear.
18
- Frontend -
c3
Checkwheel bearing play.

Rockthewheelat12and6 o'clockposition.
lfthere
is play,wheelbearings
shouldbe serviced
imme-
diately.
Checkwheel bearingnoise.
Letthe wheelfotatefreelyafterspinning.Check
wheelbearingfor noise.
Wheelbearings whichare not adjustedproperly
cancausenoise.
Frontend
D1
Se|ice every7,500miles: 12,500km
Checkfront shockabsorbers.
Visuallycheckshockabsorbers
for leakage.
NOTE:
Do not mistakemoistureon shockabsorberfor
reaKage.
Checkfront springs.
Checkspring attachmentand condition
Check steering gear.

Check
steeringgearrubberbellows
for damage.
Checkthatsteeringgearis tirmlyattached
by try-
ingto moveit by hand.
19
Gtoup17,7,500Mile MaintenanceService
- Frontend -
D4
Checksteeringrackfor play.
Jigglewheelat 3 and I o'clockpositions.
Check
playalongaxisof the rackand innersteeringrod
lornt,
ou
o, (
Checkcontrolarm bushingsand strut

attachment.
Turnwheelsfullyto eachsideandiigglewheelat
12and6 o'clockpositionsfor eachextreme.
o
check control arm bushings,shock absorber
spindleand upperstrutaftachment for play.
or0
Checksteeringrod play.
Jigglewheel at 3 and I o'clockpositionswith
wheelspointingstraightahead.
Judgement guideline:
Playalongradiusof wheelis not permittedand
shouldbe remedied immediately.
eI
0
D7
check ball ioints.

Vehiclerestingon wheels. Check
play.
Maximumplaypermittedis 3 mm (=1/8")Check
serviceimmediately
rubberbellows.lf damaged,
20
Group17,7,500Mile MaintenanceSeNice
- Frontend -
IN
Checksteeringrod ends.
Checkrubber sealsfor damage.Checkthat nuts
are locked.lf not, correctilnmediatelv.
Checksteeringrod for damage.Jigglewith a pair
of pliers.Checkthatjoint doesnot haveanywear.
Squeezejoints with a pair of pliers to checkfor
axialplay,as shownin illustration.
Rubbersealdamaged= serviceimmediately.
Roddamaged: serviceimmediately.
Joint worn = serviceimmediatelv.
l/laximumallowableaxialplayfor joint = 3 mm
El18"'t.
D9
Checkcontrolarms.
Checkcontrolarmsfor damage.
Checkcontrolarm bushingsusinga pry bar as
shownin illustration.
Checkfor wear,cracksor other damage.
Controlarm damaged= seiviceimmediately.
Bushingplay= serviceimmediately.
Bushingdamaged= serviceimmediately.
D'0
Checkstabilizerbar and links.

and rubberbushings.
Checkattachment
21
Group 17,7,500Mile Maintenance Setvice
- Brckes -
Brakes
E
Seruice evety 7,500 miles : 12,500 kfi
EXCEPT AS STATED
Checkbrakehoses.
Checkbrakehosesforleaks.Checkthathosesare
correctly
installed
andthatconnectionsaretioht.
Checkthatbrake hosesarenotchafedandareiree
lrom sharp edgesor other obiectsthat could
*a (
Gheckbrakelines.
Checkthat all brakelinesare correctlyinstalled
and secured. Also checkthat they arefreefrom
0)
d a m a g ea n d d o n o t . u b a g a i n sst h a r pe d g e s .
LnecKTor teakaoe
Checkparkingbrake.
Checkthat rubberbellows,outercablesand sus-
pensionarein order.
0
E4
0
Service at:
15-30-45-60-7 5-go.thousa nd mil es
25-5L7r100-1 25-150-th ousand km
lnteruals:15.0(nmiles: 25.000km
Checkwheel brakes.
Bemovewheels.Checkpadthickness witn mrrror
andwiregauge3 mm = 0.12".
lf pad thickness is lessthan 3 mm (wiregauge
cannotbe inserted), padsareconsidered worn.
lf wire gaugefits but liftleclearanceis left,pads
will haveto be replaced within lessthan 15,000
mtles.
Checkfor signs of leakageat caliperor connec-
tion.
22
Powertrcnsmission-
Powertransmission
F1
Serviceevery7,500miles: 12,500km
Diesel.
Checkclutchplay.
Checkfreeplayof clutchtork.lt shouldbe3-5mm
= 1/8"-3/16".
F2
B21F-Turbo+
B23E
Clutchnegativeplay.
Throw-out bearinghasa smallpre-load
appliedby
a springat pedalbracket.Pedaland clutchfork
musthavea freemovementrearward(=negative
play)to allowfor wear
Freemovementrearwardshouldbe 1-3 mm =
approx.5/64".
F3
--L N Tari-Tl 1
i IF -tt" Y+ Automatictransmission:
rr@r sfrifr 06
Adiustshift control.
Clearance betweenpositionsD and N shallbethe
sameas clearance betweenposition2 and 1.
lf necessary,adjustat the bottomend of gear
setecror.
F4
Checkpropellershaft and support

bearings.
Checkthat U-jointboltsaretight.Turnshaftsto
find out it U-jointsareworn.
Checksupponbearings for play.
and retainer
Checkthat rubberbellowsarenotworn or dama-
gedand arecorrectly installed.
23
croup 17,7,500Mile MaintenanceSeruice
- Rearend -
Rearend
Seflice every 7,500 miles : 12,500km
nra
Checkrearshockabsorbers. Checkrearsuspension,
Manually check shock absorberattachment. Usea pry barto checkbushings for trailingarms,
Checkfor leaks. brakereactionrods,trackrod andstabilizerCheck
Do not mistakemoistureon shockabsorber{or springattachment and condition.
teaKage,
{
NOTE:
There is no need to retor-
que all bolts. nuts etc
unlesspartsarefoundtobe
loose. Specificationsare
provided as a guide for
tighteningloosehardware.
Nm ft. lbs.
Rerctionrod:
A Bodyattachment 62
B Rearaxle attachment 62
T.ackrod (Panhardrodl:
c Rearaxleattachment 44
D Body attachment 62
RearSpring:
E Upperattachment 32
F Lowerattachment 14
Shockabsorber:
G Upperattachment 62
H Lowerattachment 62
Trailingarm:
I Bodyaftachment 110 .. 80
Rearattachment {atrearaxle). . .. . .. . . 125.. 90
Stabilizer:
J Frontattachment ( .shockabsorberl 85 62
K Rearattachment 45 32
Wheels:
.. . . .. . . .. . . . . 115 .... 85
Nuts,tightened criss-cross
0
24
T Group17,7,500Mile MaintenanceService
Exhaustsvstem Rearaxle.manualtransmission-
Service at:
1130-4860-7 s-go-tho usand mil es Checkexhaustsystem.
2 5-50- 7, I 00- 125- 150- t housand km Checkcondition,
alignmentand suspension.
t lntervals: 15.000miles : 25.000km
D24Diesel
Seruiceevery7,500miles : 12,500km
a Check rear axle.

Checkfor leakage and oil level.
Oil levelshouldbe up to fillerplughole.
FluidtyperAPIGL-5(t\4lL-L-2105 I or C)
ViscosityrSAE90
Whentemperature is steadilybelow15'F= -10'C,
useAPIGL-5SAE80 W oil.
Useoilswith properadditivesfor carsequipped
with limitedsiipdifferential.
*-
€**.*"
Manual4-speedtransmissionwith over-
drive,M46.
Checkfor leakage andoil Level.
Oillevelshouldbe
up to Jillerplughole.Transmission andoverdrive
arelubricated by the sameoil.
Fluidtype:AutomaticTransmission Fluidtype
ForG.
25
Group17,7,500Mile MaintenanceSeryice
- Engineoil and filter-
Gasolineengines
EMTSSTOwS
Se&ice every 7,500miles : 12,500km
NOTE:Turbofrequency,twice as
Replaceoil filter. J,
Oilfilteris normallyreplaced
at 15,000
mileinter'
vals.However.any adverseconditionsrequireoil
filterchangemoreoften,
Usespecialtool 2903to removeold oilfilter.Oil
newfilterrubberseal.Checkinstallation instruc-
tions on filter.
Screwon oilfilter by hand,retorqueif necessarys.
Mr
Drainengineoil,
Checkthat engine does not leak oil, fuel or
oil drainptug.
coolant.Reinstall
0r (
0r (
Gasolineengines Oil and filter changes

Replacedfirst time at 600-1,200mile('1,000-2,000
Ouality: km) insoection.
According to APIService SF(minimum). {Oilswith Subseqirentchanges:Mileageor time
specificationsSF,SF/CCand SF/CDcomply.) (whichever
comesfirst).Seechanbelow:
Syntheticor semisynthetic oils may be usedif
specificationscomply.
Fuel-saving oils are recommended, When using
suchoils,oil changeintervalsrecommended
Volvomust be Jollowed.
by ( 1 2 , 5 0k0m ) o r (6.2s0km) or
0
3,750miles(6,250
{ 1 2 , 5 0k0m )o r
0,'I
Viscositv:(stableambienttemperatures)
0
Adversedriving conditions:
- sustained
drivingin dusty/sandy conditions
- trailerhauling
sustained
- sustained
hill climbing
- sustained
highspeeddriving
- low speeddrivingor idling
sustained
whendrivingshondistances(7 miles= 10km)at
lowtemoeratures :
132'F 0" C).
sAE 15W40is recommendedtoruse in extemedrivinocondi

l i o n sr h a l : n v o l vhei g l "o i l l e m p e r a r uar en oc o n s u r p t , o n
e.q.
mountaindrivingwirhfrequentdecelerarions or fastmotoMay
driving.
Notehoweverthe lowertemperatu/e limits.
26
- Engineoil and filtet -
Dieselengine
EMISSIONS
Serviceevery7,500miles: 12,500km
Replaceoil filter.
Oilfilteris normaly replaced
at 15,000
mileinteF
vals,However,any advefseconditionsrequireoil
filter change more often.
Use specialtool 2903 to removeold oil fllter.Oi
new filter rubber seal.Checkinstallationinstruc-
tions on filter.
Screwon oil filtef by hand, retorqueif necessary.
Oillilter,diesel.
lf replacingoilfilter separately(no oil change)add
0.8liter = 0.85US qt.
J4
Drainengineoil.
Check that engine does not eak fuel or
coolant.Reinstalloil d r a i np l u g .
Ouality: Oil and filter changes.

According CD(minimum).
to APIService Oilswith Replaced rnile(1,000-2,000
firsttime at 6001,200
SE/CDand SF/CDcomply.
specifications km) inspection.
0 specifications
comply.
oils may be usedif
Syntheticor semisynthetic Subsequent
(whichever
changes:Mileageor time interval
comesfirst).Seechartbelow:
Drivlnsunderadverse E a c h7 , 5 0 0m i l e s( 1 2 , 5 0k0m )
c o n d i t i o n ss e eb e o w or everyth rd monlhwilh oiL
fiherchangeeverysecond
0 (stableambienttemperatures)
Viscositv:
t l o , m a la , r i n g
"ondiiiN
E a c h7 , 5 0 0m i l e s( 1 2 , 5 0 0k h )
or everysixrhmonthwnh oil
filter changeeverysecond
3p 2p -rp q rg 2p 30 4p "c
Adversedrivingconditions:
sustalneddriving in dusty/sandyconditions
sustainedtrailer hau ing
SAt1o!/Jo - s u s t a i n e hd i l c l i n r b i n g
- sustainedhigh speeddriving
sAEl5*/rr0
sustainedlow speeddrivlng or id ing
- when drivingshortdistances(7 miles= 10km) at
ow temperatures (32'F - 0'C).
Capacities:
D24i
o SAE15W40is recommendedfor useln extremedrlvingcondl-
t i o n sr h a ti n v o l v eh i g ho i l r e m p e r a r Lar n
mounlaind rivingwilh tfequentdecelerario
driving.
e dc o n s u m p t i oen. g ,
nso r fasrholo May
Excl.oll fi ter: 6.2liters: 6.6US qts
Incl.oi flltefi7.0= 7.4US qts
Difference betweenMin.and Max:1.0liters=
Notehoweverthe lowertemperature imits, I US qt.
27
- Ftuids-
- Engrnecoolrngsysrem
K'
Seryiceevery7,500miles: 12,500km
Volvoall weatherAnti-Frceze TypeC {b ue-s€en)shouldbe

usedall year .ound.Coolingsystemshouldalwaysconlain
waterplus anti-freeze, evendufing summer.Expenence has Coolant:checkanti-freeze.
a l s o s h o w n t h a t e x t r e m e l y w e a k a n l i - f f e e z e s o l u l i o n s ( 1 0 -Check
2 0 % ) coolantfreezingpoint.Fillcoolant(50%wa-
providepoor rusl prolection,For this reasonralio of anli-
treeze/summer coolanttowatershouldbe l to 1, ter, 50 % anti-freeze)to correct level.
Seruiceat: K2
3l)-60-90-thousand mi les (
50-100-1s(Lthousa nd km
Inbruals: 30,000miles : 50.000km
Replacecoolant. (
Removereservoirfiller cap. Drain coolantby
disconnecting lowerradiatorhose,
Fillwith new coolant(50%water,50%antifreeze).
Useonly VolvocoolantTypeC, blue-green.
Re-installfillercap.
Fluids
Serviceevery 7,500miles : 12.500km
K3 0
Brakefluid level.
In enginecompanmenL, checkbrale lines and
rese;voir
brake-fluid for leaks. I- (
Checkbrakefluid levelwithoutremovingcap.lf
brakefluid has to be relilled,use brakefluid
accordingto specification
DOT4.
) I
K4
Checkoil levelof power steering

reseryoU.
lf necessary, AutomaticTransmission
Fluidto
normal level.
Checkfluid levelwith eng;neidling while Jluid is
still hot from driving.Wipe reservoirclean.Fluid
levelshouldbe within markingson dipstickwhich
is attached to cover,
28
- Replacingautomatictrcnsmissionfluid -
K5
Battery.
Checkbatteryelectrolytelevel.(Fill with distilled
wateronlv,)
Checkbaftoryholddownbracketfortightnessand
that cablesare secured.
Automatictransmission:replacefluid
L1
Setuiceat: Checkcondition of Automatic Transmis-
22,t45-67.r90-t housand miles
37,5-7r112,r14r-thousand km sion Fluid.
Discolorationand smell can be causedby heavy
tnteruals:22.500 miles : 37.500km engineloads,suchastowing,
lf this is the case,removeand clean oil pan, oil
ForVolvos with automatictransmission, anoptional strainerand panicle magnet.Follow procedurcs
Volvoautomatlctransmlsslonotl cooler must be outlinedin L7-L10.
installedwh€n trailsr wgight exc€€ds2,000lbs =
908kgs.
Ov.rdfs should not bo u.sd whib towins. drainfluidby removing
Undernormalconditions.
ObseNelegalrequirements of the sratein whichthe drainplug.
vshicl€sa€ rcsist€rcd. FollowDrocedures
outlinedin L2-L6.
Drainingthroughdrainplug
L2
Dlain automatictransmission.
drainplug.
drainpluganddrain.Relnstall
Remove
\I'ARNING:
Oil can be scalding hot if vehicle was recently
driven.
Disconnectoil coolerreturn pipefrom

rearend of transmission.
Connectone end of a transoarentolastichoseto
oilcoolerreturnpipe.Letotherend ofplastichose
end in enginebay with a drip pan beneathhose
end.
29
- Replacingautomatictransm ission fluid -
Fill2 quartsol AutomaticTransmission

Fluid.
BW55:ATFtvoeF or G.
AW70/AW71:Dexronll.
S,
-
Runengine.
Stan engineand let idle.SwitchengineOFFwhen
alr bubblesbecomevisible in hose.
Fill2 quartsof AutomaticTransmission

0
Fluid.
BW55: ATF tvoe F or G.
AW70/AW71:Dexron 11.
Q. I
Runengine.
Startengineand let idle.SwitchengineOFFwhen
air bubblesbecomevisible in hose.
Checkconditionof AutomaticTransmis-
sionFluid.
Fluidmustnot carryimpurities,
sme .
discoloratjon
or I
(
L6
Reconnectreturn pipeto automatic
transmission.
Fill2 quartsof AutomaticTransmission

Fluid.
8W55:ATFtvoe F or G.
AW70/4W71:Dexronll.
,,..-.t
Adiusttluid levelas describedin L11.
30
- Replacingautomaticttansmissionfluid
Removingoil pan
Drainautomatictransmission.
fillertubeat pan and drain.
Disconnect
WARNING!
Oil can be scalding hot if vehiclewas recently
L8
Removeoil pan.
Cleanoil pan,strainerand particlemagnet.
NOTE!
Alsocleanoil cooler
Reinstalloil pan and filler tube.

D Applyoil to pan gasketpriorto installation.
new gasket.
Use
Torques: Nm ft.lbs.
- Fillertubeconnector 90 65
- Panbolts:
8 W 5 5y, e l l o wm a r k i n g . . . . . . . . . . 8 6
B W 5 5b, l u em a r k i n .g. . . . . . . . . . . 1 0 7
L10
Filloil.
Totalojl capacitycannotbe refilled.Approx.3.4
liters= 3.6qtswasdrained, the restbeingstored
in torqueconverter andcontrolsystems,
Fill2.9liters= 3 USqtsolAutomatic Transmission
Fluid:
- BW55:ATFtype F or G.
- AW70/AW71: Dexronll.
DONOTstartengineuntiloil is tilled.
Startengineand adjustoil levelas described
in
nextoperation.
31
grylp-ll,f -9!!Yl9A4! !9!t!ES9!, ice
- Checkinoautomatictransmissionfluid -
L11
Dipstickmarkings.
Seruiceevery 7,500 miles : 12,500km
ffil@lfM-ax-
Coldoil- oiltemperature Thisis a
+105"{+40'C)
normaltemperature afteridling
for transmission
below
for about10 minutes.At oil temperature
+40'C,levelmav be belowMIN mark.
Checkoil levelforautomatic
transmission.
Fluidto
fill AutomaticTransmission
lf necessary,
normal level.When checkingfluid level, car
shouldbe on levelgroundin PARKpositionwith {,
(
engine idling. lf topping up is necessary,fill
M "90'C throughdipsticktube.
NOTE:
Warmoil oil temperature
temperatureisobtained
+195"F(+90'c).This
whendrivingfor about30
minutes.At oil temperatureabove +90"C,level
Dipstickhasgraduations for hot and cold trans-
missionfluid.Whenchecking
ragthatwill not leavelint.
fluidleveluseclean I
maybe aboveMAX mark.
0 I
I
Group17,7,500Mile e Service
- 821and 823 -
Followingoperationsreferto 821and 823 (alll
M1
Seruiceevery 7,5(n miles : 12,500km
Automatictransmission:
Adiust kickdowncable.
Checkcablelengthat closedand open throttle
(engineoff).Adjustif necessary.
Open throttle measurementshould be checked
with throttlepedalin cardepressed,NOTby actua-
ting linkageby hand.
Closedthrottle: L = 1 mm = 0.04"
Openthrottle:L = 51mm = 2.01"
Setuiceevery 7,5(n miles : 12,500km
Checkenginecontrols
Checkjoints,bushings andthrottleshaftfor wear.
Checkthatcable,linksandspringsareserviceable
installed.
and correctly
Adlustplay.Lubricateioints,usinga lightoil.
NOTE:
Do not applylubricant
to cable.
Mi,
Service at: I EMISSTOIS
30-60-90- th ousand m il es
o 50- 1(n- 15O-thousadd km

ln|€,ruals:30,000miles : 50,000km
o Checkdrive belt tension.

lf necessary adlust.lt shouldbe possibleto de-
press drive belts 5-10mm = 3/16-5/16"halfway
betweenoullevs,
33
-T
- 821and 823: adjust valves-
B21and B23adjustvalves
N1
3(L60-!n-tho usand mi |es

50-104150-thousandkm
lnteruals:30.000miles: 50.000km
t,
Removevalvecover.
Turncamshaft to positionfor firingNo 1 cylinder.
Bothcam lobesfor No 1 cylindershouldpointup
at equallylargeangles.Pulleytimingmarkshould
be at 0'.
NOTEI
Alwaysturn crankshaft(centerbolt).
N2.
Cyl.1: usefeelergaugeto checkvalve
clearance.
Whenchecking,clearanceshouldbe:
e
mm = 0-010-0.018"
coldengine:0.25-0.45
hotengine:0.300.50mm = 0.012-0.020"
Whensetting,clearance
shouldbe:
mm = 0.014-0.016"
coldengine:0.35-0.40
0
mm - 0.016-0.018"
hotengine:0.40-0.45
Sameclearance
for intakeand exhaustvalves.
NOTE:
Alwayscheckvalveclearancewith cylinderat top
deadcenter.Alwaysturn 1/4turn aftertop dead
centerto set.
,v3 c
lf clearanceis incorrect:
Lineup valvedepressors,
Turnvalvedepressorsso that notchesareat right
angleto enginecenterline.
I
I
Attachtool 5022and deDressvalve

depressors.
Screwdown tool spindleuntil depressorgrooveis
just dboveedge ard accessiblew th plie's.
34
Gtoup 17,7,500Mile MaintenanceService
- 821and 823: adiust valves-
N5
Usetool 5026to removedisc.
N6
Use micrometer to measurcdisc thick-

ness.Calculatethicknessot discto be
used.
Example:
Measuredclearance0.50 mm. Correctclearance
0.40mm. Difference +0.10mm.
Measuredthicknesson existinq disci 3.80 mm.
Correctthicknesson new discw-illthus be 3.90+
0.10mm = 3.90mm.
N7
+
oo
Discsavailable.
From3.30to 4.50mm in incrementsof 0.05mm.
NOTE:
Installdiscswith marksdown.
N8
Posiiionnew disc.
It should be oiled.
N9
Removetool 5022.
35
-T
- 821and 823: adjustvalves-
N10
Cyl.3:
Rotateengine crankshaftto correct position for
Ir
firing No. 3. cylinder.Check clearanceas
'a 'n describedpreviously.

correctclearance.
lf necessary,
Cyl.4:
Repeatprocedure.
N12
0)I
Cy[2:
Repeatprocedure.
Nt3
t
Re-checkon all cylinders.

Turnenginea few turnsbeforechecking. f
Positionvalvecovergasket.
N15
Installvalvecover.
Hex10mm.
Torque:12.5Nm = 9 ft.lbs.
36
Group17,7.500Mile MaintenanceSetvice
- 821and 823: rcplacetiming gear belt -
B.21and B23treplacetiming gear belt
o1
SeNice at:
4rglr-thousand miles
7rls(Lthousand km
1l Inhruals: 45,000miles
= 75.000km
Lineup timing belt.

Removevalvecoverand rotateengineto line up
camshaft marks {shown),crankshaftand inter-
mediateshaft marks.Removeold belt.
02
Installnervtiming belt.
Timingb€ltshouldbe in goodconditionandfree
Irom greaseand dirt.
Firstplacetiming belt on crankshaftsprocketand
then on intermediateshaftsprocket.
Newbeltshaveyellowmarks.Two lineson timing
beltshouldtit towardcrankshaftmarks.Nextmark
shouldthen lit toward intermediateshaft marks,
etc.
o3
Stretchon tensionsideand fit timing belt

on camshaftsprocket.
o4
Fit timing belt on tensionerroller.

Useof toolsmay damagetimingbelt.
37
Group17,7.500Mile MaintonanceService
- 821and 823: replacetiminggear belt-
05
Tensiontiming beli.
Loosentensionernut to let springtensionaq on
rollerandthustensiontimingbelt.
Tightennut.
Ho( 17 mm
06
Checkmarksand torque nut.

Rotateclockwiseand re-checkmarks.
Torque:50 Nm : 37 ft.lbs.
o7
0,1
Installtiming gearcover.
Ho<10 mm
Group17,7,500Mile MaihtenanceSetvice
_ B21A_
B21AlGanada
Checks(haustsystem.
Checkcondition,
alignmentand suspension.
P2
@ Checkdamperoil level.
AutomaticTransmission
Fluidto 6 mm fromtopof
cylinder
P3
Checkchokecontrol.
CheckoDerationof chokecontrol.Checkthat
indi-
A
catorlightcomeson whenchokecontrolis en-
gaged.
39
- B21A-
P4
I Breakerpoints,checkcondition.
Worn points may indicatedefectivecapacitor
l,
b^
zAJ-+I l
lurq[! Botor,capand cables,checkcondition.
Alsocheckrubbersealsand attachments
f=7
[,
ChecUadrust
dwell angle.
Shouldbe:62"t 3". {,(
Run starter motor from remote staner oick-uo
point.
P6|
Check"Pulsair"air iniectionsystem.
Disconnectair hoseat air cleaner.
Checkthat air is beingdrawnin andthat no back
oressureexists, t, I
I
In caseof problems:
Disconnecthosesat Pulsairvalves,
Startengineand hold hand abovevalves.
should be suckedin through valves and
exhaustgasesbeforcedout.
40
Gtoup 17,7,500Mile Maintenance Service
- B21A-
Seryice following at:

25- 50-7 5-10O- 125- t 5 0-t h ousan d k m
NOTE:
@\-^ Drivingunderadverseconditions(forinstance
city driving under hot conditionslrequires
servicemore often (15,000mile intervals).
Volvorecommends cleaninqflame quaroaL
15,000 mile intervals.
Positivecrankcaseventilation.
Checkhosesfor conditionand clogging.Clean
nippleandflameguard.
D
Replacesparkplugs.
Sparkplugsmustbe tightenedto specifictorque
for properoperationand to avoid damageto
threads.
Sparkplugremovaland installation
mustbe peF
tormedwhenengineis cold{lowreadingon tem-
peraruregaugel.
)o B21A
Gap ... ... ... . ... ... . ... ... .
VolvoP/N273592-6(set of toud
or EoschWTDC
0.7-0.8mm : 0.028-0.O32'
Torque(plug threadsnot oiled) 20-30Nm = 15-18ft. lbs.
Lubricatedistributor
lelt wickin distributor
Removerotorandlubricate
shaftcentersparingiy.
NOTE:
Maximumamountof oil requiredis 1-2drops
i!
41
Group | 7,L! 99!79!3t!19!?!99s9ry@
- B21A-
or "lMag-
InstrumentsusedareVolvoMono-Tester P10
netic Timing Units" equipped with proper
adapter.
Checkand adiusttiming.
Disconnect
700-800
vacuumhoses.Disengage
tionerRunengineat a sufficiently
tor centrilugal
advanceaystem.
air condi-
lowidlespeed,
romto avoidanvinfluencelrom distribu-
o{
B21A:
7' at 750 rpm. I
I
CheckEGRvalveoperation.
Increaseenginespeed,Observemovementol
EGRvalverod in observation
housingwhenvalveopens,
window in valve el
Release throttlequicklvand observethat valve
closes.
checksolenoidvalveoperataon.
lf inooerative:
IIISPECTION
Functiontest.
1.cold enqine,@olantteFp.rature below+55oC.
ln caseof oroblems: EGBv6lvtshourdbe Llosedat a l sDeedsw h d cold engr.e
Performa more thorouahIunctiontesl.
tncrease rpm and checkthatEGBvalvedoesnot open Check
by observinqconrrolrod,seeillusnalion
IfEGRvalveooens.it is an indicationthatthermostaticvalve is
0'l
defectiveand should be replaced.lr should nol open unlil
c o o l a n t t e m p e r a thuar esr e a c h e d5+5 6 0 ' C = 1 3 0 1 4 0 ' F
0ra
2. W.rm engine,coolanllemperaruteabove+ 60'C
EGBvalveshouldooenal rDmsaboveidle speedwrlh warm
il
Rur engineuniilit reachesnormalope.atingtemperature
I
lncreaserom above id e speed.Checklhat lhe EGRvalve
o p e n sl .f i a d o e sn o t o p e n , t r a c e f a u l t a c c o r d iinngsttor u d i o n s
L e t e n a i n e ied. c h e c k t h a t E G F v a l v e c l o si tedso. el fs n o t c L o s e ,
discoi;ectvacuum hoseat EGRvalve.lt EGBvalveclosesnow
il indicatesa defedivevacuumamplifie..Try a newone.
lf EGRvalvedoesnol close.it is stuck.Bemoveand clean {; (
42
Group 17,7,500Mile MainrcnanceService
- B21A-
Alternarive
ted method,
D meihodisto usethe stong vacuumdeated
An ahernaiivetesi
in enqineintakemainfoldal idle.The connectionis lsed for
vacuunconrrolofignitiondistriburoror for powerbrakeunrt,
lfthisvacuunisconhected to EGFvalvewhenen9ineisidling,
valveshouldopen.Exhaostgases aredivertedto engineandit
shouldrun very poorlyor stop-
Chsking lhsrmostaticvalve.
1o Engineat opefatingtemperat!rebut nol running.

Disconnedvacuumhoseat EGRvalveand vacuumamplifier
lcornectionmarked"B'). Use mourhto blow throughand
checklhat thermostaticvalveis open and vacuurnlinesnol
f thermoslaticvalvedoes no1open,first checkthal coolanl

iemperatureis high enooghto open. coo a Gmperatu.e
+ 6 0 ' C= 1 4 0 ' F .
s h o u l db ew e l l a b o v e
)D
s
:
Cleanfuel pumpstrainer.
Alsocleanfuel pumpsludgeaccumulator
Carefullycheckseal and s;aling surfacesbefore
re-installing.
ID
P13
Replaceair filter cartridge.

Whendrivingunderdirtyanddustyconditions, air
filter cartridgeshouldbe replacedmore olten.
Fordry, dusty,pollutedregionsan air tiltercart-

ridgewith superiorfilteringabilityis available.
lt
D shouldbeusedonlyin suchregions.
intervals
dependon operating
Replacement
conditions
43
- B21A-
Pl4
Checkcentrifugaladvance.
Runengineat 2,500rpm (= 1,250
Vacuumunit disconnected,
distributor
Timing point should increaseconsiderablv,
rpml.
to
cDl
approx.25-30'BTDC.No increase, or smail in-
crease, indicates defective distributor mecha,
nism.
Pl5
CI.
Checkfuel linesfor tightness.
Checkthatthereare no tuel leaksin enginecom-
panmenL
Alsocheckfor oil andfluid leaks.
COemissionscheck
B21A,Canada
{,
Serviceat:
25-50-75-100-125-150-thousand km
lnteruals: 25,000km
0
a1
ConnectCO-meter.
Insertprobeapprox.40 cm = '16"into exhaust
ptpe.
Connecttachometer.
Formeasuring
rpm, I
- B2lA COcheck-
DisconneqtPulsair.
Disconnecthosefrom a t r cleaner.Plug discon-
necteoend,
Adlustidle speed.
Engineat normaloperatingtemperature.
During
and afterCOadjustment,idle speedshouldbe:
900 1 50 rDm.
D a4
CheckCO.
COvaluesof 2.5-4.01" arc permitted,provided
engineruns properly.Priorto readingsincrease
enginespeedmomentarily to 1500rpm to allow
coldfuelto entercarburetor,
a5
COsetting.
lnitialCOsettingis madeat thefactoryandshould
notneedto bechanged. TheCOadjustment screw
is sealedfrom access.lf COis outsidelimits,and
all othercausesfor incorrectCO readingshave
beenchecked, usethe procedures thatfollow
@ adjustment.
lf COis outsidelimits,it shouldbe setto 3 %.
0 Theadiustment screwis sealedwith a flatwasher
and a lockwasher,
45
- B21ACOcheck-
COadjustment: a6
Removepistonassembly.
Removepiston, diaphragmand fuel needte {) (
assembly
from carburetor
Removeretainingscrewfor fuel needle.
COadiustment: a7
Pressup adiustmentassembly.
Pressup fuel needle and adiustmentscrew
approx.810 mrn,use a tube,outerdiametermax.
f_l
7 mm and innerdiametermin.3 mm, length100
mm.
COadiustment:
a8
{l
Pressdown adiustmentscrew.
Usea ounchmax.3 mm diameterto oressdown
screwto bottomposition.Upperlock
adlustment
washershouldremainat top. {
COadiustment:
a9
Removelockwasherand flat washer.

Turnlockwashersideways andusea steelwireto
removeit, Shakeout flatwasher
t,' I
46
.t- Group17,7,500Mile MaintenanceService
- B2lA COcheck-
410
o Pressdown lower lock washer.

Usetool 5159.
Installretaining
screwlor fuelneedle.Install
piston, diaphragmand needle assemblyin
carburetor.
COadjustment: alt
Priorto checking@:
- Checkdamperoil level.
- Installdamperplunger.
- Momentarilyrevengineto 3000rpm (50r/s)
COadjustment: 412
Adiust@.
Use tool 5159to adjustluel needlepositionin
carburetor.Adlustingrangeis approi. + turns.
Turning tool clockwise increasesCO. counter-
clockwisercducesCO.
Makesure tool lugs grip recesses in air valve
spindle.Otherwisecarburetordiaphragmmay
oecomedamageo,
COadiustment: 413
Install@ adiustmentseal.
Removedamperoil. Use paperto absorbit or
removeoistonand oourit out.
InstallnewIlatwasherandnew lockwasherUse
tool 5159.
o Filldamperoil and installdamperplunger
47
Group17,7,500Mile MaintonanceSeruice
- B21ACOcheck-
au
ReconnectPulsair.
Checkthat @ drops.
To confirmthat Pulsairis functioning.
l-10
.0
Adiust idle speed.

Engineat normal operatingtemperature.Duing
and after CO adjustment,idle speedshould be:
900 t 50 em.
o
48
- B21F-Turbo-
t
B21F-Turbo
Seruiceevery 7,500miles : 12,500km

R1
Tightennuts,checkfor leakage.
Exhaustpipeto turbo(threenuts)
Hex:13mm
Torque:22-25Nm 16{8ft.tbs.
821F-Turbo:
Checkadiustmentsealing.
Sealon controlrod from pressurercgulatorto
wastegateactuatormust be unbrokenand intact,
Sealcanbe a compressed sleevenut or wire and
leadseal.
Anti-tamperseal.
It isimportant
to windwiretightlyaroundactuator
rod,as shown,otherwisesealwill loosendueto
vibrations.
Volvoanti-tamper sealtongs,PartNumber998
6408-4have"Volvo"stampedon grips.
NOTE:
Tamperingwith emissioncontrolcomponents
t may be a violationof Federal
regulation.
133212
49
- B2lF-Tutbo
B3
Torqueclampscrews.
Fourclamps,two at eachendot intermediate
betweencompressor
betorqued,
andthrottlehousing,
pipe
should ol
Torque:3 Nm:2.5 ft.lbs.
"' cte
Connectpressurepump and gauge.
Usepumpandgaugenormallyusedto testradia-
tor pressure.
- Volvotools:pump998-5496
999-5230.
andpressure
gauge el,l
Connect air pressure
to distributor unit.Plughose
removed.
gs,i)
Connectinstrumentto checkLamboa
systemduty cycle.
Forthispurposea highqualitydwellmetercanbe
used.Scalemustextendto at least70"{4-cyl.set,
rngl.
Dwellmeteris connected
otcK-uo,
to Lambdasondservtce
0-r
DIELL
0-rl
R6
Checktiming retard.
Startengine,run at idle. Note ignitiontiming.
Pumppressure to 36 kPa= 5 osi.
lgnitiontimingshouldretard6-10'.In caseof
incorrect reading: checkdistributor,
replace
distributorpressure unit,as appropriate.
Reinstalland clamoDressure hose.
I
50
Gtoup 17,7,500Mile Maintenance SeNice
- B21F-Turbo-
R7
0
Checkfull load enrichmentsystem.
Connectair pressurepump and gaugein line
leadingfrom intakemanifoldto pressure
switch
on firewall.
Enginerunning,pumpairpressure untlldwellme-
ter{measuringdutycycleof Lambdasondsystem}
displayssteadyreadingof 58.5"(56-62'allowed).
Air pressure
readingat thatinstantshouldbe20.3
kPa= 2.9psi.
J DITL
"./ (c
R8
Checkoverloadprotestionswitch,
Pumppressureuntil enginestalls,Air pressure
=$4.,,,
jl .^. 1
readingshouldbe 70 kPa= 10psi.
At the sametime air pressuregaugeon instru-
ment panelshouldgo to red and red "Turbo"
l0 -'l71,--1''.. warninglighton instrument
nate.
clustershouldillumi-
In caseof incorrect
reading: replaceoverload pro-
tectionswitch (insidefirewall,ciose to clutch
pedalbracket).
rD
51
Group 17,7.b00Mile Maintenance Service
- B21F-Turbo-
Seruiceat:
15-30-4, 60-75-90-th ousand mi les
25-50- 75-100-12r15$-th ousand km
lntervals:15.000miles: 25.000km
Lubricatedistributor. 0) |
feltwickin distributor
Removerotorandlubricate
sha{tcentersparingly.
NOTE:
Maximumamountof oil requiredis 1-2drops.
{_l
30-60-90-thousa nd m il es
km
so-1oo-lsLthousand
Intelals: 30.000miles = 50.000km
{l
Replaceair lilter cartridge.
air
Whendrivingunderdirtyanddustyconditions,
filtercanridgeshouldbe replaced
moreoften.
30-60-90-th o usand n i les

50-1 00-150-th ou sand km
i: "_'+,r _
lnteNals: 30.000miles: 50.000km
I
--, :;;:- -
, Replacesparkplugs.
f.]--i3i Sparkplugs must be tightenedto specifictorque
for proper operation and to avoid damage to
threads,
I
Sparkplug removaland installationmust be per-
formed when engineis cold (low readingon tem'
peraturegauge).
B2'lF-Turbo (setof four)

"Super"sparkp ug VolvoP/N273594-2
or BoschWRTDS
fr,
Gap................. 0.7-0.8mm : 0.0280.032'
Torque(plugthreadsnotoiled) . . . . . 20-30Nm : 1F22 ft. lbs.
52
- g2lF-Turbo-
30-60-90-thousand miles
50-100-150-thousand km
0 Replaceorygen sensor.
Applyanti-seizecompound"Never-Seez" to sen-
sor threadsprior to installation.Coat entire
thread.Do not applycompoundto slottedpart o{
sensor.
Torque:55 t 5 Nm = 40 t 4ft.lbs.
Checkelectrical
connections,
120395
r0 30-60-9 O-th o usan d m iIes

50-100-150-th ou sand km
lnteruals: 30-000miles : 50.000km
ResetLambda-sondremindetlight.
Removepanelandswitchcover.Pressbutton.Re-
panel.
installcover
Seruiceat: 60.(n0miles:100.000km
lntervats: 60-(n0 miles : 1N,000 km
) 0
)
Replacefuel filter.
Fuelfilterlocatedon Iirewall.Noteflow direction
arrowon filter
53
Group17,7,500Mile MaintananceSeNice
- B2lF-Turbo-
Seryiceat: 60,(nOmiles= 1(n.0anknt

tnEwals: 60,000miles: 100,000knr
NOTE:
Drivingunderadverseconditions (for instance
city driving under hot conditions)requires
servicemore often (15,000mile intorvals),
Checkhoses for condition and clogging. Clean
ntoDle,
nr6 o
ln'€wals: 60,(n0miles= 100,Unkm
tr*'e -
'Tr
It
qI
{n
.!F
E'@<@I
Replacefuel tank filter.

Usetool 5169to romovoand reinstallfuel gauge
sender.
o
54
Group 17,7,500Mile Maintenance Scrvice
- B23F -
0 B23F
30-60-90-thousand m i les
50-1 00- 150-tho usand km
lntetvals: 30,000 miles : 50,000km
Replaceair filter cartridge.

Whendrivingunderdirtyanddustyconditions,air
filterca.tridgeshouldbe replaced
moreoften.
)0
Fordry, dusty,pollutedregionsan air filtercart-
lt
shouldbeusedonlyin suchregions. Replacement
irtervalsdependon operatingconditions.
I
30-60-90-thousand mi les
50-100-1so-thousand km
Intervals: 30.(n0 miles :
)
tf:' '
4':;:7' - Replacesparkplugs.
Sparkplugsmustbe tightenedto specifictorque
) D for properoperationand to avoid damageto
tnreads,
Sparkplugremovaland installation
mustbe per-
formedwhenengineis cold{lowreadingon tem-
peraluregaugel.
B23F (setof four)

"Super"sparkplugVolvoP/N273594-2
or BoschWRTDS
t Gap.................
Torque(plugthreadsnot oiled) . .. . .
0.7-0.8mm = 0.028-0.032'
20-30Nm = 15-22ft. lbs.
55
Group17,7,500Mile MaintenanceSetvice
_ B23F
30-60-90-th ousand m i les

50-100-t so-thousa nd km
Intelals: 30,000miles = 50,000km
Replaceoxygensensor.
compound"Never-Seez"
Applyanti-seize to sen-
sor threads prior to installation.Coat entire
o,
thread.Do notapplycompoundto slottedpartof
T o r q u e5:5 t 5 N m : 4 0 t 4 f t . l b s .
Checkelectrical
connections.
3(L6t0-90-thousand mil es
5(L100-150-tho usand km
teruals: i0,000 niles : 50,000km
cl
ResetLambda-sondreminderlight.
Removepanelandswitchcover.Pressbutton.Re-
panel.
installcover
cl
Serviceat: 60,000miles:100,000 km
tnteNals: 60,000miles : 100,000km
t) !
LH-Jetronic:
Replacefuel filter
Fuelfilterlocatedunderneath
car,underlelt rear
seat.
Removefuel tiller cap

Cll
To preventvacuumin tank when replacingfuel
filter
Disconnectfuel linesat tuelfilter.

lmportant:
0)l
Have a vessel ready when looseningfuel filter
connections.Fuel in fuel system (not tank) will
come out,
Replacefuel filtel
Bemove clampretainingfuelfilterto bracket.
Transfer
bracketto newfuellilter.
Noteflow direction on fuelfilter.
Installfuelfilterand clampassemblyto bracket.
Checkfuelflow directionon fuel filter.
Connectfuel linesto fuel filter.
Makesurecoppersealsarecorrectly
;nstalled. I
Installluel filler cap.
56
Group17,7,500Mile MaintenanceService I
B23F,
Serviceat: 60.0(n miles : 100.000km

lntelals: 60,000 fiiles :
NOTE:
0 Drivingunderadverse (forinstance
conditions
cirv driving under hot conditions)requires
servicemoreoften(15,000 mileintervals).
Volvorecommends cleaningflame guardat
15,000 mile intervals.
Check hoses for condition and clogging. Clean
nippleand flame guard.
Seruiceat: 60.000miles : 100,000km

lnte|als:60,000miles:100,000km
0 .ll
6e-<t-
tt]i
JH
-<@
Reolacefuel tank lilter-

fuel gauge
Usetool 5169to removeand reinstall
sender.
)'0
57
- D24 diesel -
D24diesel
o(
Seruiceevety 7,500miles = 12.500km a1
Drainingcondensate.
a panunderscrew2 to collectcondensa-
Position
Loosenbleederscrew1 severalturns.
Loosendrainscrew2. Drainuntilcleanfuelflows
out. Tightenscrew
ol
Tightenbleederscrew1.
cl
a2
seNice at: 1r30-4r6o-7r90-thousand mites
25-50-711 0O-125-tso-thousa nd km
: 15,000miles =
0)
Remove hose,Cleanhoseandconnections, Check
hosefor damages,replaceiI necessary.
Hosemustbeinstalled sothatno oilwilldraininto
air intakemainfold.
0il
Seryice at:
30-60-90-thousand
50- t(n- 150- thousand km
lnt€rvals: 30,0(n miles : 50.000km
Coolingsystempressurecheck.
Connectpressuretesterin hosebetweenradrator
andexpansion tank.Thisway coolingsystemwill
becheckedin trueworkingconditions.
shouldbe65-85kPa: 9-12psi.
Capreliefpressure
When pumped,pressure shouldstandfor mini-
mum 30seconds.
I
123136
58
Group17
- D24 diesel
30- 60- !n- thou sand mil es

50- 100- 150-th ousand km
Interuals:30.000miles:50.000 km
, Replaceair filter cartridge.

Fordry, dusty,pollutedregionsan air filtercan-
lt
shouldbeusedonlyin suchregions. Replacement
intervals
dependoF operatingconditions.
Serviceat: EMtSSIONS
30- A0- 90- thousand mi les
50-100-lso-thousand km
lnteruals: 30,000miles : 50,000km
Replacingfuel filter.
i0 Positionoil fiherwrenchas high up on fuelfilteras
possible.Removefilter.
Apply dieselfuel to rubber seal on new filter.
lnstallseal.Tightenby hand unti sealmakestight
fit. Thentighten1/4turn by hand.DO NOTuseany
tools to instal fuel filter.
Startengineand checkfor leakage.lf rubber seal
does not seal properly,air wiLl be sucked into
systemand impair operation.
r7 30- 60- 90- tho usan d mi les

50- 100- 150- th o usand km
lntervals: 30,0oo miles : 50,000km
Fuellines.
Checkfor leaksffom supplyand returnlines,as
we I asfromdeliverypipesystemandfuelsystem
Torquefor deliverypipesis
Repairas necessary.
25 Nm : T8ft.lbs.
30- 60- 90-th ousand mi les

50- 100- 150- thousand km
lntervals: 30,000miles : 50,000km
Checkdrive belt tension.

lf necessary
adjust.lt shouldbe possibleto de-
pressdrivebelts5-10mrn = 3/16-5/16"haltway
betlveenpulleys.
I
-
- D24diesel:valveclearanceacliustmpnt
Valveclearance
adjustment
Specialtools: 5195Pliers Seryice at:
Forremovingvalvedepressor
disc. 30- 60- 90- tho usand rn iles
50- 100-, so-thousandkm
5196Prcsstool Inte&als: 30.000 miles : 50,000krn Q,, {
Forvalvedepressors
Afterrepairsto the cylinderhead,for examplegrindingvalves,replacing
camshaft
etc,valveclearance
shouldbe re-checked km : 600-1,200
afterdriving1000-2000 miles.
bl
Removevalvecover
b2 cl
CylinderNo.1.
Usea 27mm - 1-1l16" socketon vibrationdamper
boltto turn engineto positionfor firingon No.1
cylinder.BothcamlobeslorNo.l cylindershould
pointup at equallylargeangles.Flywheeltiming
cre
markat 0.
b3
Checkvalveclearancefor cylinderNo. 1. ()
coldengine(= at roomtempera-
Valveclearance,
ture):
lntakevalves:
mm = 0.006-0.010".
0.15-0.25
Exhaust
valvesl
mm - 0.014-0.018".
0.35-0.45
warmengine1: nearoperating
Valveclearances,
temperature):
cl
123156
NOTE:
lntakevalves:
mm = 0.008-0.012".
0.20-0.30
Exhaustvalves:
cl
Alwayscheckvalveclearance with cylinderat top
dead center.Alwaysturn 1/4turn after top dead mm = 0.016-0.020".
0.40-0.50
centerto set. is requiredif valveclearances
arc
No adjustment
withinthesecheckvalues.
Ir][l Lr tl rlf rl
| - intakevalve
A : exhaustvalve
A]EA] Al [A tA--']t4 O
60
GrouD17.7,500Mile MaintenanceService
- D24diesel: valve clearanceadiustment-
---rlr- Incorrent clearance,adiustmentrequired----r
M
Tum engineapprox.1/4turn.
Enginemust not be at top deadcenterwhen set-
Withpistonattopthereis no
tingvalveclearance.
spacelor depressing.
b5
Depressvalve depressors.
Line up valve depressors.Turn them so that
notchespointslightlyinward.
Use tool 5196to depressvalve depressors.De-
pressorgroovesmust be abovethe face so that
disccan be grippedwith pliers5'195.
b6
Removedisc.
Use pliers5195,
b7
Calculatethicknessof discto be used.

Valveclearanceswhen setting:
Coldengine:
lntakevalves:0.20mm = 0.008".
Exhaustvalves:0.4Omm = 0.016".
Warmengine:
lntakevalves:0,25mm : 0.010".
Exhaustvalves:0.45mm = 0.018".
to measurediscthickness.
use micrometet
61
Group 17,7,500Mile Maintenance Setvice
- D24 diesel: valve clearcnce adjustment-
b8
Calculatedisc thickness.
Discsare available
in thicknessesof 3.00to 4.25
mm in incrementsof 0.05mm. lt is advisable to
usemetricmeasurements to simplifycalculation,
(US:approx.0.1181"
to 0.1673"jn increments
of
0.002").
Useonly newdiscs.
'@l
Positionnew disc.
It shouldbe oiled. cl
Installwith marksDOWN.
bl0 0)
Checldsetvalveclearancefor remaining
cylinders.
Usefollowingcylindersequence:
1,5,3-6-2-4 0rI
{_)
b11
Recheckvalveclearancefor all cylinders.
Rotateengineseveralturns beforerechecking,
Adjustif necessary.
b12
Installvalvecover.
Usenewvalvecovergasketif required. {)
62
F
- D24diesel:idle speeds-
Setting idle speeds

Serviceat: IEMtSSfOflS
30-60-90-thousandm iles
:l 50- 100- 150-thou sand km
lnbrvals: 30,000miles : 50,000km
c1
Connecttachometer.
UseVolvoMonotesterand adapter9950.
lf Volvo Monotesteris not available,use
photo-electric
tachometer(VolvoP/N999
9795-9or 9990901-2, or similar).
c2
r0 Runengineto normaloperating
temperature.
c3
Checldadiust
low idle speed.
Shouldbe 750 1 50 rpm. Applytamper
sealon screwand locknut with paintafter
I adJustment,
c4
)e Checuadiusthigh idle speed.

Maximumspeedis 5200t 100rpm.
Applytampersealon screwand locknut
with paintafteradjustment.
DONOTraceenginelongerthanabsolu-
tely necessary.
)0 cp
Removeinstrument.
c6
ChecUadrust
enginecontrols.
I This shouldalwaysbe done after idle
adjustment.
63
- D24diesel:enginecontrols-
Setting enginecontrols
Seuice at:
30-6lr-9g-thousa nd miles
50- 10(L, sl)-t housand km
tnteryals:30,000miles=
d1
Coldstart device.
lf engineis cold,cold startdevicemust be dis-
engagedbeloresettingcontrols.
Losenscrew1,pushleverforwardand turn sleeve
90'.
NOTE:
DO NOTtouch screw2. lf this screwis loosened,
cold startdevicemust be re-seton test bench,
Engdged
123169
d2
Disconnectlink rod at leveron

iniectionpump.
Adiustacceleratorcable 0tl
Turncablesheathuntilcableis stretched
but does not inlluencepulleyposition.
Pullevshouldtouchidlestoo.
0tl
d3
Checkmax acceleratorposition
Depressaccelerator pedal lully. Pulley
shouldtouchfull speedstop.
0 I
64
9!9!.PlLlp99!t!9!9!p ,ice
- D24diesel:enginecontrcls-
d4
Connectlink rod to iniectionpump

lever.
Adiustlink rod in max. position

Turnpulleyto max.position. Adjustlink
rod lengthso that injectionpump lever
touchesmax.speedadjustingscrew.
d5
t
Adlust link rod in idle position
Returnpulleyto idlestop.Movelinkrod
balllointin oblongholein injectionpump
leveruntil levertouchesidle adjusting
D Re-adiustlink rod
d6
Bepeatoperations 7 and8 untilcontrolis

correctlyadjusted.
A clearanceof max 0.3 mm = 0.012"is
permitted between pulley and max.
speedstop.
Re-connest
cold start device
(lf disconnected)
Service at:
15-30-4160- 7s-gFthous and mil es
2r50-7r1 0O-12r1 5o-thousand km
Intelals:15,000 miles: 25,000
Automatictransmission:
Adiustkickdowncable.
Depressacceleratorpedal to floor. Kickdown
cableshouldmoveapprox.52mm : 2.05"be-
tweenend positions,
Kickdown in idleposi-
cableshouldbe stretched
tion and distancebetweenkickdowncableclip
andcablesheathshouldbe 0.25-1.00mm : 0.01-
o.o4".
65
G.oup 17,7,500Mile MaintenanceSeruice
- Servicesat 75,000miles -
Diesel
MaintenanceServices
at 75,000mib (125,000
km) intervals
Thefollowing maintenanceserviceitemsareto be performedat 75.000mile (125.000
km) intervals.
Beadthroughand understandtheseitemsso that they are knownshouldit be necessaryto perform
them at an earlierlnterval(i.e.during repairsetcl.
C o m p r e s s itoens t. . . . . . . . . . . . e'l-e10
Checking/adjusting injectors t1-f7
Beplacingtiming gear belts s1-933
- D24 diesel:comprcssiontest-
Compressiontest Seruiceintervals:
Specialtool: 5191 (nipptelto
Adapter connectcompressrontester. 75,@0 miles : 1 ,000 km
0 e1
Disconnectwire at stop valve.

pumpwill not pumpfuelandfuelspillis
lnjection
therebvavoided.
e2
Removevacuumpumpandvacuum
pumpplunger.
e3
Clean.
Throughly clean luel delivery pipes and
connections,
e4
Removefuel deliverypipes.
to preventdin fromentering
Plugall connections
fuel system.
67
- D24 diesel: comptession test -
e5
Removeiniectors.
Use27 mm socket{VolvoP/N 1158146) = 11116".
Lift out heat shieldsunder injectors,Otherwise
rheywillfly up during compressiontest.
After removinginjoctors.injectortest scheduled

at 75,000miles = 125,000km, should be perfor-
meo.
Compressiontest
Positionheat shieldin cylinderhead,Screwin

nipple5191and seal.Torqueto70 Nm = 50ft.lbs.
Connectioncompressiontesterto nipple5191.
Run€nginewith startermotorand readcompres_
sronoressuro.
<7ONm
5191
Correctcompressionpressures:
- New engine:3.2 MPa= 455 psi.
- Minimum:2.4MP. = 340psi.
- Max.differencebetweenrylinders:0.8 MPa=
115psi.
128153
-r - - - ---- -- - - - - rrE-I
e7
25 Nm
Installiniectors.
Positionnew heat shield in cvlinderhead
lnstallinjectors,Torqueto: 70 Nm = 50 ft.lbs.
25 Nm = 20 ft.lbs.
124154
68
Group 17,7,500Mile Maintenance Service
- D24 diesel: compression test
lnstallfuel deliverypipes.
Torqueto:
25 Nm = 18ft.lbs.
Connectwire to stoo valve.
0 ,','uo
e10
Installvacuumpumpplungerand
vacuumpump.
CheckO-ringon vacuumpump,replaceit neces-
0
- D24 diesel: injectors
Checking/adlusting
injectors
Serviceonly in caseof iniectormalfunction.
Extremecleanlinessmust be observedwhen The fuel jet duringtestingN4IJST NOTcome in

workingwith injectors.Any contamination will contactwith anypartofthehumanbody.Because
causemalfunction ofthe fuelsystem, of the high pressure,the fuel can penetrate
the
Testsandrepairsshouldbeaccomplished in a dirt skinandcausesevereinjury,Therearemanyex-
anddustfreeareas, amplesof bloodpoisoning and amputation.
Fortesting,only usetestoil or filtereddieseloil. N4any statesrequireoperationoJ air evacuation
GasolineMIJST NOT be used. Volatilefuels
maycauseexplosron.
equipment duringtestingof dieselinjectors.
fuelfumesmay be dangerous if inhaled.
The Oi I
When testing.opening pressureand injector

tightnessaremost important.Spraypatternand
One must considerthat real injectionis into a
comoletelvdifferentenvironmentthan the test
0r I
iniectionsound are more difficultto assess. bay.Ouiteoften injectorsfunctionsatisfactorilyin
They do not give any satisfactory
indicationof the enginein spiteof questionablespraypattern
nozzlecondition. andiniectionsound.
f1
Installiniectorin iniectortester.
Seal fuel return line connectionswith rubber
plugsand hoseclamps.
0rI
f2
c)|
Checkspraypattern.
gaugedisengaged.
Pressure
Pumpwith short,quickstrokes(4-6strokesper
Sprayjet should be fairly compactand stop
abruptly.
Injectormustnot drip.
70
Group 17,7,500Mile Maintenance Service
D24 diesel: injectors
f3
a Checkiniectionsound.
gaugedisengaged.
Pressure
Slowlydepresstesterleverfully (1-2strokesper
A corect iniectorwill whir duringspray.
f4
0
Checkiniectoropeningpressure.
Pressuregauge engaged,
S owly depresslevef and read injector opening
pressure.
It shouLdbe 12"13MPa: 17001850psi.
lf openingpressureis incorrect,first performleak
test (nextoperation)before adjusting.
0 f5
Leaktest.
,0 Prpc<"ro .r".6 6n.rno.l
Wipe injectornozzle.Pump pressure11 MPa =

1560psi and retainthis pressurefor 10seconds.
Theremust be no fuet drip fronrnozzle.A moist
nozzleis acceptable.
f6
Adjustinginiectoropeningpressure.
Opening pressure is adjusted by washers.
Washers areavailable in thicknesses 1.00-1.95 mm
= 0.040"-0.0768" in incrernents of 0.05 mrn :
0.a02".
A 0 . 0 5 . n mt h i c k ewr a s h e ' w i liln c r e a soep e r i n g
pressure by approx.5kPa= 7 psi.
0 Fordisassembling injectors, seeinstructions that
71
- D24 diesel: injectots -
f7
a-
wtrf uppernozzre
retainer Disassembling
iniectors.
Makesureoutsideof iniectoris clean.
- Disassemble injector.
PartsN4UST NOTbecome
openlng oamageo.
pressure cannotbe reused.
needleisdropped,it
lf a nozzle
lmmersepans in cleandieseloil immediately
Spring afterdisassembling.
- Makesureall partsfor one injectorare stored
Thrustpin togetherand not mixedwith partsfrom other
rnlectors.
Cleanand checkparts.
Guide - Use cleandieseloilto cleanall pans.
- Use nozzlecleanertool to clean nozzleneedle (
and nozzlesleeve.
Replacedamaged parts. Nozzle needle and
nozzLesleeveare matchedand replacedas an
assemDty,
Nozzlesleeve Assemblinginiectors.
- Usecleangasoline
to cleanstoragegreasefrom
- Thenimmersenew partsin dieseloil priorto
assemDry,
retainer
Assemble Torqueto 70 Nm = 50ft.lbs.
injector.
- Re-testinjector.
tD
@l
0l
ft]
Prepareiniectorfor installationor storage

Femove iniector from tester. lnstall orotective
caps on pipe connection.
Protect nozzle from damage when installing
Intector.
72
G,oup1f.2fl9!!9J!jt!E!9!99f !9!
D24 cliesel:timing geat belts -
Replace:- Timing gearbelt for camshaft

- Timinggearbelt tor iniectionpump Serviceinteruals:
- ldlerpulleylor camshafttiminggearbelt 75,000miles: 125,000
km
g1
Disconnectbafterygroundcable.
o Jackup vehicle.
Usefrontrightjacksupport.Whendrainingcoo-
lant,it runsa ong spiashguardunderengineand
doesnot messfloor,
Placevesselunderleftsteeringrod,
e g2
g.l Draincoolant.
Removeexpansiontank cap,
Disconnectlower radiatorhose at radiator.
Disconnectlowerhoseat thermostatfor cold start
device.Poinl hose downward ard drain pngine
coolant.Thereare no drain cocks.
Lowervehicleand removejack.
Remove:
- raotator,
coolingfan with spacerand pulley.
- fan belt.
- drivebeltfor powersteeringpump.
- timinggearbeltcover.
- valvecover,
0
73
Group 17,7,504Mib Maintenance Service
- D24 diesel: timing gear belts
94
Set cylinderNo. 1 to top deadcenterand

injection.
Usea 27 mm : 1{/16" socketon vibrationdamper
bolt to turn engine to position for injection of
cylinderNo. 1.
Both cam lobes should point up at equally large
angles.
Flywheeltiming mark at 0.
Removevibrationdamoercenterbolt.
Use wrench5187to hold. Use wrench5188to (
removebolt.
It might be necessary
to turn engineslightlvto
permitwrench5187to reston coo ingfanjournal.
s60
Checkthat cylinderNo.1 is at top dead

center.
',2! lf necessary,adjust flywheel to
wrench 5187to turn engine.
0-mark.Use @l
@l
g7
JI r
a Removevibrationdamper,
Removefour screws,inhex6 mm, Pul vibration
damper.
NOTE:
gear may be
Vibrationdamperand crankshaft
sluckroqelhe..
Taplhemaparl.
O
74
- D24 diesel: timing gear belts -
g8
Removelower belt shield.

Releaseretaining
boltsfor coolantpump.Loosen
and removetiminggearbelt.
Replaceidler pulley.
MUSTbe replacedwhen replacingtiming gear
belt.
Rernove centerbolt. Use puller5202to remove
idlerpulley.
Tapnew idler pulleyinto position.Installcenter
llolt.
c 910
Removereargearon camshaft.
Usewrench5199to hold reargear Usewrench
5201to removecenterbolt.
Makesurecamshaftis not rotated,
r0
911
Lockcamshaftin position.
Lift valve cover gasket.Installgauge 5190in
grooveon camshaftgearrearend.
Positiona 0.2mm : 0.008"feelergaugeunderleft
sideof gauge5190.
The0.2mm gapisto compensate
forclearances
in
trmrnggears.
D24diesel:timing gear belts-
s12
Removecamshaftfront gear.
Usewrench5199to hold gear.CamshaftMUST
NOTrotate.
Tapgearloosefrom camshaft
taperedend.
nrt
a
Installgearbelt and camshaftfront gear.
suregearbeltfits securelyon gears.
lvlake
Installcenterbolt finger tight. Gear must be
allowedto rotate.CamshaftMUSTNOTrotate.
s14
lnstalllower belt shieldand vibration

damper.
damperfits onewayonly.Thereis a pin
Vibration
gearto locatevibrationdamper,
on crankshaft
Install6 mm inhexbolts.Torqueto:
I
20 Nm : 15ft.lbs.
m (
124229
s15
lnstallcenterbolt.
rqr Applysealingagent{P/N277961-9)to
and contactsurfaces.
boltthreads
Usewrench5187to holdvibrationdamper.lt can

reston coolingfan journal.use wrench5188to
torquecenterboltto:
350 Nm : 255ft.lbs.
Thistorqueonly appliesif wrench5188is used. 0

Torquewrenchmustbe in linewith wrench5188.
5187
76
Group 1/, /,b00 Mile Maintenance Service
916
a Checkthat cylinderNo. 1 is at top dead

center.
Flywheelmark at O.
s17
Tensiontiming gearbelt.
Usecoolantpumpto adjusttiminggearbeltten-
sion.
Installbehtensiongauge5197ontiminggearbelt.
Setgaugeto 12.5.Tensiontiming gearbelt until
markon plungeris flushwith gaugesleeve.
Depresstiminggearbeltheavilyby hand.Recheck
timinggearbelttension.Adjustif required.
918
Tightencamshaftfront gear.
Usewrench5199toholdgear.Makesurecamshaft
or geardoesnot rotate.
Torquecenterboltto:
) 4 5N m : 3 3 f t . l b s .
Removegauge5190andfeelergauge.
s19
Disconnectcold start device.

Loosenscrew1. Pushleverforward,Rotatesleeve
90'.
Pushleverbackagainststop.
NOTE:
DONOTtouchscrew2. ll it is loosened,cold start
devicemust be re-seton test bench.
77
Group 17.7,500 Mile Maintenance Service
g20
,.---e Basicsettingof iniectionpump.

Looseninjectionpumpretainingscrews(inhex6
Yi::>;
mm).Turn injectionpump so that markingson
| ,,lv'' injectionpumpand bracketcoincide.
Tightenretaining
screws.
n"a(
Installindicatorgauge.
Usestop5193to lockinjectionpumpgear
CylinderNo. l shouldbe at position{or
injection.
RemoveplugoI injectionpumpdistribu-
tor. Installholder5194and an indicator
gaugewitha measurjng rangeof0-3mm.
Setindicator gaugeat approx.2 mm.
Turn injection pump clockwiseuntil
marks on injection pump gear and
bracketcoincide.
gz (b
Set indicatorgauge.
Turn injection pump gear slightly
counterclockwise untilindicatorgaugeis
at minimumreading.
Setindicator gaugeat zero.Turninjection
pumpgearclockwise untilmarkingon in-
lectionpumpgearand bracketcoincide.
lJsestop5193to lockiniection pumpgear
in thisposiiion.Insertstopthrougha hole
in injectionpumpgearand into a holein
llracket.
@(
923
Installrearcamshaftgearand iniection
pump drive belt.
Installgearoncamshaft. Tightencenterboltfinger
tightso it can rotateon camshaft.
lnstalldrivebelt.
78
Gtoup 17,7,500Mile Maintenance Service
924
Tensioniniectionpump gearbelt.
Useinjectionpumpbracket to tensiongearbelt.
Use belttensiongauge5197to set belt tension.
Installgauge
on beltandsetitto 12.5.Tensionbelt
until markon plungeris flushwith tool sleeve.
Tighteniniectionpumpretaining screws.
Depressbelt heavilyby hand. Re,checkbelt
tension.Adjustif required.
s25
Set iniectionpump.
Installwrench5199to hold camshaftreargear
Installwrench 5201with a torquewrench.ltshould
0 be at a right angleto wrench5201to give correct
readrngs.
lJsewrench5199to turn camshaftgearuntilthe
indicator gaugeregisters 0.85mm:0.0334".
Holdcamshaftgear in this positionwhile tight-
eningcenterboltto 100Nm = 73ft.lbs.Camshaft
or gearmustnot changeposition.
s26
Removestop 5193.
Checkiniectionpump setting.
Turnengjnetwo full turnsuntilcylinderNo.1 is at
top deadcenterand iniection(= bothcam lobes
for cylinderNo. 1 shouldpoint up equallylarge.
angles, flywheeltimingmarkat 0).
I n d i c a t ogr a u g es h o u l dn o w r e a d0 . 8 5m m :
0.0334".
Correctreading:
Tighteninjectionpump retainingscrews.Then
continuefrom op, 29,
Incorrectreading;
Re-adjust
according
to instructions.
Group17,7,500Mile MaintenanceSetvice
s27
Readinglessthat 0.85mm:
Looseninjectionpump retainingscrews.
Turn iniection pump inward to obtain
reading0.85mm = 0.0334".
Tightenretainingscrews.
Be-checkiniectionpump setting.
123663
s28
Readingmorethan 0.85mm:
Looseniniectionpump retainingscrows.
Then turn injectionpump outlvard until
readingon indicatorgaugeisapprox.0.75
mm = 0.029".Thenturn inwardto obtain
reading0..85mm = 0.0334".
Tightenretainingscrews,
Re-check injectionpump setting.
NOTE:
Injectionpump MUST NOTbe tappedor
knockedas this will altersettings,
Removeindicatorgaugeand gauge
holdeL
Installplug.
Torque:9 Nm= 6.5ft.lbs.
g3o
Reconnectcold start device.

Pushleverforwardandturn sleeve90'.Tighten
NOTE:
DONOTtouchscrew2. lf it is loosened,
coldstart
devicemustbe re-seton testbench.
o
Engaged
80
Gtoup 17.7,500Mile MaintenanceService
- D24diesel:timing gear belts
931
lnstall.
rf Installcoolingfanwith spacerand pulley.Torque
retainingbohsto 9 Nm = 6.5ft.lbs.lnstallfan belt
and powersteeringpumpdrivebelt.Adjustbelt
tensron.
Installradiatorand radiatorhoses.Installsplash
Si guardunderengine.
s32
(f
ftepare bleedingof coolingsystem,
Disconnect uDoerhoseat coldstartdevice.Place
vesselunderhoseend.Holdhoseendin levelwith
exoansion tanktoo,
Using this methodwill bleed cooling system
quicklyandefficiently air pockets.
and eliminate
c s33
Volvo a I wealher Anli-FreezeType C (blue-grcen)should be

used all year ro!nd. cooling system shou d a ways coniain
water pl!s anliiieeze, even during summer. Experience has
also shown th€texiremelyweakanu freezesol!iions (10 20%)
provide poor rosi prolection. For this reason ratio of anli-
i r e e z e / s u m m ecro o l a r t t o w a l e r s h o ! l d b e 1 t o 1 .
Fill coolant.
Manualtransmission: 9.4liters: 10US qts- 9.4
liters= '10US qts
l/ioLl/io coourr TYrf c Automatictransmissionl
c00|r nPf t - 9.2liters= 9.8USqts
rflru m ourm lrn6tt l/roLIrio
vtc romt au romE Arn6tr rYPrc
Flushcoolingsystempriorto fillingnew coolant.
Otherwise refill old coolant.
SetheatcontroltoN4AX. Startengineand run at
increasedidlespeedfor 5 minuteswhile refilling
coolant,
Reconnect hoseat coldstartdevice.Fillexpaosion
(t tankFULL(aboveIMAX)and installcap.
Gtoup 17,7,500Mile MaintenanceSetvice
- Roadtest-
Roadtest
Engine
Check and adjust as necessary:
1 - Startingabilfty,cold and hot engine,
2 -Fast idle.
3 - Correctidlespeedand no misiiring.
4 -That the enginedoesnot stallwhen accelerating afterthrottlemovements.
or decelerating
5 -That rhereareno abnormalnoises from valves,timinggoars,crankshaft or pistonsand
connecting rods, water pump etc,
6 -That normaloperatingtomperature is reachedwithina reasonable warm-upperiod.
7 -That the enginedoesnot behaveabnormally,
I -That the acceleration is normalandthat the engineoperatessmoothly.
I - Openthe hood.Checkfor visibleleaks.
10 -That hardwarer€movedat factoryis reinstalled and that everythingis in order.
Elactrical
Check:
1 - Thatstarterand alternatoroperatecorrectlyand withoutabnormalnoises.
2 - Thatwipersand washersoperatecorrectlyand arecorrectlyaligned.
3 - Thatsteeringlockoperatescorectly.
4 - That instrumentsand controllightsoperatecorrectlyandthat no abnormalnoisesare noticed.
Drive train
Check
1 -That the clutchis correctlyadjustedand that thereare no abnormalnoisesfrom the
throw-outbearing.
2 -That the clutchoperatescorrectlywithoutslippingor chatter.
Manualtransmission
Ch6ck:
1 -That thetransmission
operates withoutabnormal
correctly, noises,
andthatshifiingoperation
is smooth.
Automatic transmission
Check:
'l -That the gearselectorplayis correct.
2 -That the starteroperatesonly in positionP or N andthe back-uplightsoperatein positionR
3 - Runthe transmission to normaloperatingtemperature,

4 -That thereis no slippageat stallspeedin positionD and R (seeServiceManuar,.
5 - Upshift1-2 and 2-3 by accelerating on pan throttlewith the gearselectorin positionD.
6 -That the enginedoesnot slipduringshifting,whichwould indicatethat a brakeor clutchslips.
7 - Employkick-downoperationand checkdownshift.
8 - lf trafficconditionspermit,retainkick{own positionand checkthat upshiftoccursat correct
speeos,
9 - Placethe gearselectorin position2 and checkdownshiftand onginebraking.
1 0 - Placethe gearselectorin position1 and checkdownshiftand enginebraking.
1 l - lf possible,parkon inclineand checkholdingcapabilityin positionP and that the gearselector
doesnot moveout of DositionP bv itself.
-Thal driveshafis,rearaxleor driveshaftbearingsdo no1generatevibralionsor abnormal
noises.
82
- Roadtest-
Brakes
Check
1 -That the power assistfunctions when braking by noting pedal pressure.
2 -That the brakesdo not pull when braking hard.
3 Thal brake discsare not out-of round or warped by noting pedal pulsationor movement.
4 -That the brakesare correctlyadjustedand that the brake pedal
does not feel spongy .
5 -That the parking brake is correctlyadjustedand operates
correctlv.
Steering
Check:
'I
That the steeringis correct and thar the vehicledoes not pull or is unstable.
2 - Steeringwheel position and return when driving.
3 -That the steeringwheel efiort is normal.
4 Steeringlooseness.
5 - That power steeringfunctions correctly,
Springs and wheels

Check:
1 Thatthereareno abnormal
noises
fromshockabsorbers
or rearwheelsuspension.
2 - When driving that the rear axle is ttght.
3 - Tire unbalanceor out-of-roundness,when
drivinq.
Body and interiorequipment

Check:
1 That all dealerinstalledaccessoriesoperatecorrectlv,
2 -That heaterand heatercontrolsoperatecorreclly,
3 -That thereare no abnormalspeed notses.
4 -That there are no abnormalbody noises(rattle,vibrations
etc.)
5 Visibledefects.
o 6
7
- Wipe off steerangwheel and gear selector.
Cleanall other soiledor dirty areascausedby the maintenanceDrocedures,
- Fauhsdetectedshould,i{ not previouslynoted, be
- Checkoff group and note the fault.
noted in the servicerecord.
8
I - Faultsnormallyremediedat the serviceshould not be noted.
Make sure all faults are
remediedbelore the customer o,cls uo his car.
83
llational
lnslitute tor
tun owt
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Volvo 240, Manual (1) Service and Maintaince

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SeruiceManual Section1 (17l

7,500 Mile 12,500km Maintenance

Volvo7,500Mile (12,500km) MaintenanceServiceChart

Contlols and lighting

In car All items on this pageshould

.sss&",S oS.,SoS "SS."}S .s"l€l$rm

7,500 15,000 22.54O 30,000 45,000 60,000 75,000

Checkthal brakelightscome on with light

Checkrear reflectorsand lenses.

Pressuretest brake system.

Lubricatedoor hinges,door stops and

Lubricatetrunk lid (tail gatefor wagons).

a t- == =-1. Checktires and tire pressure.

Checkwheel bearing play.

Check steering gear.

Checkcontrolarm bushingsand strut

check ball ioints.

Checkstabilizerbar and links.

Checkpropellershaft and support

a Check rear axle.

Gasolineengines Oil and filter changes

sAE 15W40is recommendedtoruse in extemedrivinocondi

Ouality: Oil and filter changes.

Volvoall weatherAnti-Frceze TypeC {b ue-s€en)shouldbe

Checkoil levelof power steering

Disconnectoil coolerreturn pipefrom

Fill2 quartsol AutomaticTransmission

Fill2 quartsof AutomaticTransmission

Fill2 quartsof AutomaticTransmission

Reinstalloil pan and filler tube.

Followingoperationsreferto 821and 823 (alll

Setuiceevery 7,5(n miles : 12,500km

o 50- 1(n- 15O-thousadd km

o Checkdrive belt tension.

3(L60-!n-tho usand mi |es

Attachtool 5022and deDressvalve

Usetool 5026to removedisc.

Use micrometer to measurcdisc thick-

'a 'n describedpreviously.

Re-checkon all cylinders.

Lineup timing belt.

Stretchon tensionsideand fit timing belt

Fit timing belt on tensionerroller.

Checkmarksand torque nut.

Seryice following at:

1o Engineat opefatingtemperat!rebut nol running.

f thermoslaticvalvedoes no1open,first checkthal coolanl

Replaceair filter cartridge.

Fordry, dusty,pollutedregionsan air tiltercart-

Removeretainingscrewfor fuel needle.

Removelockwasherand flat washer.

o Pressdown lower lock washer.

o Filldamperoil and installdamperplunger

Adiust idle speed.

Seruiceevery 7,500miles : 12,500km

30-60-90-th o usand n i les

B2'lF-Turbo (setof four)

r0 30-60-9 O-th o usan d m iIes

Seryiceat: 60,(nOmiles= 1(n.0anknt

Replacefuel tank filter.

Replaceair filter cartridge.

B23F (setof four)

30-60-90-th ousand m i les