SeruiceManual
Section1 (17l
Repairs and maintenance
7,500Mile MaintenanceService 1984 DL,GL GLE(Canadal Turbo,Diesel
Contents lntroduction Volvo7.500Mile MaintenanceServiceChart 7,500Mile MaintenanceServiceProcedures Controls and lighting I nc a r , . , , . . , , . . , , . , , , Exterior,..,,......... On lift - Tires,wheels - Frontend -Brakes,,..,........ - Powertransmission -Rearend........... E x h a u s ty s t e mD, i e s e. |. . . . . . . . . . . . . . . . . . . . -Rearaxle,manualtransmission........... - Engineoil andfilter: ' G a s o l i neen g i n e s ' D i e s eel n g i n e Underhood: - E n g i n ceo o l i n sg y s t e m. . . . . . . . . . . . . . . . . . . F | u i d .s. . . . . . . . . . . . . . - 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 . . . . 821and 823 - lMiscellaneous - Adiustvalves R e p l a c e t i m ignega rb e l t . . . . . . . . . . . . . . . . . . . B2lNCanadai - lMiscellaneous - COemissions check 821F-Turbo: B23F:................ D24diesel: - Miscellaneous - Valve c l e a r a n caed j u s t m e r,t. , , , . , , . . , , . . ldlespeeds.......... - S e t t i n eg n g i n e c o n t r o.l.s. . . . . . . . . . . . . . . . - Compression test C h e c k i n g a d j u s ti n ; nj eg c t o ' s. . . . . . . . . . . . - R e p l a c i ntgi m i n gg e a rb e l l s . . . . . . . . . . . . . . Road test
TP30600n 7500.08.83 Printedin U.S.A.
Opeation Page 1 2 1 18 41-A6 81-83
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G,e!PJf,lE99!]ls!e - Chaft -
elviee
7,500 Mile 12,500km Maintenance Service lntroduction Thesemaintenanceinstructionsare presentedin a "Work RelatedSequence".Stepby step proceduresare designed to assistthe technician in performing the tasksin an efficientand logicalmanner.
VolvoMaintenance ServiceChan The VolvoMaintenanceServiceproceduresare listedon the followingpages(seechart).They appearin the sameorderas in the Warranties Records Manualsuooliedwith eachnewvehicle. and Maintenance 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 emissionrelatedserprogram. vicemainlenance Theseitemsreouireservicemaintenance at mileageintervals shownto ensure trouble-freeoperation.
Seruiceat: IEMTSSTOTVS 15- 30- 45-60- 7' 90- t 05- t 2, 50- 7r, 0lr- 12, 150- t 75- 20O-t housand km
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
2 3 4 5 6 7 I 9
Hazard warningflasher Blower Heatercontrols Reardemist AIRCONDcontrol norn Turn signals Headlights and LIGHTS switch panellights Instrument
In car A2 A3 A5 A6
Powerbrakefunction Pressure test brakesystem Parking brake Warninglights Autotransshiftcontrol Steering
Exterior- lubrication 81 82 83
Hoodhinges Doorhinges Trunklid
On lift Tires.wheels Tires Tire pressure Wheelbearingplay Wheelbearingnojse Frontend D 1 Frontshockabsorbers D2 Frontsprings D3 Steeringgear D4 Steeringrack D5 Controlarm bushings, strut D6 Steeringrod play D7 Ealltoints D8 Steeringrod ends D9 Controlarms D 1 0 Stabilizer barand links C1 C2 C3 C4
10 11 12 't4
17 18
Parking lights Brakelights Taillights Back-uplights Reflectors and lenses Fillwasherfluid Wiperblades Wipercontrol Washeriets
All items on this pageshould be inspectedal 7,500mile = = 12,500km intervals: miles km = 7,500 12,500 15,000: 25,000 22,500: 37,500 30,000= 50,000 37,500= 62,500 45,000: 75,000 52,500: 87,500 60,000= 100,000 6 7 , 5 0 0 :1 1 2 , 5 0 0 75,000-- 125,000 82,500 137,500 90,000= I50,500 97,500= 162,500 = 175,000 105,000 = 187,500 112,500 = 200,000 120,000
O
Group17,7,500Mile MaintenanceService - Chart-
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Fluids Rearaxle lvl46manualtransmission Engineoil andfilter: J1-J2 Gasoline engines INOTE:Turbointervals!) J3-J4 Dieselengine Enginecoolingsystem: K1 Checkanti-freeze K2 Replace coolant Fl!ids: K3 Brakefluid level K4 Powersteeringgear K5 Battery
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821and 823(all) Autotrans:adjustkickdowncable Enginecontrols Drivebelttension Adjustvalves Replace timinggearbelt
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3
-r Group17,7,500Mile MaintenanceService - Chaft-
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B21l'lcanada Exhaustsystem Damperoil level Chokecontrol points,rotoretc Breaker Dwellangle Pulsair aaPT Positive crankkcase ventilation Replace aaPs sparkplugs aaPg Lubricate distributor aaP10 ChecUadjust timing a a Pll EGRvalveoperation P12 Cleanfuel pumpstrainer P13 Replace airfiltercartridge P14 Checkcentrifugal advance P15 Checkfuel lines 01-O16 COemissions check
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Pl P2 P3 P4 P5 P6
821F-Turbo Rl Tightennuts,exhaustpipeto turbo R2 Checkturboseal R3 Torqueclampscrews Checkof turbo system: R4-R5 Connectinstrument R6 Checktimingretard R7 Checkfull loadenrichment system R8 Checkoverloadprotectionswitch R9 Lubricate distributor R10 Replace airtiltercanridge EMtSStONS R11 Replace sparkplugs EMtSSTONS R 1 2 - R 1 3Replace oxygensensor, resetlight EMtSStONS R14 Replace fuelfilter R15 Positive crankcase ventilation same:adverse conditions R16 Replace fueltankfilter
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Group17,7,500Mile MaintenanceService - Chart -
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B23F Replace air filtercartridge Replace sparkplugs Replaceoxygensensor, resetlight Replace fuelfilter Positivecrankcaseventilation - same;adverse conditions Replace fueltanktilter
D24diesel Draincondensate Positivecrankcaseventilation a3 Coolingsystempressurecheck Replacing a4 airIiltercartridge a5 Replace fuelfilter a6 Checkluel lines Drivebelt tension a7 b1-h12 Valveclearanceadjustment c1-dj Enginecontrols Maintenance servicesat 75,000mile intervals: e'l-el0 Compressiontest f1-f8 Checking/adjustinginjectors g1-933 Replacing timinggearbelts
EMtSStONS EMtSStONS EMtSStONS
EMtSStONS EMtSSIONS EMtSStONS EMTSStONS EMtSStONS EMtSStONS EMtSStONS
5
Group17,7,500Mile MaintenanceService - Chart -
Roadtest
_---I
Item
Adjust
Engine l l
3 4 5 6 7 8 I 10
Startingability Fastidle(coldengine) ldle(warmengine) No stallson acceleration or deceleration No noisefrom engine Normalwarm up Normalengineoperation Normalacceleration Leaks Reinstall hardware removedat Jactory
Elestrical l
2 3 4
Staner/alternator operation lgnitionandsteeringlock Instruments, controllights
Drivetrain l
2
Clutchadjustment Clutchoperation
Manualtransmission Correctoperation
o
Group17,7,500Mile MaintenanceService - Chaft -
Automatictransmission 1__
Gearseloctorplay Starteroperationonly in P and N Runto normaloperating temperature No slippageat stallspeed Upshift No slippageduringshifting Kickdown Upshiftwith kickdown Gearselectorin 2, downshiftand braking Gearselectorin 1, downshiftand brakino Parkpositionoperation Driveshaftsand bearingnoises
o3 5 6 1 8
10 11 12
Biakes 1
Powerassist No pullwhenbrakinghard Pedalpulsatlon "Spongy"brakepedal Parkingbrake
3
Steering 1 2
Correctsteering Stoeringwheel positionand return Steeringwheeleffort Steeringlooseness Powersteeringlunction
5
I
Serines and wheels No suspension noises Rearaxletight Tireunbalance
2 3
Bodyand equipment 't
__
Accessoryoperation Heaterand heatercontrols Speednoises Body noises Visibledefects Cleansteeringwheeletc Notefaultsdetected Checkoff Remedyfaults
7
Group17,7,500Mile MaintenanceService - 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 12,500 7,500= 1 2 , 5 0 0 15,000= 25,000 22,500= 37,500 30,000= 50,000 37,500= 62,500 45,000= 75,000 52,500= 87,500 60,000= 100,000 67,500= 1 1 2 , 5 0 0 75,000, 125,000 82,500: 137,500 90,000= 150,000 97,500- 162,500 = 175,000 105,000 = 187,500 112,500 = 200,000 120.000 127,500= 212,500 : 225,000 135,000 142,500: 237,500 = 250,000 150,000 = 262,500 157,500 : 275,000 165,000 172,500= 247,500 = 300,000 180,000 : 312,500 187,500 = 325,000 135,000 202,500- 337,500 210,000= 350,000 2 1 7 , 5 0 0 : 362,500 225,000= 375,000 232,500: 387,500 240,000: 400,000 247,500= 412,500 255,000= 425,000 262,500: 437,500 270,000= 450,000 277,500- 462,500 285,000= 475,000 292,500- 487,500 300,000= 500,000
15,000 22.54O 25,000 37,500
30,000 50,000
45,000 75,000
60,000 75,000 100,000 125,000
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9
Group17,7,500Mile MaintenanceService - Controlsand lighting-
Procedures Controlsand lighting
Hazardwarningflasher. Pressin switch.Checkthat all fourturn indicator lightsand switchindicatorlight flash.Turn off
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D n t,4l tl l-!21l-ll EI E
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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 ventopenings. Depress FLOOR control.Checkthat air is blowing from floor vent openings.Also checkthat air is blowingto rearseat. Runengineuntilat normaloperating temperatu-
-11-
10
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.
c
Group17,7,500Mile MaintenanceService - Controlsand lighting-
Checkelectricallyheatedrearwindow (demist). Actuate REARDEMISTswitch for rear window heater. Checkthat lightin switchcomeson. type.SystemremainsON Switchis a spring-back for 1G-15 minutesunlesskeyis turnedOFF.
CheckAIRCONDcontrol. Startengine. ActuateAIR CONDswitch.Checkthat maonetic clutchfunctions, visuallyand by sound. Switchengineoff.
Checkhorn. Depress places.Check horncontactsat alternate that hornoperates at all points.
Checkturn signals. Check thatleftandrightfrontandrearturnindjcator lightsaswellas indicatorlightson instrument panelflash.Checkthat leverreturnsto neutral afterturningsteering wheel.
11
Group 17,7,500Mile Maintenance Seyice - Controls and lighting -
Checkheadlightsand LIGHTSswitch.
position. PlaceLIGHTS switchin headlight Switch between highandlow beams.Checkin highbeam position thatheadlights andindicator lightareon. 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.Checkthatlightintensity increasesand decreasesby turning rheostat first clockwise,then counterclockwise.
10Q
Checkparkinglights.
0)
Checkthat all lightsareon.
Qr 11
Checkbrakelights. nonroc.
hrrL6.6.lil
Checkthal brakelightscome on with light pressureon peoar.
0r 12
Group17,7,500Mile MaintenanceService - 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 actuatins 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 insen 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 pullingforce beobtained afterpulling2-8notches, 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 threadprorruotnq,
15
Group17,7,500Mile MaintenanceService -lncar44
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.
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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. Turnsteeringwheelfully to right and left positions.Checksteeringeffortand steeringgearfor play.
0) 0
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
Group17,7,500Mile MaintenanceService - Tircs, wheels -
On lift
o Tires,wheels Seruiceevety 7.500miles : 12,500km
0; Checktires. atrpressure arrpressure too high
Checktreaddepth.Minimumallowableis 1 mm l=1/32"1. Checkwear pattern.lt may indicateunbalance, incorrect camber, toe-inor incorrect tirepressure, Checkthattiresmountedon bothfrontand both t^ rearwheelsarethe same(radial,cross-ply, tread, U studded).
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t- == =-1.
Checktires and tire pressure. qca
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Generally: Economy andmax5 persons in vehicle:use36psi front and rear, Comfortandmax3 personsin vehicle:use26 psi front and 27-30psi rear.
18
Group17,7,500Mile MaintenanceService - Frontend -
c3
Checkwheel bearing play.
lfthere Rockthewheelat12and6 o'clockposition. immeis play,wheelbearings shouldbe serviced diately.
Checkwheel bearingnoise. Letthe wheelfotatefreelyafterspinning.Check wheelbearingfor noise. Wheelbearings whichare not adjustedproperly cancausenoise.
Frontend Se|ice every7,500miles: 12,500km
D1
Checkfront shockabsorbers.
Visuallycheckshockabsorbers for leakage. NOTE: Do not mistakemoistureon shockabsorberfor reaKage.
Checkfront springs. Checkspring attachmentand condition
Check steering gear. gearrubberbellows for damage. Check steering
by tryCheckthatsteeringgearis tirmlyattached ingto moveit by hand.
19
Gtoup17,7,500Mile MaintenanceService - Frontend D4
Checksteeringrackfor play.
Check Jigglewheelat 3 and I o'clockpositions. playalongaxisof the rackand innersteeringrod lornt,
ou o, Checkcontrolarm bushingsand strut attachment.
Turnwheelsfullyto eachsideandiigglewheelat for eachextreme. 12and6 o'clockpositions check control arm bushings,shock absorber for play. spindleand upperstrutaftachment
(
o
or0 Checksteeringrod play.
Jigglewheel at 3 and I o'clockpositionswith wheelspointingstraightahead. guideline: Judgement 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 Seruice evety 7,500 miles : 12,500 kfi EXCEPT AS STATED
E
Checkbrakehoses. Checkbrakehosesforleaks.Checkthathosesare correctly installed andthatconnections aretioht. Checkthatbrake hosesarenotchafedandareiree lrom sharp edgesor other obiectsthat could
*a Gheckbrakelines.
Checkthat all brakelinesare correctlyinstalled and secured. Also checkthat they arefreefrom 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 .
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LnecKTor teakaoe
0 Checkparkingbrake. Checkthat rubberbellows,outercablesand suspensionarein order.
E4 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 padsareconsidered cannotbe inserted), worn. lf wire gaugefits but liftleclearance is left,pads will haveto be replaced within lessthan 15,000 mtles. Checkfor signs of leakageat caliperor connection.
22
0 0
(
Group17,7,500Mile MaintenanceService Powertrcnsmission-
Powertransmission Serviceevery7,500miles: 12,500km
F1
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+ rr@r sfrifr
06
Automatictransmission: 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 and retainer for play. Checkthat rubberbellowsarenotworn or damagedand arecorrectly installed.
23
croup 17,7,500Mile MaintenanceSeruice - Rearend -
Rearend Seflice every 7,500 miles : 12,500km
nra Checkrearshockabsorbers.
Checkrearsuspension,
for trailingarms, Usea pry barto checkbushings brakereactionrods,trackrod andstabilizerCheck and condition. springattachment
Manually check shock absorberattachment. Checkfor leaks. Do not mistakemoistureon shockabsorber{or teaKage,
NOTE: There is no need to retorque all bolts. nuts etc unlesspartsarefoundtobe loose. Specificationsare provided as a guide for tighteningloosehardware.
Nm A B
c
D E F
G H I J K
24
Rerctionrod: Bodyattachment Rearaxle attachment T.ackrod (Panhardrodl: Rearaxleattachment Body attachment RearSpring: Upperattachment Lowerattachment Shockabsorber: Upperattachment Lowerattachment Trailingarm: Bodyaftachment . Rearattachment {atrearaxle). . .. . .. Stabilizer: ( .shockabsorberl Frontattachment Rearattachment Wheels: .. . . .. . . .. . criss-cross Nuts,tightened
{
ft. lbs. 62 62 44 62 32 14 62 62
.
.
.
.
110 .. 125..
80 90
85 45
62 32
115 ....
85
0
T t
Group17,7,500Mile MaintenanceService Exhaustsvstem Rearaxle.manualtransmission-
Service at: 1130-4860-7 s-go-tho usand mil es 2 5-50- 7, I 00- 125- 150- t housand km lntervals: 15.000miles : 25.000km
Checkexhaustsystem. Checkcondition, alignmentand suspension.
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 overdrive,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,
at 15,000 mileinter' Oilfilteris normallyreplaced vals.However.any adverseconditionsrequireoil filterchangemoreoften, Usespecialtool 2903to removeold oilfilter.Oil instrucnewfilterrubberseal.Checkinstallation tions on filter. Screwon oilfilter by hand,retorqueif necessarys. Mr
Drainengineoil, Checkthat engine does not leak oil, fuel or coolant.Reinstall oil drainptug.
Gasolineengines Ouality:
According to APIService SF(minimum). {Oilswith specificationsSF,SF/CCand SF/CDcomply.) Syntheticor semisynthetic oils may be usedif specifications comply. Fuel-saving oils are recommended, When using by suchoils,oil changeintervalsrecommended Volvomust be Jollowed.
0r
(
0r
(
Oil and filter changes Replacedfirst time at 600-1,200mile('1,000-2,000
km) insoection. Subseqirent changes:Mileageor time (whichever comesfirst).Seechanbelow:
( 1 2 , 5 0k0m ) o r
(6.2s0km) or
0
3,750miles(6,250 { 1 2 , 5 0k0m )o r
0,'I
0
Viscositv:(stableambienttemperatures)
Adversedriving conditions:
-
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
conditions sustained drivingin dusty/sandy trailerhauling sustained sustained hill climbing sustained highspeeddriving low speeddrivingor idling sustained miles= 10km)at whendrivingshondistances(7 : lowtemoeratures 132'F 0" C).
Group17,7,500Mile MaintenanceService - Engineoil and filtet -
Dieselengine EMISSIONS Serviceevery7,500miles: 12,500km
Replaceoil filter. Oilfilteris normaly replaced mileinteF at 15,000 vals,However,any advefseconditionsrequireoil filter change more often. Use specialtool 2903 to removeold oil fllter.Oi new filter rubber seal.Checkinstallationinstructions 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 coolant.Reinstalloil d r a i np l u g .
0
Ouality: According to APIService CD(minimum). Oilswith specifications SE/CDand SF/CDcomply. Syntheticor semisynthetic oils may be usedif specifications comply.
Oil and filter changes. Replaced firsttime at 6001,200 rnile(1,000-2,000 km) inspection. Subsequent changes:Mileageor time interval (whichever comesfirst).Seechartbelow: Drivlnsunderadverse c o n d i t i o n ss e eb e o w
0
t l o , m a la , r i n g
"ondiiiN
(stableambienttemperatures) Viscositv:
3p 2p -rp q
fuel or
E a c h7 , 5 0 0m i l e s( 1 2 , 5 0k0m ) or everyth rd monlhwilh oiL fiherchangeeverysecond E a c h7 , 5 0 0m i l e s( 1 2 , 5 0 0k h )
or everysixrhmonthwnh oil filter changeeverysecond
rg 2p 30 4p "c Adversedrivingconditions:
SAt1o!/Jo sAEl5*/rr0
o
sustalneddriving in dusty/sandyconditions sustainedtrailer hau ing - s u s t a i n e hd i l c l i n r b i n g - sustainedhigh speeddriving sustainedlow speeddrivlng or id ing - when drivingshortdistances(7 miles= 10km) at (32'F ow temperatures 0'C).
Capacities: D24i SAE15W40is recommendedfor useln extremedrlvingcondlt 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 e dc o n s u m p t i oen. g , mounlaind rivingwilh tfequentdecelerario nso r fasrholo May driving. Notehoweverthe lowertemperature imits,
Excl.oll fi ter: 6.2liters: 6.6US qts Incl.oi flltefi7.0= 7.4US qts Difference betweenMin.and Max:1.0liters= I US qt.
27
Group17,7,500Mile MaintenanceService - 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%waprovidepoor rusl prolection,For this reasonralio of anliter, 50 % anti-freeze)to correct level. treeze/summer coolanttowatershouldbe l to 1,
Seruiceat: 3l)-60-90-thousand mi les 50-100-1s(Lthousa nd km Inbruals: 30,000miles : 50.000km
K2 (
(
Replacecoolant.
Removereservoirfiller cap. Drain coolantby disconnecting lowerradiatorhose, Fillwith new coolant(50%water,50%antifreeze). Useonly VolvocoolantTypeC, blue-green. fillercap. Re-install
Fluids Serviceevery 7,500miles : 12.500km
K3
0
Brakefluid level. In enginecompanmenL, checkbrale lines and rese;voir for leaks. brake-fluid Checkbrakefluid levelwithoutremovingcap.lf brakefluid has to be relilled,use brakefluid according to specification DOT4.
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
I-
(
)
I
Group17,7,500Mile MaintenanceSeNice - Replacingautomatictrcnsmissionfluid K5
Battery.
Checkbatteryelectrolytelevel.(Fill with distilled wateronlv,) Checkbaftoryholddownbracketfortightnessand that cablesare secured.
Automatictransmission:replacefluid Setuiceat:
22,t45-67.r90-t housand miles 37,5-7r112,r14r-thousand km tnteruals:22.500 miles : 37.500km ForVolvos with automatictransmission, anoptional Volvoautomatlctransmlsslonotl cooler must be installedwh€n trailsr wgight exc€€ds2,000lbs = 908kgs. Ov.rdfs should not bo u.sd whib towins. ObseNelegalrequirements of the sratein whichthe vshicl€sa€ rcsist€rcd.
L1
Checkcondition of Automatic Transmission Fluid. Discolorationand smell can be causedby heavy engineloads,suchastowing, lf this is the case,removeand clean oil pan, oil strainerand panicle magnet.Follow procedurcs outlinedin L7-L10. drainfluidby removing Undernormalconditions. drainplug. FollowDrocedures outlinedin L2-L6.
Drainingthroughdrainplug
L2
Dlain automatictransmission.
drainplug. Remove drainpluganddrain.Relnstall
\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
Group17,7,500Mile MaintenanceService - 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.
0
Fill2 quartsof AutomaticTransmission Fluid. BW55: ATF tvoe F or G. AW70/AW71:Dexron 11.
Q.
I
Runengine. Startengineand let idle.SwitchengineOFFwhen air bubblesbecomevisible in hose.
Checkconditionof AutomaticTransmissionFluid. Fluidmustnot carryimpurities, discoloratjon or sme .
I (
L6
Reconnectreturn pipeto automatic transmission. Fill2 quartsof AutomaticTransmission Fluid. 8W55:ATFtvoe F or G. AW70/4W71:Dexronll.
Adiusttluid levelas describedin L11.
30
,,..-.t
Removingoil pan
Group17,7,500Mile MaintenanceService - Replacingautomaticttansmissionfluid
Drainautomatictransmission.
Disconnect fillertubeat pan and drain.
WARNING! Oil can be scalding hot if vehiclewas recently
L8
Removeoil pan.
Cleanoil pan,strainerand particlemagnet. NOTE! Alsocleanoil cooler
I
D
Reinstalloil pan and filler tube.
Applyoil to pan gasketpriorto installation. Use new gasket. 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
Filloil.
L10
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-axThisis a +105"{+40'C) Coldoil- oiltemperature afteridling for transmission normaltemperature below for about10 minutes.At oil temperature +40'C,levelmav be belowMIN mark.
Checkoil levelforautomatic transmission.
M
"90'C
This +195"F(+90'c). Warmoil oil temperature whendrivingfor about30 temperature isobtained minutes.At oil temperatureabove +90"C,level maybe aboveMAX mark.
Fluidto fill AutomaticTransmission lf necessary, normal level.When checkingfluid level, car shouldbe on levelgroundin PARKpositionwith fill engine idling. lf topping up is necessary, throughdipsticktube.
{,
NOTE: for hot and cold transDipstickhasgraduations fluidleveluseclean missionfluid.Whenchecking ragthatwill not leavelint.
(
I
t
0 I I
Group17,7,500Mile - 821and 823 -
e Service
Followingoperationsreferto 821and 823 (alll
Seruiceevery 7,5(n miles : 12,500km
M1
Automatictransmission: Adiust kickdowncable. Checkcablelengthat closedand open throttle (engineoff).Adjustif necessary. Open throttle measurementshould be checked with throttlepedalin cardepressed,NOTby actuating 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. Checkthat cable,linksandspringsareserviceable installed. and correctly Adlustplay.Lubricate ioints,usinga lightoil. NOTE: Do not applylubricant to cable.
o o
I EMISSTOIS Service at: 30-60-90- th ousand m il es 50- 1(n- 15O-thousadd km ln|€,ruals:30,000miles : 50,000km
Mi,
Checkdrive belt tension.
lf necessary adlust.lt shouldbe possibleto depress drive belts 5-10mm = 3/16-5/16"halfway betweenoullevs,
I 33
-T Group17,7,500Mile MaintenanceService - 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).
Cyl.1: usefeelergaugeto checkvalve clearance.
N2.
Whenchecking, clearance shouldbe: coldengine:0.25-0.45 mm = 0-010-0.018" hotengine:0.300.50mm = 0.012-0.020"
e 0
Whensetting,clearance shouldbe: coldengine:0.35-0.40 mm = 0.014-0.016" hotengine:0.40-0.45 mm - 0.016-0.018" Sameclearance for intakeand exhaustvalves. NOTE: Alwayscheckvalveclearance with cylinderat top deadcenter.Alwaysturn 1/4turn aftertop dead centerto set.
,v3 c lf clearanceis incorrect: Lineup valvedepressors, Turnvalvedepressors so 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 valvesN5
Usetool 5026to removedisc.
N6
Use micrometer to measurcdisc thickness.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 Gtoup17,7,500Mile MaintenanceService - 821and 823: adjustvalvesN10
Cyl.3:
'a 'n
Rotateengine crankshaftto correct position for firing No. 3. cylinder.Check clearanceas describedpreviously. lf necessary, correctclearance.
Ir
Cyl.4:
Repeatprocedure.
0)I N12
Cy[2:
Repeatprocedure.
Nt3
Re-checkon all cylinders.
f
Turnenginea few turnsbeforechecking.
Positionvalvecovergasket.
N15
Installvalvecover. Hex10mm. Torque:12.5Nm = 9 ft.lbs.
36
t
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 intermediateshaft 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.
A
CheckoDeration of chokecontrol.Checkthat indicatorlightcomeson whenchokecontrolis engaged.
39
Group17,7,500Mile MaintenanceService - B21AP4
Breakerpoints,checkcondition.
I
b^
zAJ-+I
Worn points may indicatedefectivecapacitor
l,
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. Disconnect air hoseat air cleaner. Checkthat air is beingdrawnin andthat no back oressureexists,
t,
I
I In caseof problems: Disconnect hosesat Pulsairvalves, Startengineand hold hand abovevalves. should be suckedin through valves and exhaustgasesbeforcedout.
40
Gtoup 17,7,500Mile Maintenance Service
- B21ASeryice 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 temperarure gaugel.
D
)o
B21A Gap ... ... ... . ... ... . ... ... . Torque(plug threadsnot oiled)
VolvoP/N273592-6(set of toud or EoschWTDC 0.7-0.8mm : 0.028-0.O32' 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-
P10
InstrumentsusedareVolvoMono-Tester or "lMagnetic Timing Units" equipped with proper adapter.
Checkand adiusttiming. Disconnect vacuumhoses.Disengage air conditionerRunengineat a sufficiently lowidlespeed, 700-800 romto avoidanvinfluence lrom distributor centrilugal advanceaystem.
o{
B21A:
I
7' at 750 rpm.
I CheckEGRvalveoperation.
Increaseenginespeed,Observemovementol window in valve EGRvalverod in observation housingwhenvalveopens, throttlequicklvand observethat valve Release closes. lf inooerative: checksolenoidvalveoperataon.
el
IIISPECTION
Functiontest. ln caseof oroblems: Performa more thorouahIunctiontesl.
1.cold enqine,@olantteFp.rature below+55oC. w h d cold engr.e EGBv6lvtshourdbe Llosedat a l sDeeds tncrease rpm and checkthatEGBvalvedoesnot open Check by observinqconrrolrod,seeillusnalion is IfEGRvalveooens.it is an indicationthatthermostaticvalve 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
0'l
0ra il
2. W.rm engine,coolanllemperaruteabove+ 60'C EGBvalveshouldooenal rDmsaboveidle speedwrlh warm
I
Rur engineuniilit reachesnormalope.atingtemperature 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, An ahernaiivetesi meihodisto usethe stong vacuumdeated in enqineintakemainfoldal idle.The connectionis lsed for vacuunconrrolofignitiondistriburoror for powerbrakeunrt, lfthisvacuunisconhected to EGFvalvewhenen9ineisidling, valveshouldopen.Exhaostgases aredivertedto engineandit shouldrun very poorlyor stop-
D
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 s h o u l db ew e l l a b o v e + 6 0 ' C= 1 4 0 ' F .
D
)D
s
:
Cleanfuel pumpstrainer.
Alsocleanfuel pumpsludgeaccumulator Carefullycheckseal and s;aling surfacesbefore re-installing.
ID P13
Replaceair filter cartridge. Whendrivingunderdirtyanddustyconditions, air filter cartridgeshouldbe replacedmore olten.
D
Fordry, dusty,pollutedregionsan air tiltercartlt ridgewith superiorfilteringabilityis available. shouldbeusedonlyin suchregions. Replacement intervals dependon operating conditions
43
Gtoup 17,7,500Mile MaintenanceService - B21APl4
Checkcentrifugaladvance.
Runengineat 2,500rpm (= 1,250 distributor rpml. Vacuumunit disconnected, Timing point should increaseconsiderablv, to approx.25-30'BTDC.No increase, or smail increase, indicates defective distributor mecha, nism.
Pl5
cDl
CI.
Checkfuel linesfor tightness.
Checkthatthereare no tuel leaksin enginecompanmenL 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
Group17,7,500Mile MaintenanceService - B2lA COcheck-
DisconneqtPulsair. Disconnect hosefrom a t r cleaner.Plug disconnecteoend,
Adlustidle speed. Engineat normaloperating temperature. 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.
0
lf COis outsidelimits,it shouldbe setto 3 %. Theadiustment screwis sealedwith a flatwasher and a lockwasher,
45
Group17,7,500Mile MaintenanceService - B21ACOcheckCOadjustment:
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. 7 mm and innerdiametermin.3 mm, length100 mm.
COadiustment:
a8
f_l
{l
Pressdown adiustmentscrew. Usea ounchmax.3 mm diameterto oressdown adlustment screwto bottomposition.Upperlock washershouldremainat top.
{
(
COadiustment:
a9
Removelockwasherand flat washer.
Turnlockwashersideways andusea steelwireto removeit, Shakeout flatwasher
t,'
46
I
.tGroup17,7,500Mile MaintenanceService - B2lA COcheck-
410
o
Pressdown lower lock washer. Usetool 5159.
Installretaining screwlor fuelneedle.Install piston, diaphragmand needle assemblyin carburetor.
alt
COadjustment:
Priorto checking@:
- Checkdamperoil level. - Installdamperplunger. - Momentarily revengineto 3000rpm (50r/s)
COadjustment:
412
Adiust@. Use tool 5159to adjustluel needlepositionin carburetor. Adlustingrangeis approi. + turns. Turning tool clockwise increasesCO. counterclockwisercducesCO. Makesure tool lugs grip recesses in air valve spindle.Otherwisecarburetordiaphragmmay oecomedamageo,
COadiustment:
413
Install@ adiustmentseal.
o
Removedamperoil. Use paperto absorbit or removeoistonand oourit out. InstallnewIlatwasherandnew lockwasherUse tool 5159. 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
Group17,7,500Mile MaintenanceService - 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 regulation. may be a violationof Federal
t 133212
49
Group17,7,500Mile MaintenanceService - B2lF-Tutbo
B3
Torqueclampscrews.
Fourclamps,two at eachendot intermediate pipe between compressor andthrottlehousing, should betorqued,
ol
Torque:3 Nm:2.5 ft.lbs.
"' cte Connectpressurepump and gauge.
Usepumpandgaugenormallyusedto testradiator pressure. - Volvotools:pump998-5496 gauge andpressure 999-5230.
el,l
Connect to distributor air pressure unit.Plughose removed.
gs,i) Connectinstrumentto checkLamboa systemduty cycle.
Forthispurposea highqualitydwellmetercanbe used.Scalemustextendto at least70"{4-cyl.set, rngl. Dwellmeteris connected to Lambdasondservtce otcK-uo, DIELL
0-r
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 pressure distributor unit,as appropriate. Reinstalland clamoDressure hose.
50
I
Gtoup 17,7,500Mile Maintenance SeNice - B21F-Turbo-
R7
0 Checkfull load enrichmentsystem. Connect air pressurepump and gaugein line
leadingfrom intakemanifoldto pressure switch on firewall.
Enginerunning,pumpairpressure untlldwellmeter{measuring dutycycleof Lambdasondsystem} displays steadyreadingof 58.5"(56-62'allowed). Air pressure readingat thatinstantshouldbe20.3 kPa= 2.9psi.
J "./
(c
DITL
R8
Checkoverloadprotestionswitch,
=$4.,,,
jl .^. 1 -'l71,--1''..
l0
rD
Pumppressureuntil enginestalls,Air pressure readingshouldbe 70 kPa= 10psi. At the sametime air pressuregaugeon instrument panelshouldgo to red and red "Turbo" warninglighton instrument clustershouldilluminate. In caseof incorrect proreading : replace overload tectionswitch (insidefirewall,ciose to clutch pedalbracket).
0 51
Group 17,7.b00Mile Maintenance Service - B21F-Turbo-
Seruiceat: 15-30-4, 60-75-90-th ousand mi les 25-50- 75-100-12r15$-th ousand km lntervals:15.000miles: 25.000km
Lubricatedistributor.
0) |
Removerotorandlubricate feltwickin distributor 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, moreoften. filtercanridgeshouldbe replaced
30-60-90-th o usand n i les 50-1 00-150-th ou sand km
I
lnteNals: 30.000miles: 50.000km
i: "_'+,r _ --, :;;:-
,
f.]--i3i
B2'lF-Turbo Gap................. Torque(plugthreadsnotoiled) . . . . .
52
Replacesparkplugs.
I
Sparkplugs must be tightenedto specifictorque for proper operation and to avoid damage to threads, Sparkplug removaland installationmust be performed when engineis cold (low readingon tem' peraturegauge).
(setof four) "Super"sparkp ug VolvoP/N273594-2 or BoschWRTDS 0.7-0.8mm : 0.0280.032' 20-30Nm : 1F22 ft. lbs.
fr,
Group17,7,500Mile MaintenanceSeNice - g2lF-Turbo-
30-60-90-thousand miles 50-100-150-thousand km
0
Replaceorygen sensor.
Applyanti-seize compound"Never-Seez" to sensor 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.Repanel. installcover
Seruiceat: 60.(n0miles:100.000km lntervats: 60-(n0 miles : 1N,000 km
)
0
)
Replacefuel filter. Fuelfilterlocatedon Iirewall.Noteflow direction arrowon filter
0 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),
Positivecrankcaseventilation. Checkhoses for condition and clogging. Clean ntoDle,
ln'€wals: 60,(n0miles= 100,Unkm
nr6 o
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 filtercartridgewith superiorfilteringabilityis available. 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' -
)
)
D
B23F
t
Gap................. Torque(plugthreadsnot oiled) . .. . .
Replacesparkplugs.
Sparkplugsmustbe tightenedto specifictorque for properoperationand to avoid damageto tnreads, Sparkplugremovaland installation mustbe performedwhenengineis cold{lowreadingon temperaluregaugel.
(setof four) "Super"sparkplugVolvoP/N273594-2 or BoschWRTDS 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.
Applyanti-seize compound"Never-Seez" to sensor threads prior to installation.Coat entire thread.Do notapplycompoundto slottedpartof
o,
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
ResetLambda-sondreminderlight.
Removepanelandswitchcover.Pressbutton.Repanel. installcover
Serviceat: 60,000miles:100,000 km tnteNals: 60,000miles : 100,000km
cl cl t)
!
LH-Jetronic: Replacefuel filter Fuelfilterlocatedunderneath car,underlelt rear seat.
Removefuel tiller cap
Cll
Disconnectfuel linesat tuelfilter. lmportant:
0)l
To preventvacuumin tank when replacingfuel filter
Have a vessel ready when looseningfuel filter connections.Fuel in fuel system (not tank) will come out,
Replacefuel filtel Bemove clampretaining fuelfilterto bracket. Transfer bracketto newfuellilter.
Noteflow direction on fuelfilter. Installfuelfilterand clampassembly to bracket.
Checkfuelflow directionon fuel filter. Connectfuel linesto fuel filter.
Makesurecoppersealsarecorrectly ;nstalled.
Installluel filler cap.
56
I
Group17,7,500Mile MaintenanceService B23F, Serviceat: 60.0(n miles : 100.000km lntelals: 60,000 fiiles :
NOTE:
0
(forinstance Drivingunderadverse conditions cirv driving under hot conditions)requires mileintervals). servicemoreoften(15,000 Volvorecommends cleaningflame guardat 15,000 mile intervals.
Positivecrankcaseventilation. Check hoses for condition and clogging. Clean nippleand flame guard.
Seruiceat: 60.000miles : 100,000km lnte|als:60,000miles:100,000km
0
.ll
6e-
-
tt]i
JH
-<@
Reolacefuel tank lilter-
fuel gauge Usetool 5169to removeand reinstall sender.
)'0
0 57
I
Gtoup17,7,500Mile MaintenanceService - D24 diesel -
D24diesel Seruiceevety 7,500miles = 12.500km
o( a1
Drainingcondensate.
Position a panunderscrew2 to collectcondensaLoosenbleederscrew1 severalturns. Loosendrainscrew2. Drainuntilcleanfuelflows out. Tightenscrew Tightenbleederscrew1.
ol cl
a2 seNice at: 1r30-4r6o-7r90-thousand 25-50-711 0O-125-tso-thousa nd km : 15,000miles =
mites
Positivecrankcaseventilation.
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.
Connectpressure testerin hosebetweenradrator andexpansion tank.Thisway coolingsystemwill becheckedin trueworkingconditions. Capreliefpressure shouldbe65-85kPa: 9-12psi. When pumped,pressure shouldstandfor minimum 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 filtercanridgewith superiorfilteringabilityis available. 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
i0
r7
Replacingfuel filter. 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.
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.
I
lf necessary adjust.lt shouldbe possibleto depressdrivebelts5-10mrn = 3/16-5/16"haltway betlveenpulleys.
Group17,7,500Mile MaintenanceService - D24diesel:valveclearanceacliustmpnt
Valveclearance adjustment Specialtools: 5195Pliers
Seryice at:
Forremovingvalvedepressor disc.
30- 60- 90- tho usand rn iles 50- 100-, so-thousandkm Inte&als: 30.000 miles : 50,000krn
5196Prcsstool Forvalvedepressors
Q,, {
camshaft etc,valveclearance Afterrepairsto the cylinderhead,for examplegrindingvalves,replacing km : 600-1,200 miles. shouldbe re-checked afterdriving1000-2000
bl
Removevalvecover b2 CylinderNo.1.
Usea 27mm - 1-1l16" socketon vibrationdamper boltto turn engineto positionfor firingon No.1 cylinder. BothcamlobeslorNo.l cylindershould pointup at equallylargeangles.Flywheeltiming markat 0.
cl cre
b3 Checkvalveclearancefor cylinderNo. 1.
Valveclearance, coldengine(= at roomtemperature):
()
lntakevalves: 0.15-0.25 mm = 0.006-0.010". Exhaust valvesl 0.35-0.45 mm - 0.014-0.018". Valveclearances, warmengine1: nearoperating temperature): lntakevalves: 0.20-0.30 mm = 0.008-0.012".
123156
NOTE: with cylinderat top Alwayscheckvalveclearance dead center.Alwaysturn 1/4turn after top dead centerto set.
Exhaustvalves: mm = 0.016-0.020". 0.40-0.50 is requiredif valveclearances arc No adjustment withinthesecheckvalues.
rlf
Lr tl
Ir][l
rl | - intakevalve A : exhaustvalve
A]EA]
60
Al
[A
cl cl
tA--']t4
O
GrouD17.7,500Mile MaintenanceService - D24diesel: valve clearanceadiustment-
---rlr-
Incorrent clearance,adiustmentrequired----r
M
Tum engineapprox.1/4turn.
Enginemust not be at top deadcenterwhen setWithpistonattopthereis no tingvalveclearance. spacelor depressing.
b5
Depressvalve depressors.
Line up valve depressors.Turn them so that notchespointslightlyinward. Use tool 5196to depressvalve depressors.Depressorgroovesmust 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 thicknesses of 3.00to 4.25 mm in increments of 0.05mm. lt is advisable to usemetricmeasurements to simplifycalculation,
(US:approx.0.1181" to 0.1673"jn increments of 0.002"). Useonly newdiscs.
'@l
cl
Positionnew disc. It shouldbe oiled.
Installwith marksDOWN.
bl0
0)
Checldsetvalveclearancefor remaining cylinders.
0rI
Usefollowingcylindersequence: 1,5,3-6-2-4
{_) b11 Recheckvalveclearancefor all cylinders.
Rotateengineseveralturns beforerechecking, Adjustif necessary.
b12 Installvalvecover.
Usenewvalvecovergasketif required.
62
{)
F Gtoup 17,7,500Mile MaintenanceService - D24diesel:idle speeds-
Setting idle speeds
:l
Serviceat: IEMtSSfOflS 30-60-90-thousandm iles 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.
I
Shouldbe 750 1 50 rpm. Applytamper sealon screwand locknut with paintafter adJustment,
c4
)e )0
Checuadiusthigh idle speed.
Maximumspeedis 5200t 100rpm. Applytampersealon screwand locknut with paintafteradjustment. DONOTraceenginelongerthanabsolutely necessary. cp
Removeinstrument.
c6
I
ChecUadrust enginecontrols. This shouldalwaysbe done after idle adjustment.
63
Gtoup17,7,500Mile MaintenanceService - 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 disengagedbeloresettingcontrols. 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.
0tl
Adiustacceleratorcable Turncablesheathuntilcableis stretched but does not inlluencepulleyposition. Pullevshouldtouchidlestoo.
0tl
d3
Checkmax acceleratorposition
pedal lully. Pulley Depressaccelerator 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
d6 Re-adiustlink rod Bepeat operations 7 and8 untilcontrolis correctlyadjusted. A clearance of 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"betweenend positions, Kickdown in idleposicableshouldbe stretched tion and distancebetweenkickdowncableclip mm : 0.01andcablesheathshouldbe 0.25-1.00
o.o4".
65
G.oup 17,7,500Mile MaintenanceSeruice - Servicesat 75,000miles -
Diesel Maintenance Services 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. . . . . . . . . . . . Checking/adjusting injectors Beplacingtiming gear belts
e'l-e10 t1-f7 s1-933
Gtoup 17,7,500Mile MaintenanceService - D24 diesel:comprcssiontest-
Compressiontest
0
(nipptelto Specialtool: 5191 Adapter connectcompressrontester.
Seruiceintervals: 75,@0 miles : 1 ,000 km
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.
Plugall connections to preventdin fromentering fuel system.
67
Group17,7,500Mile MaintenanceService - D24 diesel: comptession test -
e5 Removeiniectors.
= 11116". Use27 mm socket{VolvoP/N 1158146) Lift out heat shieldsunder injectors,Otherwise rheywillfly up during compressiontest.
After removinginjoctors.injectortest scheduled at 75,000miles = 125,000km, should be performeo.
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
25 Nm Installiniectors.
Positionnew heat shield in cvlinderhead lnstallinjectors,Torqueto: 70 Nm = 50 ft.lbs. 25 Nm = 20 ft.lbs.
124154
68
e7
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
Group17,7,500Mile MaintenanceService - D24 diesel: injectors
Checking/adlusting injectors Serviceonly in caseof iniectormalfunction.
Extremecleanlinessmust be observedwhen workingwith injectors.Any contamination will causemalfunction ofthe fuelsystem, Testsandrepairsshouldbeaccomplished in a dirt anddustfreeareas, Fortesting,only usetestoil or filtereddieseloil. GasolineMIJST NOT be used. Volatilefuels maycauseexplosron.
The fuel jet duringtestingN4IJST NOTcome in contactwith anypartofthehumanbody.Because the of the high pressure, the fuel can penetrate skinandcausesevereinjury,Therearemanyexamplesof bloodpoisoning and amputation. N4any statesrequireoperationoJ air evacuation equipment duringtestingof dieselinjectors. The fuelfumesmay be dangerous if inhaled.
When testing.opening pressureand injector tightnessaremost important. Spraypatternand iniectionsound are more difficultto assess. They do not give any satisfactory indicationof nozzlecondition.
One must considerthat real injectionis into a comoletelvdifferentenvironmentthan the test bay.Ouiteoften injectorsfunctionsatisfactorilyin the enginein spiteof questionable spraypattern andiniectionsound.
Oi I
0r I
f1
Installiniectorin iniectortester. Seal fuel return line connectionswith rubber plugsand hoseclamps.
f2
Checkspraypattern.
gaugedisengaged. Pressure Pumpwith short,quickstrokes(4-6strokesper Sprayjet should be fairly compactand stop abruptly. Injectormustnot drip.
70
0rI
c)|
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
,0
f5
Leaktest. Prpc<"ro
.r".6
6n.rno.l
Wipe injectornozzle.Pump pressure11 MPa = 1560psi and retainthis pressure for 10seconds. Theremust be no fuet drip fronrnozzle. A moist nozzleis acceptable.
f6
Adjustinginiectoropeningpressure.
0
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. Fordisassembling injectors, seeinstructions that
71
Group17,7,500Mile MaintenanceService - D24 diesel: injectots -
f7
a-
wtrf
uppernozzre retainer openlng pressure Spring Thrustpin Guide
Nozzlesleeve
Disassembling iniectors.
Makesureoutsideof iniectoris clean. - Disassemble NOTbecome injector. PartsN4UST oamageo. cannotbe reused. lf a nozzle needleisdropped,it lmmersepans in cleandieseloil immediately afterdisassembling. - Makesureall partsfor one injectorare stored togetherand not mixedwith partsfrom other rnlectors.
Cleanand checkparts.
- Use cleandieseloilto cleanall pans. - Use nozzlecleanertool to clean nozzleneedle and nozzlesleeve. Replacedamaged parts. Nozzle needle and nozzLesleeveare matchedand replacedas an assemDty,
(
Assemblinginiectors.
- Usecleangasoline to cleanstoragegreasefrom retainer
- Thenimmersenew partsin dieseloil priorto assemDry, Assemble injector. Torqueto 70 Nm = 50ft.lbs. - 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 D24 cliesel:timing geat belts -
Replace:- Timing gearbelt for camshaft - Timinggearbelt tor iniectionpump - ldlerpulleylor camshafttiminggearbelt
!9!
Serviceinteruals: 75,000miles: 125,000 km
g1
Disconnectbafterygroundcable.
o
Jackup vehicle.
Usefrontrightjacksupport.Whendrainingcoolant,it runsa ong spiashguardunderengineand doesnot messfloor, Placevesselunderleftsteeringrod,
e g.l
g2
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:
0
- raotator, coolingfan with spacerand pulley. - fan belt. - drivebeltfor powersteeringpump. - timinggearbeltcover. - valvecover,
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
',2!
Checkthat cylinderNo.1 is at top dead center. 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
Group17,7,500Mile MaintenanceService - D24 diesel: timing gear belts -
g8
Removelower belt shield.
Release retaining boltsfor coolantpump.Loosen and removetiminggearbelt.
Replaceidler pulley. MUSTbe replacedwhen replacingtiming gear belt. Rernove centerbolt. Use puller5202to remove idlerpulley. Tapnew idler pulleyinto position.Installcenter llolt.
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910
Removereargearon camshaft.
Usewrench5199to hold reargear Usewrench 5201to removecenterbolt. Makesurecamshaftis not rotated,
r0 911 Lockcamshaftin position.
Lift valve cover gasket.Installgauge 5190in grooveon camshaftgearrearend. Position a 0.2mm : 0.008"feelergaugeunderleft sideof gauge5190. The0.2mm gapisto compensate forclearances in trmrnggears.
Group17,7,500Mile MaintenanceService D24diesel:timing gear belts-
s12
Removecamshaftfront gear.
Usewrench5199to hold gear.CamshaftMUST NOTrotate. taperedend. Tapgearloosefrom camshaft
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Installgearbelt and camshaftfront gear. lvlake suregearbeltfits securelyon gears.
Installcenterbolt finger tight. Gear must be allowedto rotate.CamshaftMUSTNOTrotate.
s14 lnstalllower belt shieldand vibration damper.
Vibration damperfits onewayonly.Thereis a pin gearto locatevibrationdamper, on crankshaft
I
Install6 mm inhexbolts.Torqueto: 20 Nm : 15ft.lbs. m
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124229
s15 lnstallcenterbolt.
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Applysealingagent{P/N277961-9)to boltthreads and contactsurfaces. Usewrench5187to holdvibrationdamper.lt can reston coolingfan journal.use wrench5188to torquecenterboltto: 350 Nm : 255ft.lbs. Thistorqueonly appliesif wrench5188is used. Torquewrenchmustbe in linewith wrench5188.
5187
76
0
Group 1/, /,b00 Mile Maintenance Service - D24 diesel: timing gear belts -
916
a
Checkthat cylinderNo. 1 is at top dead center. Flywheelmark at O.
s17 Tensiontiming gearbelt.
Usecoolantpumpto adjusttiminggearbelttension. Installbehtensiongauge5197ontiminggearbelt. Setgaugeto 12.5.Tensiontiming gearbelt until markon plungeris flushwith gaugesleeve. Depress timinggearbeltheavilyby hand.Recheck timinggearbelttension.Adjustif required.
918
Tightencamshaftfront gear.
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Usewrench5199toholdgear.Makesurecamshaft or geardoesnot rotate. Torquecenterboltto: 4 5N m : 3 3 f t . l b s . Removegauge5190andfeelergauge.
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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 - D24 diesel: timing gear belts -
g20
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Basicsettingof iniectionpump.
Looseninjectionpumpretaining screws(inhex6 mm).Turn injectionpump so that markingson injectionpumpand bracketcoincide. Tightenretaining screws.
n"a( Installindicatorgauge.
pumpgear Usestop5193to lockinjection CylinderNo. l shouldbe at position{or injection. RemoveplugoI injectionpumpdistributor. Installholder5194and an indicator gaugewitha measurjng rangeof0-3mm. gaugeat approx.2 mm. Setindicator Turn injection pump clockwiseuntil marks on injection pump gear and bracketcoincide.
gz (b Set indicatorgauge.
Turn injection pump gear slightly counterclockwise untilindicatorgaugeis at minimumreading. gaugeat zero.Turninjection Setindicator pumpgearclockwise untilmarkingon inlectionpumpgearand bracketcoincide. pumpgear lJsestop5193to lockiniection 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 - D24 diesel: timing gear belts -
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.
0
Installwrench5199to hold camshaftreargear Installwrench 5201with a torquewrench.ltshould be at a right angleto wrench5201to give correct readrngs. lJsewrench5199to turn camshaftgearuntilthe gaugeregisters indicator 0.85mm:0.0334". Holdcamshaftgear in this positionwhile tighteningcenterboltto 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 - D24 diesel: timing gear belts -
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.
Engaged
80
o
Gtoup 17.7,500Mile MaintenanceService - D24diesel:timing gear belts
931
lnstall.
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Installcoolingfanwith spacerand pulley.Torque retaining bohsto 9 Nm = 6.5ft.lbs.lnstallfan belt and powersteeringpumpdrivebelt.Adjustbelt tensron. Installradiatorand radiatorhoses.Installsplash guardunderengine.
s32
(f ftepare bleedingof coolingsystem,
Disconnect uDoerhoseat coldstartdevice.Place vesselunderhoseend.Holdhoseendin levelwith exoansion tanktoo, Using this methodwill bleed cooling system quicklyandefficiently and eliminate air pockets.
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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 anlii 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 .
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Fill coolant. Manualtransmission: 9.4liters: 10US qts- 9.4 liters= '10US qts Automatictransmissionl - 9.2liters= 9.8USqts Flushcoolingsystempriorto fillingnew coolant. Otherwise refill old coolant. SetheatcontroltoN4AX. Startengineand run at increased idlespeedfor 5 minuteswhile refilling coolant, Reconnect hoseat coldstartdevice.Fillexpaosion tankFULL(aboveIMAX)and installcap.
Gtoup 17,7,500Mile MaintenanceSetvice - Roadtest-
Roadtest Engine Check and adjust as necessary:
- Startingabilfty,cold and hot engine, -Fast idle. - Correctidlespeedand no misiiring. -That the enginedoesnot stallwhen accelerating or decelerating afterthrottlemovements. -That rhereareno abnormalnoises or pistonsand from valves,timinggoars,crankshaft pump rods, water etc, connecting -That normaloperatingtomperature warm-upperiod. is reachedwithina reasonable 6 -That the enginedoesnot behaveabnormally, 7 -That the acceleration I is normalandthat the engineoperatessmoothly. I Openthe hood.Checkfor visibleleaks. 10 -That hardwarer€movedat factoryis reinstalled and that everythingis in order. 1 2 3 4 5
Elactrical Check: 1 2 3 4
-
Thatstarterand alternatoroperatecorrectlyand withoutabnormalnoises. Thatwipersand washersoperatecorrectlyand arecorrectlyaligned. Thatsteeringlockoperatescorectly. That instruments and controllightsoperatecorrectlyandthat no abnormalnoisesare noticed.
Drive train Check 1 2
-That the clutchis correctlyadjustedand that thereare no abnormalnoisesfrom the throw-outbearing. -That the clutchoperatescorrectlywithoutslippingor chatter.
Manualtransmission Ch6ck: 1 -That thetransmission withoutabnormal noises, operates correctly, andthatshifiingoperation is smooth.
Automatic transmission Check: 'l
2
-That the gearselectorplayis correct. -That the starteroperatesonly in positionP or N andthe back-uplightsoperatein positionR
- Runthe transmission to normaloperatingtemperature, -That thereis no slippageat stallspeedin positionD and R (seeServiceManuar,. - Upshift1-2 and 2-3 by accelerating on pan throttlewith the gearselectorin positionD. -That the enginedoesnot slipduringshifting,whichwould indicatethat a brakeor clutchslips. - Employkick-downoperationand checkdownshift. - 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.
3 4 5 6 7 8
82
Group17,7,500Mile MaintenanceService - Roadtest-
Brakes Check 1 2 3 4 5
-That the power assistfunctions when braking by noting pedal pressure. -That the brakesdo not pull when braking hard. Thal brake discsare not out-of round or warped by noting pedal pulsationor movement. -That the brakesare correctlyadjustedand that the brake pedal does not feel spongy . -That the parking brake is correctlyadjustedand operates correctlv.
Steering Check: 'I 2 3 4 5
That the steeringis correct and thar the vehicledoes not pull or is unstable. - Steeringwheel position and return when driving. -That the steeringwheel efiort is normal. Steeringlooseness. - That power steeringfunctions correctly,
Springs and wheels Check: Thatthereareno abnormal 1 noises fromshockabsorbers or rearwheelsuspension.
2 3
- When driving that the rear axle is ttght. - Tire unbalanceor out-of-roundness,when drivinq.
Body and interiorequipment Check:
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1 2 3 4 5 6
7 8 I
That all dealerinstalledaccessoriesoperatecorrectlv, -That heaterand heatercontrolsoperatecorreclly, -That thereare no abnormalspeed notses. -That there are no abnormalbody noises(rattle,vibrations etc.) Visibledefects. - Wipe off steerangwheel and gear selector. Cleanall other soiledor dirty areascausedby the maintenanceDrocedures, - Fauhsdetectedshould,i{ not previouslynoted, be noted in the servicerecord. - Checkoff group and note the fault. - Faultsnormallyremediedat the serviceshould not be noted. Make sure all faults are remediedbelore the customer o,cls uo his car.
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