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Service and maintenance

pg. 51 Service and maintenance

Maintenance services 53
Service requirements 54
Engine B230F 56
Road assistance 57
Fuel requirements 58
Engine fluids 59
Engine oil, Oil/oil filter change interval 60
Cooling system 61
Servicing 63
Transmission oil 68
Rear axle, power steering, brake fluid 70
Lubrication 71
Coolant 72
Alternator, jump starting 73
Replacing bulbs 74
Fuses 79
Wheels and tires 80
Wheel changing 82
Replacing wiper blades 84
Washing, cleaning 85
Cleaning, anti-rust treatment 85
Paint touch-up 86
Long distance trips, cold weather 89
Service diagnosis 90
Label information 94

pg. 52 240 DL Wagon

pg. 53 Maintenance service


Maintenance services
Your Volvo has passed two major inspections before it was delivered to you, according to Volvo specifications. When driven 600-1,200 miles (1,000-2,000 km), your car should be brought to the Volvo dealer for a maintenance service. Engine, manual transmission and rear axle oils, will be changed at this time.
Following this inspection, maintenance inspections as outlined in this book should be performed every 5,000 miles (8,000 km).
Engine oil and oil filter changes should be performed every 5,000 miles (8,000 km), or at the time intervals outlined on page 60.

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 questions arise concerning maintenance. See your "Warranty Information and Maintenance Records Booklets"

Maintenance inspection intervals
Volvo advises you to follow the inspection program at 5,000 mile or 8,000 km intervals which is outlined in the "Warranties and 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 Clean Air Act requires vehicle manufacturers 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 "Warranties and Maintenance Records Manual" for further details.
In accordance with Federal Regulations, your Volvo is warranted to meet certain Emission Performance Standards. Refer to your Warranty Information Manual for detailed information concerning:

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

    pg. 54 Servicing

      A = Adjust (Correct if necessary)
      R = Replace
      I = Inspect (Correct or Replace if necessary)
      L = Lubricate
    Maintenance Operation Miles 600-
    5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 60,0002
      (Km) (1,000-
    (8,000) (16,000) (24,000) (32,000) (40,000) (48,000) (56,000) (64,000) (72,000) (80,000) (88,000) (96,000)
    Engine oil and Oil filter 1 R R R R R R R R R R R R R
    Cooling System Hoses and Connections4 I                        
    Engine Drive Belts A           I           I
    Torque Manifold Nuts A                        
    Valve Clearance             I           I
    Timing Belt A                   R 3    
    Vacuum Fittings, Hoses and Connections4 I                        
    Air Cleaner Filter             R           R
    Idle RPM I                        
    Fuel System Cap, Tank, Lines and Connections4 I3                        
    Spark Plugs             R           R
    Catalytic Converter Mounting Bolts A                        
    Manual Transmission Oil5 R I I I I I I I I I I I I
    Automatic Transmission Oil5 I I I I R I I I R I I I R
    Rear Axle Oil5 R I I I I I I I I I I I I

    1) See section in Owner's Manual for "Engine Oil" for detailed information
    2) For services beyond 60,000 miles (96,000 km), consult your Maintenance Service Chart.
    3) Recommended, but not mandatory to maintain Volvo emission warranty.
    4) Does not pertain to B230F/Renix,B230F/EGR.
    5) B230F/Renix, B230F/EGR inspect every 10,000 miles (16,000 km).

    pg. 55 Servicing

      A = Adjust (Correct if necessary)
      R = Replace
      I = Inspect (Correct or Replace if necessary)
      L = Lubricate
    Maintenance Operation Miles 600-
    5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 60,0001
      (Km) (1,000-
    (8,000) (16,000) (24,000) (32,000) (40,000) (48,000) (56,000) (64,000) (72,000) (80,000) (88,000) (96,000)
    Engine Coolant I   I   I   R   I   I   R
    Fuel (Line) Filter                         R
    PCV Nipple (Orifice)                         I
    Ventilation Hoses                         I
    Inspect Brakes. Replace components as necessary.     I   I   I   I   I   I
    Change Brake Fluid             R           R
    Tire Wear (Align front end if needed.) I   I   I   I   I   I   I
    Check power steering fluid level. I I I I I I I I I I I I I
    Trunk, Door and Hood Hinges and Latches. L   L   L   L   L   L   L

    1) For services beyond 60,000 miles (96,000 km), consult your Maintenance Service Chart.

    pg. 56 Service Engine

    The following items should be checked wee by the owner. (This only takes a few moments.) Description on page
    Engine oil level
    Brake fluid 59
    Radiator coolant level 70
    Tire pressures (including spare) 72
    Operation of all lights80, 101
    Horns -
    Windshield wipers -
    Level of windshield fluid -
    The following should also be carried out regular intervals. Description on page
    Washing 84
    Polishing 85
    Cleaning 85
    Rust protection inspection 85

    pg. 57 Service Engine

    Engine B230F
    1 Data plate
    2 Oil filler cap, engine
    3 Oil dipstick, engine
    4 Brake fluid reservoir
    5 Washer fluid reservoir
    6 Expansion tank, coolant
    7 Oil reservoir, power steering
    8 Battery
    9 Fuse engine control

    pg. 58 Fuel requirements

    Unleaded Fuel
    Each Volvo has a catalytic converter and must use only unleaded gasoline (as specified on the instrument panel and by a label near the filler inlet). U.S. and Canadian regulations require that pumps delivering unleaded gasoline be labeled "UNLEADED". Only these pumps have nozzles which fit your car's filler inlet. It is unlawful to dispense leaded fuel into a vehicle labeled "unleaded gasoline only".
    Leaded gasoline damages the catalytic converter and the oxygen sensor system. Repeated use of leaded gasoline will lessen the effectiveness of the emission control system and could result in loss of emission warranty coverage. State and local vehicle inspection programs will make detection of misfueling easier, possibly resulting in emission test failure for misfueled vehicles.

    Octane Rating
    Volvo engines require unleaded gasoline with an (R+M)/2 octane rating (also called the Anti Knock Index, or AKI) of 87 or higher. This is generally equivalent to a Research Octane Number (RON) of 91 or higher. Volvo recommends the use of premium unleaded gasoline with an (R+M)/2 rating of 91, for improved performance and driveability at high altitudes and in hot climates.

    Detergent or Injector Cleaning Gasoline
    The use of specially formulated gasoline which contains so called "detergent" or "injector cleaning" additives is allowed and recommended by Volvo. The use of these detergent additives in gasoline has been shown to be effective in reducing the build-up of certain injector deposits.

    Gasoline Containing Alcohol
    Some fuel suppliers sell gasoline containing alcohol without advertising the presence of alcohol if you are not sure whether there is alcohol in the gasoline you buy, check with the service station operator.
    Blends of unleaded gasoline and ethanol (ethyl alcohol, grain alcohol), sometimes called "gasohol", are available in some areas. Gasohol, if used, must contain no more than 10 percent ethanol and must have an (R+M)/2 rating of 87 or higher. If you experience problems with starting, driveability, or fuel economy with gasohol, you should discontinue its use. Take care not to spill gasoline during refueling Gasolines containing alcohol can cause damage to painted surfaces, which may not be covered under the New Vehicle Limited Warranty.

    Do not use gasolines containing methanol (methyl alcohol, wood alcohol). This practice can result in vehicle performance deterioration and can damage critical parts in the fuel system. Such damage may not be covered under the New Vehicle Warranty.

    Fuel Tank
    The fuel tank is designed to hold approx. 15.8 US gal. (60 liters), with sufficient volume left over to accommodate possible expansion of the fuel in hot weather.
    Be aware that the "usable" tank capacity will be somewhat less than the 15.8-US gal. (60-liter) maximum. When the fuel level is low, such factors as ambient temperature, the fuel's "vapor pressure" characteristics, and terrain can affect the fuel pumps' ability to supply the engine with an adequate supply of fuel. Therefore, it is advisable to refuel as soon as possible when the needle nears the red zone. After the needle enters the red zone, you should be able to drive approx. 25 miles (40 km) depending on driving style and conditions.

    pg. 59 Engine fluids

    Checking oil level
    The oil level should be checked each time the fuel tank is refilled. 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 quart (1 liter) of oil.

    Changing oil filter
    Replace the oil filter at every oil change. If the oil filter is changed separately 1/2 US qt = .5 liters of oil should be added.

    To add oil or change oil
    engine oil of the same kind as already used. See engine oil section.

    Maintain fluid level between MAX and MIN marks on expansion tank.
    Mixture of 50 percent Volvo anti-freeze type C (blue-green) or corresponding and 50 percent water should be used. See "Coolant" section.

    Brake fluid
    Check that the level is above the MIN mark, without removing the cap.
    Brake fluid DOT 4. See "Brake fluid" section.

    Check level in conjunction with normal service or once a year. Electrolyte level 1/4 - 1/2 (5-10 mm) above plates Use distilled water. Never add acid.

    Battery gases are explosives if brought in contact with open flame or sparks.

    Washer fluid
    Washer fluid reservoir.
    Water and solvent (wintertime use windshield washer anti-freeze). See "Washer fluid reservoir" section.

    pg. 60 Engine Oil, 5,000 mile (8,000 km) Oil/oil filter change interval

    Oil quality
    Meeting API specification SF (CCMC class G3)
    *Oils with designations SF/CC and SF/CD comply with these requirements

    Viscosity (stable ambient temperatures):

    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 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:

    Including oil filter: 4.0 US qts - 3.85 litres

    Check oil level when filling fuel.
    SAE 15W/40 is recommended for use in driving conditions that raise c temperature and increase oil consumption (i.e., mountain driving; trailer towing).

    Note: SAE 15W/40 must not be used at low ambient temperatures; see viscosity chart.
    Volvo recommends the use of oils with the American Petroleum Institute (API) label.
    This label certifies that the oil conforms to the applicable standards and specifications of the API.

    If driving conditions include: Then the correct oil. oil filter change interval is:
  • Extended periods of idling and/ or low-speed operation
  • Frequent short trips (less than 7 miles = 11 km)
  • Extended periods of driving in dusty and/or sandy areas
  • Trailer towing
  • Driving mountainous areas
    3 MONTHS
    or 5,000 miles = 8,000 km
  • Primarily highway driving
  • Frequent trips of longer than 7 miles = 11 km
    or 5,000 miles = 8,000 km

    pg. 61 Cooling system

    Changing coolant
    Every two years or 30,000 miles (48,000 km) the cooling system should be drained, flushed and refilled. Remove the expansion tank cap. Open the drain cock on right side 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: 9.9 US qts. = 9.4 liters (manual transmission models); 9.7 US qts = 9.2 liters (automatic transmission models)

    Cooling system, hoses and connections
    Check all cooling system hoses and connections for defects or deterioration of hoses and loose clamps or fittings.

    Drive belts
    The belt tension can be checked by depressing the fan belt at a point midway between the alternator and fan pulleys as illustrated. It should be possible to press down the belt about 1/4" - 1/2" (5-10 mm). This also applies to other drive belts on the engine.
    If drive belts are replaced, recheck belt tension after driving 600-1,200 miles (1,000-2,000 km).

    pg. 62 Service requirements

    Engine Mechanical Components

    Torque 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 emission and/or poor driveability.

    The valve clearance should be checked every 30,000 miles (50,000 km).

    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, EGR valve (where applicable) and connections on heater control servo systems and hydraulic brake servo.

    Exhaust Gas Recirculation (EGR)
    This system operates by returning some of the exhaust gases to the engine to be recombusted: since this lowers the combustion temperature the amount of nitrogen oxides released into the atmosphere is reduced.
    The EGR valve should be inspected every 12,000 miles (20,000 km) and cleaned every 24,000 miles (40,000 km).

    Timing belt
    The timing belt tensioner should be adjusted at the 600-1,200 mile (1,000-2,000 km) inspection.

    pg. 63 Servicing

    Engine Fuel System

    LH-Jetronic B230F engine
    The LH-Jetronic 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 the air mass meter which 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. 64 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, using equipment intended for this service.

    Fuel (line) filter
    We recommend that this filter be changed every 60,000 miles (96,000 km). The filter is replaced as one complete unit.
    Replace more frequently if contaminated fuel was introduced into the tank.

    Fuel system cap, tank, lines and connections
    The ability of the fuel system to control hydrocarbon emissions is dependent largely on a leak-free system. Check for proper sealing of gasoline filler cap which contains "O''-ring type seals. Check all evaporative hoses in vehicle for tightness. Check fuel lines under vehicle. Repair if necessary.

    Air cleaner
    Replace the air cleaner cartridge every 30,000 miles (48,000 km). The cartridge should be replaced more often when driving under dirty and/or dusty conditions. The filter cannot be cleaned and should always be replaced with a new one.

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

    Lambda-sond® (oxygen sensor) system
    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 continuously influences the amount of fuel injected. This adjusts the air-fuel ratio to provide optimum conditions for combustion and efficient reduction of the three major pollutants (hydrocarbons, carbon monoxide and nitrogen oxides) through a 3-way catalytic converter.

    pg. 65 Servicing

    Oxygen Sensor
    On the B230F engines, the oxygen sensor (Lambda-sond®) is electrically heated. The use of a PTC (Positive Temperature Coefficient) element to heat the Lambda-sond ensures a shorter warm up time and continuous operation at its working temperature.
    This type of Lambda-sond® does not require periodic replacement.

    Catalytic Converter
    This is a supplementary device in the exhaust system, designed to reduce exhaust emissions. 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 platinum and rhodium. These metals act as catalysts, permitting a chemical action to occur without actually taking part in it.
    The carbon monoxide content will increase if the Catalytic Converter is damaged.

    Vehicles with Catalytic Converter must use unleaded fuel only. Otherwise the Catalytic Converter will become damaged and ineffective.

    Torque catalytic converter mounting bolts
    The Catalytic Converter mounting bolts should be re-torqued at the 600-1,200 mile (1000-2000) km inspection.

    pg. 66 Servicing

    Engine Crankcase Ventilation System

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

    1. PCV nipple
    2. Flame Guard
    3. Oil trap

    PCV system, B230F engine
    The PCV nipple in the intake manifold should be cleaned after 60,000 miles (96, 000 km).

    pg. 67 Servicing

    Engine Evaporative Emissions

    Evaporative control systems
    Vehicles intended for the North American market are equipped with a fuel vapor 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. The components are interconnected by hoses which channel fuel vapor from the gas tank to the charcoal filter where they are stored until the engine is started and then drawn into the engine fuel induction system.

    Engine Ignition

    Change spark plugs
    The spark plugs should be changed every 30,000 miles (48,000 km).
    However, prolonged city driving or fast highway driving may necessitate changing spark plugs after 10,000 miles (16,000 km) of driving. When installing new plugs, be sure to fit the right type and use the correct torque, see "Specifications". When changing the spark 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.

    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, high-tension leads etc.

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