pg. 60 Manual transmission


Manual transmission with overdrive, M46
Capacity: 2.4 US qts = 2.3 liters.
Fluid type: Automatic Transmission Fluid Type F or G(FLM)
Replace: at 600-1,200 mile (1,000-2,000 km) service only.

The oil level should be up to the level/filler plug.
When replacing transmission oil, drain the oil immediately after driving, while it is still hot, by removing the drain plug.
Transmission and overdrive are lubricated by the same oil.
When draining transmission oil, also remove cover on the overdrive to drain oil remaining there. Also clean the overdrive strainer.

pg. 61 Automatic transmission


Automatic transmission
Capacity: 7.8 US qts (7.4 liters)
Fluid type: Automatic Transmission Fluid type Dexron II D.
Replace: every 20,000 miles (32,000 km).

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 obtained when 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 which can 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 qts (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. 62 Rear axle oil, Power steering fluid, Brake fluid


Rear axle oil
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 (A).
Drain rear axle oil through drain plug (B).
When the temperature is consistently below 15° F (-10° C), use API GL-5 SAE 80/90 W oil.
Cars equipped with limited slip differentials should use oils with proper additives.

Power steering fluid
Capacity: 0.8 US qts = 0.75 liters.
Fluid type: ATF
Replace: no fluid change required.
The dipstick is attached to the cap. Fluid level should be between MIN and MAX marks. Add fluid when the level is at the ADD mark.

Brake fluid
Fluid type: DOT 4
Replace: every 2 years or 30,000 miles (48,000 km).
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.
Change brake fluid every year when driving under extremely hard conditions (mountain driving etc.) and if the car is equipped with a non-factory air dam.

pg. 63 Body lubrication


Chassis maintenance
To simplify maintenance, your Volvo has been equipped with ball joints, steering rods and propeller shafts that do not require regular lubrication.
Points that normally require lubricating have been packed with very durable grease at the factory and then carefully sealed, eliminating the need for subsequent lubrication.

Lubricate body
To avoid rattles and unnecessary wear, the body should be lubricated once a year. Hinges on hood, doors and trunk lid as well as door stops should be lubricated every 10,000 miles (16,000 km).


Door hinges(lower) and door stop
A grease B oil

NO. Lubricating pointLubricant
1 Trunk lid lock Lock oil
2 Trunk lid hinges Oil
3 Door lock outer sliding surfaces Paraffin wax
4 Sunroof wind deflectorOil
5 Hood hingesOil
6 Hood lockParaffin wax
7 Front seat slide rails and latch devicesOil
8 Window regulatorOil, grease
  Locking device (Accessible after door upholstery panels removed) Silicon grease
9 Door hingesGrease
  Door stopOil


pg. 64 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 whenever you refuel. 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 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.


CAUTION
The cooling system must always be kept filled to the 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 Volvo Type C 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 add coolant, unscrew the cap slowly in order to allow any excess pressure to escape.

Note: Do not add water only. Water by itself reduces the rust-protective and anti-freezing qualities of the coolant and has a lower boiling point. It can also cause damage to the cooling system if it should freeze.
See "Specifications" section of the manual to type of coolant recommended.

Cooling system
The risk of overheating is greatest, especially in hot weather, when:
- towing a trailer up steep inclines for prolonged periods at full throttle, and at low engine rpm.
- idling for prolonged periods while the air conditioning system is in operation.
- stopping the engine suddenly after high speed driving, so-called after-boiling.

To avoid overheating, the following rules should be followed.

  • Reduce speed and downshift when towing a trailer up long steep inclines. The risk of overheating can be reduced by switching off the air conditioning system for a short while.
  • Do not let the engine idle unnecessarily.
  • Do not stop the engine immediately after highspeed driving, but allow the engine to idle for 1/2 - 1 minute before switching off.

    When the risk of overheating is imminent, or in the event of overheating, (the temperature gauge goes repeatedly into, or stays continually in, the red section) the following precautions should be taken:

  • Switch off the air conditioning system.
  • Stop the car and put the gear lever into neutral position-position N. Do not stop the engine!
  • Increase the engine speed to approx. 2000 rpm (twice idling speed).
  • Check the level of coolant in the expansion tank. Top-up, if necessary.

    pg. 65 Alternator, Jump starting

    Note: This car is equipped with an alternator.
    When changing the battery or when carrying out work involving the electrical system, the following should be observed:
    1 A battery connection to the wrong terminal will damage the diodes. Before connections are made. check the polarity of the battery with a voltmeter.
    2 If booster batteries are used for starting, they must be properly connected to prevent the diodes from being damaged. For correct connection, see "Jump starting".
    3 The battery leads should be disconnected any time the battery is being charged.
    4 Never disconnect the battery circuit (for example, to change the battery) while the engine is running, as this will immediately ruin the alternator. Always make sure that all the battery connections are cleaned and properly tightened.
    5 If any electrical welding work is performed on the vehicle, the ground lead and all the connecting cables of the alternator must be disconnected and the welder wires placed as near the welding point as possible.



    Jump starting


    CAUTION: Improper hook-up of jumper cables or the use of other than 12 volt batteries could result in damage to equipment and/or battery.


    Check that cars are not touching to prevent premature completion of negative circuit.
    Note the position of the battery terminals. When using jumper cables, first connect booster battery positive (+) terminal to car battery positive (+) terminal. Then connect booster battery negative (-) terminal to a stationary solid metal part on the engine at a point away from the battery. Do not connect booster cable to any part of fuel system or any moving parts. Avoid touching hot manifolds.
    After engine has started remove first (-) jumper cable, then positive (+) terminal jumper cable.

    WARNING!
    To prevent possible explosion, never expose battery to open flame or electric spark. Do not smoke near battery. Batteries generate hydrogen gas which is flammable and explosive.
    Battery fluid contains sulfuric acid.
    Do not allow battery acid to contact eyes, skin, fabrics or painted surfaces. If contact occurs, flush affected area immediately with water. Obtain medical attention immediately if eyes are affected.


    pg. 66 Replacing bulbs

    Replacing bulbs
    The replacement of bulbs in the various lighting units is shown on the following pages. Make sure when installing bulbs, that the guide pin on the socket fits into its corresponding recess.
    When installing bulbs, do not touch the glass with your fingers. The reason for this is that grease, oil or any other impurities can be carbonized onto the bulb and damage the reflector.
    Use bulbs of correct type and voltage. Failure to do so could activate the bulb failure warning light.

    Replacing headlight bulbs
    Working inside the engine compartment, separate the socket contact from the bulb holder (1). Unscrew and remove the bulb holder retaining ring (2). Pull out the bulb holder assembly, and replace it as a unit (3).
    Installation is the reverse of removal.

    Check headlight alignment.


    pg. 67 Replacing bulbs


    Tail lamp bulbs, sedan model
    All tail lamp bulbs are replaced from inside of trunk.
    1 Unscrew and remove tail lamp inside cover. Note that inside cover is hooked at the upper edge. Lift the lower end out/up and unhook upper edge.
    2 Turn bulb holder approx. 3/8" (1 cm) counterclockwise and remove it.
    3 Depress bulb in bulb holder, turn it slightly counterclockwise, and remove it.
    4 Install a new bulb. Install bulb holder in tail lamp. NOTE: One of the bulb holder tabs is wider and fits only in corresponding recess.
    Turn bulb holder clockwise. Check that bulb lights. Replace tail lamp

    Bulbs Power Socket US Bulb No
    CP W
    1 Rear fog light*32 21 Ba15s 1073
    2 Back-up light 32 21 Ba15s 1073
    3 Rear turn signal 32 21 Ba15s 1073
    4 Tail light 4 5 Ba15s 67
    5 Reflector - - - -
    6 Brake light/tail light 32/3 21/5 BaY 15s 1157

    "certain models only. On other models brake light is at location 1.

    pg. 68 Replacing bulbs


    Front light bulbs
    Loosen the Phillips screws and remove the lens.
    The bulbs can now be removed by pressing them inwards and turning them slightly counterclockwise.
    When re-installing lens, check that the gasket is in position.
    Bulbs Power
    CP(W)
    Socket
    1 Front position
    Side marker-lights
    4(5) BaY 15d 1)
    2 Front turn signal 32(21) BaY 15d 2)

    1) US Bulb No. 67
    2) US Bulb No. 1073

    Tail lamp bulbs, wagon model
    All bulbs in the tail light cluster are removed from the inside.
    Changing bulb, left hand side:

  • Remove the spare tire cover and the spare wheel.

    Changing bulb, right hand side:

  • Remove the right hand stowage cover.
  • Loosen the clip and move panel aside (see illustration).
    The procedure for changing a bulb is basically the same as for other models.
    When re-installing, hold the bulb holder with the word "Volvo" turned towards the center of the car.

    Bulbs Power Socket US Bulb No
    CP W
    1 Rear fog light*32 21 Ba15s 1073
    2 Back-up light 32 21 Ba15s 1073
    3 Rear turn signal 32 21 Ba15s 1073
    4 Brake light/tail light 32/3 21/5 BaY 15d 1157

    *certain models only. Other models have brake light at location 1.


    pg. 69 Replacing bulbs


    License plate light, sedan model
    Slide the bulb housing backwards until it is released from the front edge. Pull out the lamp housing and replace the bulb. Insert the front edge of the lamp housing and press up the rear edge by hand.

    Bulbs Power Socket
    License plate light, sedan model 4W Ba 9s

    License plate light, wagon model
    Insert a screwdriver through the opening in the housing and depress the catch tab. Pull out the housing assembly.

    Bulbs Power Socket
    License plate light, wagon 5W S 8.5-8


    High-mounted brake light

    Remove the plastic housing by pulling it up and away from the light assemble. Depress the black catch tab to release the bulb holder 1. Swing the bulb holder out and replace the bulb 2

    Bulbs Power Socket
    High-mounted brake light 20 W Ba9s


    pg. 70 Replacing bulbs


    Interior light
    Insert a screwdriver through the opening in the right side of the housing and depress the catch tab. Pull out the housing assembly and replace the bulb.

    Bulbs Power Socket
    Interior light 10W S 8.5-8

    Engine compartment light, Trunk light
    Remove screw holding the light assembly. Lift it out to remove.
    Replace the bulb.
    Reinstall by first inserting the guides into one side, then press in the light assembly and install the screw.

    Bulbs Power Socket
    Engine compartment light 15W S 8.5-8
    Trunk light 15W S 8.5-8

    Instrument and heater control lighting
    Due to the location of these bulbs, their replacement should be carried out by a Volvo dealer.

    pg. 71 Fuses


    Replacing fuses
    The fuse box is positioned in front of the left front door pillar. When replacing fuses, check that the correct amperage is used.
    Never use fuses of higher amperage, unless specified by your Volvo dealer. If one fuse repeatedly fails, take the car to your Volvo dealer for fault-tracing.
    A spare fuse kit is available from your Volvo dealer.

    WARNING!
    Turn starting (ignition) switch OFF before replacing fuses. Excessive heat may be created by a short circuit. Care must be exercised while replacing blown fuses.

    Some of the equipment listed below is optional
    1 Cigarette lighter, El. operated side mirrors, Radio, Tailgate wiper/washer, Cruise control (governor) 8 A
    2 Windshield wiper/washer, Horn 16A
    3 Heater blower 25A
    4 Fuel feed pump 8A
    5 Spare (8A)
    6 Main fuel pump 16A
    7 Brake lights, Cruise control (switch) 8A
    8 Interior light, Glove box light, Trunk light, Engine compartment light, Central locking, El. radio antenna, clock 8A
    9 Hazard warning flashers, shift indicator light 8A
    10 Window lifts 16A
    11 5th gear (manual transmission), 4th gear (automatic transmission), rear window demist, seat heaters 16A
    12 Back-up lights, Window lifts (relay), Air conditioning (with blower control), Rear window demist (relay) 8A
    13 Instruments, seat belt warning lights, Turn signals, Fuel injection system(relay) 8A
    14 Rear fog lights 8A
    15 Parking lights (left side), License plate light 8A
    16 Parking lights (right side), Light on instruments and controls, Headlights chime 8A
    17 Spare fuse storage
    Blade type fuse, serving LH-Jetronic fuel injection system. Located on the left wheel housing by the ignition coil.
    25A



    pg. 72 Wheels and tires

    Checking and correcting tire pressure
    Check the tire pressure when refueling. The tire pressure should only be corrected when the tires are cold. With warm tires, correct only when the pressure is too low. The tire temperature (and, thus, pressure) rises after driving just a few miles.

    WARNING!
    Improperly inflated tires will reduce tire life, adversely affect vehicle handling and can possibly lead to failure resulting in loss of vehicle control without prior warning.

    Vehicle Loading
    The tires on your Volvo will perform to specifications at all normal loads when inflated as recommended on the tire information label located on the rear facing side of the right front door. This label lists both tire and vehicle design limits.
    Do not load your car beyond the load limits indicated.

    Tire Pressure Label
    The tire pressure label is located on the rear facing side of the right front door.
    See section titled "Specifications" and Consumer Information Booklet for complete tire pressure information

    Wear indicator
    The tires have a so-called "wear indicator" in the form of a number of narrow strips running across or parallel to the tread. When approx. 1/16" (1.5 mm) is left on the tread, these strips show up and indicate the tire should be replaced.
    Tires with less than 1/16" (1.5 mm) tread have a very poor grip in rain or snow.



    pg. 73 Wheels and tires

    General
    When replacing worn tires, it is recommended that the tire be identical in type (radial) and size as the one being replaced. Using a tire of the same make (manufacturer) will prevent altering the driving characteristics of the vehicle.

    How to improve tire economy

  • Maintain correct tire pressure.
  • Drive smoothly: avoid fast starts, hard braking and tire screeching.
  • Tire wear increases with speed.
  • Do not change wheel location unless necessary.
  • Correct front wheel alignment is very important.
  • Unbalanced wheels impair tire economy and driving comfort.
  • Hitting curbs can damage the tires and/or wheels permanently.

    Winter Season
    Radial snow tires, installed on all four wheels, are recommended for winter driving. Use tires that are comparable in size and type to the original equipment installed by the factory.
    Mixing tires of different size, brand, or design could negatively affect tire road grip, especially when slippery road conditions exist.
    Use either 185/70R14 or 175R14 snow tires.

    Note: Overall diameter of tire and wheel combination will affect speedometer accuracy and fuel economy.

    Tire chains can be used on the rear wheels if the chains do not project too far from the tire and chafe against the brake caliper or other components. Strap-on emergency chains must not be used since the space between the brake caliper and the wheel rim is inadequate.

    Special Spare
    The spare wheel for your car is referred to as a "Special Spare". This name is embossed on the tire.
    On sedan models, the "Special Spare" tire has a 6-ply rating and, on the wagon models, an 8-ply rating tire.
    Tire pressure must be 36 psi (250 kPa) on a 6-ply rating tire and 40 psi (280 kPa) on a 8-ply rating tire irrespective of load or where the wheel is installed. In the event of a damage to this tire a new one can be purchased from your Volvo dealer.

    WARNING!
    Current legislation prohibits the use of this tire other than as a temporary replacement for a punctured tire. In other words, it must be replaced as soon as possible by a standard tire.
    Roadholding, etc., might be affected with the "Special Spare" in use. Do not exceed 50 mph (80 km/h).

    WARNING!
    Special wheel rims
    Only special wheel rims, tested and approved by Volvo, are suitable for use with the factory-installed air dam. Any other wheel rims may not permit sufficient air circulation for brake cooling.



    pg. 74 Wheel changing


    Changing a wheel
    Spare wheel, jack and tool kit are stowed in the trunk compartment. On the wagon models the jack and crank should be secured according to the above illustration to avoid any disturbing rattles. Make sure that the spare wheel is secured. Before raising the car with the jack be sure it is on firm and level ground.

    Note:
    Do not crawl or work under the car while it is raised by the jack.

    Before the car is raised with the jack the parking brake should be applied and one of the gears engaged. With automatic transmission, the selector should be in Park. Block one of the wheels on the opposite side of the car from the jack.

    Note: To avoid excessive tire wear and rebalancing, mark and reinstall wheels in same location and position as before removal. To lessen the chance of imbalance, each wheel hub is equipped with a guide stud to ensure that a removed wheel can be reinstalled in its original position.

    Removal
    To remove the wheel cap the center emblem must first be pried-off using the screwdriver provided in the tool kit. The wheel cap may then be removed by hand. Loosen the wheel nuts 1/2-1 turn with the box wrench provided in the tool kit. All of the wheel nuts have right-hand threads which are loosened by turning them counterclockwise.

    Installation
    Clean the contact surfaces on the wheel and hub. Lift the wheel and place it on the hub. Make sure that you align the wheel with the guide stud on the wheel hub prior to installation. Install the wheel nuts clockwise and tighten lightly. The beveled side of each nut should face the wheel. Lower the vehicle to the ground and alternately torque the nuts to 63 ft. lbs. (85 Nm). Install the wheel cap.

    pg. 75 Wheel changing


    Using the jack
    The spare wheel, jack and tool kit are stored in the trunk. On the wagon models the jack and crank should be secured according to the above illustration to avoid any disturbing rattle. Make sure that the spare wheel is secured.
    Before using the jack make sure the car is standing on firm, level ground. Apply the parking brake and place the transmission in either first or reverse gear. If equipped with automatic transmission place the selector lever in position P. Block the wheels standing on the ground with wooden blocks or large stones.
    There is a jack attachment adjacent to each side wheel location. Hang the jack from the attachment as shown in the illustration and crank while simultaneously guiding the base to the ground. Before raising the car check that the jack is still correctly positioned in the attachment.

    WARNING!

  • Never crawl under a car supported by a jack.
  • Use the jack intended for the car when replacing a wheel. For any other job use stands to support the end of the car being worked on.
  • Apply the parking brake, engage first or reverse gear (pos. P for cars equipped with automatic transmission).
  • Block the wheels standing on the ground. Use rigid wooden blocks or large stones.
  • The jack should stand on firm, level ground.
  • The jack should be kept well-greased.
  • Do not rotate a raised rear wheel if the car is equipped with a limited slip differential. This will also rotate the opposite wheel (on the ground) and the car may slide off the jack.




  • pg. 76 Replacing wiper blades, Washing

    Replacing wiper blades

    Washing
    The car should be washed at regular intervals since dirt, dust, insects and tar spots adhere to the paint and may cause damage.
    When washing the car, do not expose it to direct sunlight. Use lukewarm water to soften the dirt before you wash with a sponge, and plenty of water, to avoid scratching.
    A detergent can be used to facilitate the softening of dirt and oil.
    Special car washing detergent or household detergent can be used. A suitable mixture is about 2.5 fl. oz. (8.5 cl) of detergent to 2.6 US gal. = 10 liters of warm water. After washing with a detergent the car should be well rinsed with clean water.
    A water soluble grease solvent may be used in cases of sticky dirt. However, use a washplace equipped with a drainage separator.
    Dry the car with a clean chamois and remember to clean the drain holes in the doors and rocker panels.
    Tar spots can be removed with kerosene or tar remover after the car has been washed.
    Electrically operated antenna (optional) should be dried and lightly lubricated with an oil dampened cloth.


    Note: It is particularly important to wash the car frequently in the winter time, to prevent corrosion, when salt has been used on the roads. Also wash off the dirt on the underside (Wheel housings and fenders etc).

    Note:
    When the car is driven immediately after being washed, apply the brakes now and again in order to remove any moisture from the brake linings

    Previous Page   Next Page

    Contents | Top of Page