1 9 8 5
VOLVO
760 GLE, Turbo

Volvo Service

pg. 85 Volvo Service

Service - an investment!
An investment which will pay dividends in the form of improved reliability, durability, and resale value.

Maintenance schedule 86
Volvo service 88
Engine compartment 89
Engine oil 91
Exhaust Emission Service 93
Automatic transmission fluid 99
Rear axle oil 100
Power steering fluid, brake fluid 101
Lubrication, body 102
Coolant 103
Drive belts 104

pg. 86 Servicing

1985
MAINTENANCE SCHEDULE
760
    A = Adjust (Correct if necessary)
    R = Replace
    I = Inspect (Correct or Replace if necessary)
    L = Lubricate
Maintenance Operation Miles 600-
1,200
7,500 15,000 22,500 30,000 37,500 45,000
  (Km) (1,000-
2,000)
(12,500) (25,000) (37,500) (50,000) (62,500) (75,000)
EMISSION SYSTEM MAINTENANCE  
Engine oil and Oil filter 1 R R R R R R R
Cooling System Hoses and Connections I            
Engine Drive Belts A       I    
Torque Manifold Nuts A            
Valve Clearance         I    
Vacuum Fittings, Hoses and Connections I            
Oxygen sensor (760 GLE only)         R    
Adjust Service Indicator System for Oxygen Sensor (760 GLE only)         A    
Air Cleaner Filter         R    
Spark Plugs         R    
Fuel System Cap, Tank, Lines and Connections I            
Ignition Timing (760 GLE only) I            
Torque Catalytic Converter Mounting Bolts A            
Automatic Transmission Fluid I I I R I I R
Manual Transmission Fluid R I I I I I I
Rear Axle Oil R I I I I I I
Timing Gear Belt (Turbo models only) A           R 2

1) OIl and oil filter cartridge are first changed at the 600-1,200 mile (1,000-2,000 km) inspection. Subsequent oil and filter changes should be made at 7,500 mile (12,500 km) intervals or at least every six month. For Turbo models, oil and filter changes should be made at 3,750 mile (6,250 km) intervals or at least every six months. However, adverse conditions (such as high ambient temperatures, trailer towing, hill climbing, driving long distances at high speeds, extended periods of idling or low speed operation, short trip operation at freezing temperatures require oil changes more frequently (every third month).
2) Not included in emissions systems maintenance, but we recommend that the timing gear belt be replaced every 45,000 miles (75,000 km).

Maintenance beyond 45,000 miles (75,000 km)
For service intervals beyond 45,000 miles (75,000 km) refer to the Maintenance Service Schedules Chart provided with your vehicle.

pg. 87 Servicing

Maintenance Operation Miles 600-
1,200
7,500 15,000 22,500 30,000 37,500 45,000
  (Km) (1,000-
2,000)
(12,500) (25,000) (37,500) (50,000) (62,500) (75,000)
MISCELLANEOUS MAINTENANCE  
ENGINE  
Engine Coolant         R    
Fuel (Line) Filter              
PCV Nipple (Orifice)              
Ventilation Hoses              
BRAKES  
Inspect Brakes. Replace components as necessary.     I   I   I
Change Brake Fluid1         R    
STEERING  
Tire Wear (Align front end if needed.)     I   I   I
Check power steering fluid level. I I I I I I I
BODY  
Trunk, Hood Hinges and Latches.     L   L   L

1)For detailed information see page 101.

The following items should be checked weekly by the driver (it takes only a few minutes):
Engine oil level
Brake fluid level
Radiator coolant level
Tire pressure (all five tires)
Operation of all lights
Horns
Windshield wipers
Level of windshield washer fluid

The following should also be carried out at regular intervals:
Washing
Polishing
Cleaning
Rust protection

pg. 88 Maintenance service

MAINTENANCE

Maintenance services
Your Volvo has passed two major inspections before being delivered to you, according to Volvo specifications. After being driven 600-1,200 miles (1,000-2,000 km), your car should be brought to the Volvo dealer for a service inspection. Engine, manual transmission and rear axle oils will be changed at this time.
Following this inspection, the maintenance inspections outlined in this book should be performed every 7,500 miles (12,500 km), or every 3,750 mile (6,250 km) on Turbo models.
The extended maintenance inspection intervals make it even more advisable to follow this program.
Inspection and service should also be performed any time a malfunction is observed or suspected.
It is recommended that receipts for vehicle emission services be retained in the event that questions arise concerning maintenance. See your "Maintenance Records Manual".

Maintenance inspection at 7,500 miles (12,500 km) intervals.
Volvo advises you to follow the inspection program at 7,500 miles (12,500 km) intervals(3,750 miles or 6,250 km intervals on Turbo models) which is outlined in the "Maintenance Records Manual". This maintenance program contains inspections and services necessary for the proper functioning of your car over the next inspection interval.
The maintenance inspections contain several checks which require special instruments and tools and therefore must be performed by a qualified technician.
To keep your Volvo in top condition, specify time tested and proven Genuine Volvo Parts and Accessories.

THE FEDERAL CLEAN AIR ACT (USA)
The Clean Air Act requires vehicle manufactures to furnish written instructions to the ultimate purchaser to assure the proper functioning of those components that control emissions.
The maintenance instructions listed in the "Servicing" section of this Manual represent the minimum maintenance required. These services are not covered by the warranty. You will be required to pay for labor and material used. Refer to your Warranty booklet for further details.
In accordance with Federal Regulations, your Volvo is warranted to meet certain Emission Performance Standards. Refer to your Warranty booklet for detailed information,

  • Emissions Performance Warranty
  • Limited 5-Year/50,000-Mile Emission System Warranty (USA)
  • 5-Year/80,000-Kilometer Emission System Warranty (Canada)

    pg. 89 Engine compartment

    Engine compartment
    760 GLE (engine B28F)
    1 Data plate
    2 Dipstick, automatic transmission
    3 Brake/clutch fluid reservoir
    4 Fuel filter
    5 Expansion tank, coolant
    6 Battery
    7 Dipstick, engine
    8 Oil filler cap, engine
    9 Power steering fluid reservoir
    10 Air cleaner
    11 Washer fluid reservoir

    NOTE:
    The B28F is an aluminum-alloy V-6 designed to offer not only superior performance and reliability, but also good fuel economy. You will notice that this engine provides an exceptionally-smooth supply of power across a broad range of road speeds. At very low engine rpm (as when the car is idling at a standstill), you may sense a slight vibration thought the steering wheel. Such oscillation is normal and is not a cause for concern. Moving the transmission selector to "N" when idling at a standstill for prolonged periods will lessen any such oscillation, and will also help reduce unnecessary heating of the transmission oil. (Make sure to apply the brakes and/or parking brake before selecting "N" while stopped on an incline.)

    pg. 90 Engine compartment

    Engine compartment
    760 Turbo (engine B230F-Turbo)

    1 Data plate
    2 Turbocharger
    3 Oil filler cap, engine
    4 Engine oil dipstick
    5 Brake/clutch fluid reservoir
    6 Washer fluid reservoir
    7 Expansion tank, coolant
    8 Radiator
    9 Intercooler
    10 Power steering fluid reservoir
    11 Battery

    pg. 91 Engine oil

    Checking the oil level
    The oil level should be checked each time you refuel. Be sure the oil level is maintained between the upper and lower marks on the dipstick. Low oil level can cause internal damage to the engine and overfilling can result in high oil consumption. The distance between the dipstick marks represents approx. 1 US qt (1 liter) of oil.

    Drain the oil
    Drain the oil after driving while it is still hot.

    WARNING!
    The oil may be very hot.


    To add or change engine oil
    Add oil of the same kind as already used. Capacity (including filter): 6.9 US qts = 6.5 liters (760 GLE); 4.0 US qts = 3.85 liters (760 Turbo)*. After an oil change, the oil level will lie between the two marks on the dipstick i.e. between MAX and MIN. This is normal. Do not add too much oil, or excessive oil consumption will result.
    *if oil cooler is drained, add 0.7 US qts (0.6 liters)

    Changing oil filter
    Replace the oil filter at every oil change.

    pg. 92 Engine oil

    Oil quality
    Meeting API specification SF (CCMC class G2)

    Oils with designations SF/CC and SF/CD comply with these requirements.

    Viscosity (stable ambient temperatures):

    SAE 15W/40 is recommended for use in driving conditions that raise oil temperature and increase oil consumption (e.g. mountain driving with frequent decelerations, of fast highway driving). Note, however, the higher temperature range of 15W/40 oil.

    Volvo recommends the use of energy-conserving oils. When using these oils, the Volvo recommended oil-change intervals must be followed.
    Synthetic or semisynthetic oils may be used if their specifications comply with the oil quality requirements.
    Volvo does not recommend additional oil additives, as they can adversely affect the engine.

    Changing oil and oil filter
    Oil and oil filter are first changed at the 600-1,200 mile (1,000-2,000 km) service. Thereafter, changes should be made as specified by this table:

    Driving conditions Oil and oil filter change interval
    Severe conditions, such as:
  • extended periods of idling and low speed operation
  • short trip operation at freezing temperatures
  • long periods of driving in dusty or sandy areas
  • trailer hauling
  • hill climbing
  • driving long distances at high speed
  • 760 GLE
    Every 7,500 miles (12,500 km)
    or every third month, whichever comes first
    760 Turbo
    Every 3,750 miles (6,250 km)
    or every third month, whichever comes first
  • Normal conditions, that is, conditions not mentioned above
  • 760 GLE
    Every 7,500 miles (12,500 km)
    or every sixth month, whichever comes first
    760 Turbo
    Every 3,750 miles (6,250 km)
    or every sixth month, whichever comes first

    pg. 93 Servicing

    Torque exhaust manifold nuts
    The manifold nuts should be torqued at the 600-1,200 mile (1,000-2,000 km) inspection. A loose manifold could alter air/fuel ratio and cause an increase in emissions and/or poor driveability.

    Valves
    The valve clearance should be checked and, if necessary, adjusted every 30,000 miles (50,000 km).

    Air cleaner
    Replace the air cleaner cartridge with a new one every 30,000 miles (50,000 km). The cartridge should be replaced more often when driving under dirty and dusty conditions. The filter cannot be cleaned and, therefore, should always be replaced with a new one.

    Vacuum fittings, hoses and connections
    Unstable idle, misfiring, or poor emission control is often caused by leaking vacuum hoses or connections. Check hoses and connections on distributor vacuum unit, connections on heater control servo systems and hydraulic brake servo.

    Checking and adjusting idle speed
    Your Volvo is equipped with an electronically controlled idle speed system that requires no checking or adjustment.

    Fuel system cap, tank and lines, and connections
    The effectiveness of the fuel system to contain hydrocarbons is dependent largely on a leak free system. Check for proper sealing of gasoline filler cap which contains "0" ring-type seals. Check all evaporative hoses in vehicle for tightness. Check fuel lines under vehicle and repair if necessary.

    Fuel (line) filter
    The fuel filter is located on the left suspension tower brace. This filter is to be changed every 60,000 miles (100,000 km). The filter is replaced as one complete unit.
    Replace more frequently if contaminated fuel is introduced into the tank (or if there is reason to suspect that this has occurred).

    Timing Gear Belt (Turbo Models only)
    The timing gear belt should be adjusted at the 600-1200 mile (1000-2000 km) inspection. We recommend that the belt be replaced every 45,000 miles (75,000 km).

    pg. 94 Servicing

    Special instructions for work on the fuel injection system
    Extreme cleanliness is essential when working on the injection system. Great care must be observed.
    Injection system service should be handled by qualified technicians only, using equipment intended for this service.

    1 Air-fuel control unit
    2 Fuel distributor
    3 Frequency valve
    4 Injector
    5 Tank pump
    6 Fuel pump
    7 Pressure accumulator
    8 Fuel filter
    9 Control pressure regulator
    10 Start injector
    11 Air control valve (constant idle speed system)
    12 Throttle valves

    CI system (760 GLE)
    The B28F engine in the 760 GLE has a fuel injection system called the CI (Continuous Injection) system. Fuel injectors are open and inject fuel continuously as long as the engine is operating.
    This system has few moving parts, is reliable and meets the exhaust emission standards at maximum efficiency.
    The volume of air supplied measured and determines the amount of fuel injected. (Air/fuel mixture is also influenced by Oxygen Sensor System).

    Lambda-sondTM (oxygen sensor) system (760 GLE/760 Turbo)
    This is an emission control system designed to reduce emissions and improve fuel economy. An oxygen sensor monitors the composition of the exhaust gases leaving the engine. The exhaust gas analysis is fed into an electronic unit which continually influences a frequency valve. This adjusts the air-fuel ratio to provide optimum conditions for combustion and efficient reduction of the three major pollutants (hydrocarbons, carbon monoxide and nitrous gases) by a 3-way catalytic converter.

    pg. 95 Servicing


    1 Battery
    2 Injection control unit
    3 Ignition control unit
    4 Fuel filter
    5 Fuel pump
    6 Fuel feed pump
    7 Air mass meter
    8 Throttle switch
    9 Temperature sensor
    10 Injector
    11 Oxygen sensor
    12 Intercooler

    LH Jetronic 2.2 fuel system (760 Turbo)
    The LH-Jetronic 2.2 fuel injection system is all-electronic and is microprocessor controlled. It can continually compensate for variations in engine load, speed and temperature to give the best economy and power. The most unique feature of the system is an air mass meter that measures the mass of the inducted air instead of the volume. In this way the system can make instantaneous adjustments for changes in air temperature or density, thus always assuring the best economy with the lowest-possible exhaust emissions.

    pg. 96 Servicing

    Lambda-sondTM (oxygen sensor system)
    Change oxygen sensor unit and reset service indication for oxygen sensor (760 GLE only)

    The oxygen sensor must be replaced every 30,000 miles (50,000 km).
    To remind the driver about the change of the oxygen sensor unit there is a special reminder light, which comes on at 30,000 miles (50,000 km) intervals.
    (See "Warning lights"). The light will stay on until reset.
    Note: Failure to follow the recommended maintenance may result in vehicle not meeting Federal or state emissions standards.

    Catalytic Converter
    This is a supplementary device in the exhaust system, designed to clean exhaust gases.
    This device is mainly a container with a ceramic material insert, designed to let the exhaust gases pass through channels in the insert. The channel walls are covered by a thin layer of platina-palladium. These metals act as catalysts, permitting a chemical action to occur without actually taking part in it.
    The emission (CO, HC, NOx) content will increase if the Catalytic Converter is damaged. Lambda-sondTM equipped vehicles use Catalytic Converters containing platinum and rhodium.

    Torque Catalytic Converter mounting bolts
    The Catalytic Converter mounting bolts should be torqued after the first 600-1,200 miles (1,000-2,000 km).


    CAUTION:
    Vehicles with Catalytic Converter must use unleaded fuel only. Otherwise the Catalytic Converter will become ineffective.
    See "Fuel requirements"

    pg. 97 Servicing

    WARNING!
    The ignition system operates at very high voltages. Special safety precautions must be followed to prevent injury.
    Always turn the ignition off when:

  • connecting engine test and diagnostic equipment to the vehicle (timing light, tach-dwell tester, ignition oscilloscope etc).
  • Replacing ignition components e.g. plugs, coil, distributor, HT leads etc.
  • Do not touch any part of the ignition system while the engine is running. This may result in unintended movements and body injury.
  • Replacing spark plugs
    The spark plugs should be changed every 30,000 miles (50,000 km). However, city driving or fast highway driving may require changing after 7,500 miles (12,500 km) of driving. When installing new plugs, be sure to fit the right type and use correct torque, see Specifications. When changing the plugs, check that the suppressor connectors are in good condition. Cracked or damaged connectors should be replaced.
    When changing spark plugs, clean the cables and cable terminals, also the rubber seals. If the car is driven on roads where salt is used during the winter, coat the cables with silicone.

    Ignition timing, 760 GLE
    The ignition timing should be inspected at the 600 - 1,200 mile (1,000 - 2,000 km) inspection. All adjusting work should be done with the proper equipment. The distributor is one of the most sensitive engine units. Careless handling can lead to decreased engine output, high fuel consumption, and even serious damage to the engine.

    Ignition timing, 760 Turbo
    The ignition timing is set electronically and cannot be adjusted.

    pg. 98 Servicing


    Evaporative control system
    The 760 is equipped with a gas evaporative control system, which prevents gasoline fumes from being released into the atmosphere.
    The system is comprised of an expansion chamber in the fuel tank, a roll-over valve on the cross member in front of the fuel tank, and a charcoal canister with built-in vacuum valve under the left-front wheel housing.
    The components are interconnected by hoses which channel fuel vapor from the gas tank to the charcoal filter, where it is stored until the engine is started and then drawn into the engine's fuel induction system.

    Crankcase ventilation
    The engine is provided with positive crankcase ventilation which prevents crankcase gases from being released into the atmosphere. Instead, the crankcase gases are admitted to the intake manifold and cylinders.

    PCV system, B28F
    The orifice nipple in the intake manifold should be cleaned every 60,000 miles (100,000 km)
    Check/replace rubber hoses at the same time.

    PCV system, B230F-Turbo
    The orifice nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be removed and cleaned every 60,000 miles (100,000 km).
    Check/replace rubber hoses at the same time.

    pg. 99 Manual transmission, rear axle


    Manual transmission with overdrive (M46)
    Capacity: 2.4 US qts (2.3 liters)
    Fluid type: Automatic Transmission Fluid Type F or G (FLM).
    Engine oil (SAE 10W/40 or 10W/30) is recommended for use in areas where the temperature seldom drops below 14°F(-10°C).
    Note! Do not mix ATF and engine oil.
    Replace: at 600-1,200 mile (1,000-2,000 km) service only.
    The oil level should be up to the filler plug. Drain the oil immediately after driving, while it is still hot, by removing plug.
    Transmission and overdrive are lubricated by the same oil. Therefore, when the oil is drained through the drain plug, also remove cover on the overdrive and clean strainer.
    Note: Refer to "Specifications" section of this manual for additional information on transmissions.

    Rear axle
    Capacity: 1.7 US qts (1.6 liters)
    Oil type: API GL-5 (MIL-L-2105 B or C).
    Viscosity: SAE 90 or 80W /90.
    Replace: at 600-1,200 mile (1,000-2,000 km) service only.

    The oil level should be up to the filler plug.
    Drain rear axle oil through drain plug.
    When the temperature is consistently below 15°F (-10°C) use API GL-5 SAE 80W oil.

    pg. 100 Automatic transmission


    Automatic transmission oil
    Capacity: See "Specifications" section.
    Fluid type: Automatic Transmission Fluid type Dexron IID.
    Replace: Every 22,500 miles (37,500 km).


    CAUTION!
    Oil spilled on a hot exhaust pipe constitutes a fire risk.

    A Cold transmission: oil temperature = +105°F(+40°C).
    This is a normal temperature for the transmission after idling for about 10 minutes. At oil temperature below +105 °F(+40 °C), the level may be below the MIN mark.

    B Warm transmission: oil temperature = +195°F(+90°C).
    This temperature is reached after driving for about 30 minutes. At oil temperature above +195 °F(+90 °C), the level may be above the MAX mark.

    Note!
    The engine should be idling when checking transmission fluid level.

    Check the oil level as follows:
    Park the car on level surface with the engine idling.
    Slowly move the selector lever through all the gear positions and then to position P. Wait 2 minutes before checking the oil level. As the illustration shows, the dipstick has a "Cold" and a "Warm" side.
    The oil level should be between the MIN and MAX marks.
    Wipe the dipstick with a clean cloth. CAUTION! The oil may be very hot!
    Do not use rags that could leave lint on the dipstick.
    The transmission is topped up via the dipstick tube.
    The space between the MIN and MAX marks on the dipstick corresponds to 0.5 US qt. (0.5 liter). Do not fill the transmission with too much oil, since this can result in oil being ejected from the transmission.
    Too little oil, on the other hand, can negatively affect transmission operation, particularly in very cold weather.

    pg. 101 Brake and clutch fluids, power steering fluid


    Brake and clutch fluids
    The fluid reservoir serves both the brake system and (where applicable) the clutch system. The fluid level should be between the MIN and MAX marks.
    Fluid type: DOT 4
    Replace: every second year or 30,000 miles (50,000 km). The brake fluid should be replaced once a year or every 15,000 miles (25,000 km) when driving under extremely severe conditions (mountain driving etc.)
    Check, without removing the cap, that the level is above the "MIN" mark of the fluid reservoir.
    Always entrust brake fluid changing to a Volvo dealer.

    Power steering fluid

    760 Turbo
    The fluid level should lie between the MIN and MAX on the side of the dipstick. The space between the marks corresponds to 0.2 US qts/liters.

    760 GLE
    The dipstick has markings for hot and cold fluid.
    When cold, the fluid must not be above the COLD mark, and similarly, when hot it must not be above the HOT mark. Top up with ATF if the level drops to below the ADD mark.

    Fluid type: ATF
    Replace: no fluid change required

    pg. 102 Lubrication


    No. Lubricating point Lubricant
    1 Hood lock Paraffin wax
    2 Hood hinges Oil
    3 Door stop Oil
    4 Sunroof wind deflector Oil
    5 Door lock catch plate Paraffin wax
    6 Trunk lid lock
    Key hole
    Lock oil
    7 Window regulator
    Locking device
    (on inside of door)
    Oil, grease
    Silicone
    grease
    8 Front seat slide rail and latch Oil
    9 Key hole Lock oil
    10 Striker plate Paraffin wax

    To avoid rattles and unnecessary wear, the body should be lubricated a few times per year.

    Note!
    During winter, locks in the doors and trunk lid should be treated with special anti-freeze lubricant to prevent freezing.

    pg. 103 Cooling system


    Check coolant level
    The cooling system must be filled with coolant and not leak to operate at maximum efficiency. Check the coolant level when filling fuel. The level should be between the "Max" and "Min" marks on the expansion tank. The check should be made with particular thoroughness when the engine is new or when the cooling system has been drained.
    Do not remove the filler cap other than for topping-up with coolant. Frequent removal may prevent coolant circulation between the engine and the expansion tank during engine warm-up and cooling.

    Changing coolant
    Every two years or 30,000 miles (50,000 km) the cooling system should be drained, flushed and refilled.
    Remove the expansion tank cap. Open the drain cocks on both sides of the engine block and disconnect the lower radiator hose.
    Fill coolant through the expansion tank. The heater controls should be fully open when draining and filling.
    Add coolant until the level is up to the MAX mark or slightly above.
    Start engine and run until hot. Check the cooling system connections for tightness. Also re-check the coolant level.
    Capacity: See "Specifications"
    Coolant: Volvo Coolant type C (blue green)


    CAUTION
    The cooling system must always be kept filled to correct level.
    If it is not kept filled, there can be high local temperatures in the engine which could result in damage.

    Top up with coolant
    Top up with coolant by filling the expansion tank when level is at the "Min" mark. Use a mixture of 50 percent anti-freeze/summer coolant and 50 percent water all the year round. Top up to the "Max" mark.
    If the engine is warm, and you are going to top up coolant, unscrew the cap slowly in order to allow any excess pressure to escape.
    NOTE: Do not top up with water only. Water by itself reduces the rust-protective and anti-freeze qualities of the coolant and has a lower boiling point. It can also cause damage to the cooling system if it should freeze.

    pg. 104 Drive belts


    Checking the belt tension
    The belt tension can be checked by depressing the fan belt (engine not running!) at a point midway between the alternator and fan. It should be possible to press down the belt about 1/4"-3/8" (5-10 mm). This also applies to other drive belts on the engine.

    Belt check
    Check the belts regularly to make sure they are in good condition and are clean. Worn or dirty belts can cause poor cooling and low alternator output as well as impair the operation of the power steering and the air conditioning unit.

    Belt adjustment and replacement
    The belts can be difficult to reach and it is advisable to let your Volvo dealer adjust the tension of the belts or replace them, if necessary.


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