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OwnersHandbook (120)1969 - Volvo Amazon Picture Gallery

1. Number plate light Interior lighting Glove locker lighting Instrument lighting Warning lamps turn indicators headlights charging oil pressure Power transmission Clutch Clutch yoke free travel 12V Tudor 6 EX 4 E o p 60 Ah 1 28 1 21 35A 490 W 1 h p 8 amp 3 25 amp 1 Number Socket 45 40 W 45 15 8 32 15s 32 4 CP 15d 15W 15s 5W 8 5 10W 85 4W Ba9s 4W Ba 9s 2 W Ba 9s 2 W Ba 9s 2W Ba9s 2W Ba9s 3 4 mm approx V4 or corresponding Power CQ NNN AN ND 55 SPECIFICATIONS Gearbox Type designation M40 Reduction ratios 1st speed M IB 2nd speed 1 99 1 3rd speed 1 36 1 4th speed 1 1 Reverse 3 25 1 Rear axle Types cosy eX Crown wheel and pinion Hypoid Reduction ratio 41 1 Front wheel alignment Alignment values apply to an unlad en vehicle but include fuel water and spare wheel TOSIN erste DIT NOSE EXER 0 4 mm 0 to 16 Camber Castel 2s pere ur rope 0 to 41 King pin inclination 8 Wheels and tyres size sexe 165 5 15 or 6 85 15 Air pressure cold tyres 1 2 persons Fully loaded front kg cm 1 4 1 5 Digo exu RP EORR 20 22
2. The pressure must not exceed 2 1 kg cm 30 Ib sq in For size 165 SR 15 tyres the air pres sure should be 1 8 kg cm 25 5 Ib sq in front and 2 2 kg cm 31 0 Ib sq in rear irrespective of the driving speed lf inspection of the tyres shows that there are worn spots and unusual wear on the tread take the vehicle to a Volvo workshop for the wheels to be balanced Check also that the tread pattern is not less than 1 mm X 2 in depth If it is the tyre must be changed Excessively low air pressure is one of the most common reasons for tyre wear If the pressure is too low the tread shoulders bear the entire load and wear down very quickly Tyres which are in sufficiently inflated also result in difficult steering and high fuel consumption Ex cessively high air pressure means tyre wear along the centre of the tread It also tends to make travelling less com fortable Avoid running the tyres against pave ment kerbs Changing a wheel Before the car is jacked up the hand brake should be applied and one of the gears engaged to ensure that the vehicle stands still If possible block those wheels remaining on the ground as an extra safety precaution Remember that the handbrake operates only on the rear wheels Removing Fitting Lever off the hub cap with the help of the spade shaped lever Loosen the wheel nuts with the help of the box spanner and tommy bar All the wheels have nuts with
3. 2 74 U S pints Steering box aia ine oe 22 SS U S pint 2 Check without removing the cap that the level in the brake fluid con tainer is above the Min mark Right hand steering Check also the clutch fluid level 3 Check that the coolant level is between the Max and Min marks on the expansion tank 4 Check that the fluid container for the windscreen washers is filled About every other week Check the tyre pressure and the battery acid level Notes for lubricating chart Note 1 Check that the oil reaches up to filling plug Use all year round hypoid oil SAE 80 Note 2 In connection with any work in the workshop involving exposing the wheel bearings remove the bearings clean them and lubricate them with high class durable grease in accordance with the instructions in the service manual Subsequent adding or changing of this grease in addition to the above is not required the oil see page 31 of times a year PPPPE Check that the fluid is between the Min and Max marks Lubricate the felt wick under the rotor and fill a few drops of light engine oil into the lubricating cup Check the oil level when filling up with petrol Concerning changing Have the handbrake cable lubricated with graphite grease a couple Check every 10000 km 6 000 miles that the oil reaches up to the filler plug Concerning oil change see page 32 At every engine oil change check that the oil level in the cent
4. DE INSTRUC LIBRO DE INSTRUCCIONES MANUEL D INSTRUCTIONS NSTRUKSJONSBOK NSTRUKTIEBOEKJE NSTRI JC TION f OOK BET SANLEITI VRO DE INSTRU MANUEL D INSTRUCTIONS STRUKTIONSBOK TRUKTIONSBOG ERI c ian K INSTRUCTIO OK BETRIEBSANLEITUNG LIVRO DE INSTRUC 1870 DE I L P MA ic T INSTRUKTION INSTRUKSJONSBOK INSTRUKTIEBOEKJE INSTRUCTION f VR DE IN F OES LIBRO DE INSTRUCCIONES MANUEL D INSTRI INS NSTRUKTIONSE k INSTRUKTIEBOEKJE INSTRUCTION BOOK BETRIEBSANLEITUNG AKI CITI BETRIEBSANLE LIVRO DE INSTRUC LIBRO DE INSTRUC MANUEL D INSTRUCTIONS INSTRUKTION K INSTRUKTIONSE gt INSTRUKSJONSBOK INSTRUKTIEBOEKJE INSTRUCTION BOOK BETRIEBS LIV DE IN LIBRO DE INSTRUCCIONES MANUEL D INSTRUCTIONS A x Personal information Name Address ee Cm lt _ Tel No Driving Licence No Insurance Company Insurance Policy No Nearest Volvo Dealer Name Address Tel No Garage Manager Tel No Car information Type Designation Chassis No Engine No Registration No Ignition Key No Door Key No Fuel Tank Lock Key No VOLVO 120 2 DOOR CARS 120 T DESCRIPTION OPERATING INSTRUCTIONS VOLVO SERVICING AB VOLVO GOTEBORG SWEDEN Rep
5. To use the cigarette lighter push it in As soon as it attains sufficient heat it will automatically spring out DESCRIPTION DESCRIPTION 16 Heater and ventilation system 24 Lighting switch Fresh air fan switch Air flow Air temp Parking lights Dipped headlights Mainbeam Pushed right in closed FLOOR Air to front seat floor This control is used to regu Lighting switch pulled out one Lighting switch fully out and Lighting switch out fully and Interm pos full output DEFR Air to windscreen late the temperature of the ii notch foot dipper switch in dipped foot dipper switch in main Fully out half output and to rear seat floor coming air position beam position Panel light switch The heating and ventilation system of the car is operated as shown The panel light switch is regulated by rotating the small switch knob above Air is sucked in by the fan and then passes through a heater element to a distributing chamber where it is distributed to the floor and Warning signal flashers windscreen by means of the controls NOTE Under normal conditions there is sufficient air flow due to the fact there is overpressure at the air inlet of the vehicle If greater quantities of air are required use the fan The heater element is connected with a thermostat which keeps the temperature constant When the temperature control is moved there will On certain markets the car is fitted with warning signal flashers which are operated by pu
6. colour 1 If flying gravel should penetrate the paintwork and reach the metal of the bodywork the damaged surface is to be scraped completely clean with a penknife or similar If however the paintwork is not damaged by stones then all that is needed is light scrap ing to remove the dirt 2 The picture shows a damaged spot scraped clean with chamfered edges ready for touching up 3 In the event of severe damage due to flying stones it is necessary to treat the spot with anti rust primer This can be applied with a matchstick or fine brush The primer should cover the whole of the scraped and chamfered surface 4 When the anti rust primer has dried genuine Volvo paint is applied Stir the paint well but not with a brush Apply several thin coats of the paint allowing it to dry thoroughly between each application SERVICING Chromed parts The chromium plated and anodized parts should be washed with clean water as soon as they become dirty This is particularly important if you drive on gravel roads which are treated with chemicals to keep down the dust or in the winter when salt is used to melt down the snow or if you drive near the sea After washing you can apply wax or anti rust preparation 40 Anti rust treatment 41 48 The Volvo 120 models are anti rust treated at the factory The door sills are made of galvanized sheet metal and do not require any maintenance The lower part of the body is treated wit
7. for the engine ignition system During driving the key should be in the Driving position To start the engine turn the key to the Starting position and this The switch has four positions automatically engages the star 0 Locking position 1 Garage ter motor As soon as the en position 2 Driving position and gine starts release the key Oil pressure warning light This light goes on when the engine oil pressure is too low When the ignition is switched on the light should go on and then go out again when the engine has been started Never start driving until the light goes out Should the light remain on during driving the engine should be stopped and the cause for this determined In most cases it means that 3 Starting position The key can be taken out of the lock in the Locking position Removing the key when in the Locking position automatically locks the steering wheel With the key in the Garage position the entire electrical system is which automatically returns to the Driving position If the car is parked in such a way as to make it difficult to un lock the steering wheel unlock ing can be made easier by slightly turning the steering wheel one way and then the other the oil level is too low After hard driving it may happen that the warning i ght comes on when the engine is at idling speed This is normal provid ing it goes out again when the engine speed is increased 15 Cigarette lighter
8. instance when the parts concerned are reconditioned If you prefer to carry out the simpler servicing procedures yourself or if you are sometimes obliged to have them done by a workshop outside the Volvo organization this chapter contains some advice as to when and how they should be carried out For the sake of convenience the servicing procedures have been sum marized in maintenance scheme in the next two pages 27 SERVICING SERVICING Maintenance scheme In addition to the servicing procedures mentioned in this scheme you should regularly check the following from the point of view of traffic In the maintenance scheme below the servicing procedures have been safety given certain numbers which refer to the detailed descriptions on the a Lighting including brake warning light following pages Some of the work must be carried out by skilled me b Turn indicator lights chanics or requires the use of special tools and these have been mark c Horn ad L1 Once a year When filli up with fuel See page 3 e ppl with fue 0 Every third eyar 1 Also after the a 2500 km 1500 miles 3 Only after the first 5 000 km 3 000 miles ruring running 4 After every 80000 km 50000 miles the Also after the pad 5000 km 3000 miles paper filter should be replaced 29 during running in SERVICING Lubrication Chassis maintenance 1 To simplify maintenance of your Volvo the vehicle has been
9. of plug The appearance of the old sparking plugs will easily tell whether or not they were the right type for your driving 26 Ignition system 27 38 The distributor contact breaker gap should be checked at a Volvo work shop after every 10 000 km 6 000 miles All adjusting work to the engine ignition system should be done by the workshop which has the proper equipment for this purpose The distri butor is one of the most sensitive units in the engine and careless handl ing can lead to decreased engine output and high fuel consumption or even serious damage to the engine Fuel 28 The petrol used for fuel should be at least 97 ROT octane for the B 20 A engine For the B 20 B type engine an octane rating of 100 ROT is recommended If petrol with too low an octane rating is used knock Ing or pre ignition can occur However if highway motoring is often involved the octane rating should be at least 97 ROT even for the B 20 B engine Research Method SERVICING Electrical System The electrical system in the car is equipped with an alternator When changing the battery or carrying out any other work with the electrical system the following should be observed When changing the battery or when carrying out work involving the electrical system the following should be observed 1 A battery connection to the wrong terminal will damage the rectifiers Before the connections are made check the polarity of the ba
10. regulate the speed ratio between the engine and the rear axle so that the engine always operates in its most favourable speed range The gearboxes are fully synchronized The M 40 gearbox is four speed DESCRIPTION Propeller shaft The propeller shaft which is the connecting link between the gearbox and the rear axle is divided into two sections The front section is journalled at its rear end in a bearing housing consisting of a rubberized ring Rear axle The engine driving power is transmitted via the propeller shaft to the rear wheels through the rear axle The rear axle is of the hypoid type that is the drive pinion is below the centreline of the drive shafts On certain markets the rear axle is fitted with a differential brake as extra equipment The function of the differential brake is to transfer automatically the pulling power to the wheel with the best grip on the road surface when one of the wheels begins to skid Except for the differential the rear axle is similar to a conventional rear axle Brakes The brake system is of the two circuit type with disc brakes front and drum brakes rear The system is provided with a tandem type master cylinder and a directly operating booster cylinder The principle of the two circuit system is that both front wheels are connected to a rear wheel Should there be a failure in one of the circuits there is always braking power on both front wheels and the other rear wheel The pres
11. tie rod etc After every 10000 km 6000 miles the vehicle should be taken to a Volvo workshop for a check on the front end concerning excessive play in the ball joints tie rods etc At this check the ball joint seals should be inspected for damage and leakage When new seals are fitted they should be filled with the recommended grease 43 SERVICING Wheels and tyres 37 Check the tyre pressure Always make a habit of checking the air pressure in the tyres regularly The simplest way to do this is to check the pressure when filling the fuel tank See page 56 for the correct air pressures Do not forget the spare wheel when checking the air pressure Even if this wheel is not used its air pressure can go down and you may find that the tyre is flat just when you need it Do not let the spare wheel be unused for a con siderable period but change it regularly with one of the other wheels During driving the temperature of the tyre rises and also the air pressure in relation to the speed of the vehicle and its load Normally the air pressure should only be checked when the tyres are cold If the tyres are warm any altera tion should be made in those cases when the tyres must be pumped with air Size 165 S 15 or 6 85 15 tyres are in tended for speeds up to 175 km p h 110 m p h For prolonged driving at speeds above 140 km p h 90 m p h the air pressure in the tyres should be increas ed 0 3 kg cm 4 5 Ib sq in
12. 4T 48 49 50 51 52 53 54 D Green E Grey F Yellow G Brown H Red Flasher unit turn indicators Door contact right Control lamp for charging Control lamp for mainbeam headlights Control lamp for turn indi cators Control lamp for oil pressure Fuel gauge Instrument lighting Windscreen wiper Ventilation fan Control for windscreen wiper and washer Lighting switch Ignition switch Cigarette lighter Switch for ventilation fan Glove compartment lighting Switch for glove locker lighting Fuel gauge pickup Rear lamp left with rear light stop light flasher and back up light Number plate light Rear lamp right with rear light stop light flasher and back up light Wiring diagram ACCESSORIES By choosing the right accessories the motorist can often get more enjoyment from his car When choos ing accessories you must be certain that you are re A ceiving value for your money particularly in regard to quality reliability and use Genuine Volvo accessories meet all these demands and have the same six month factory guarantee as all other Volvo products Towing hitch Revolution counter Reclining seat fittings Wheel trims Roof rack Reclining seat fittings Trunk basket Children s safety seat Lockable tank cap Fog light Spot light Lockable tank caps 109006 Liquid wax and po
13. ICING Rear axle The oil level in the rear axle should be checked after every 10 000 km 6000 miles The oil should be up to the level of the filler hole Top up with the recommended oil if necessary The oil in the rear axle should be changed after the first 5 000 km 3 000 miles and should also be flushed thoroughly with the same type of oil used for topping up The used oil should be drained off imme diately after the vehicle has been run when the oil is still warm After this oil change only the oil level need be checked and the oil topped up if necessary Oil grade Viscosity Oil capacity SAE 90 Continuously below 1 3 litres Hypoid oil 10 C 14 F SAE 80 2 3 Imp pints 2 7 U S pints Rear axle with differential brake A rear axle fitted with differential brake is filled at the factory with transmission oil according to the American military standard MIL L 2105 B provided with an additive for rear axles with differential brake The same type of oil should be used for topping up and when changing Oil level checking and changing should take place at the same intervals and in the same way as for a rear axle without differential brake Transmission oil MIL L 2105 B with additive for differential brake 33 SERVICING 11 12 13 34 Steering box The oil level in the steering box should be checked after every 10 000 km 6000 miles The oil should be at the level of the filler plug If necessary
14. Never check the e ectrolyte level by lighting a match The gases formed in the cells are highly explosive 39 SERVICING 29 Check the state of charge of the battery The state of charge of the battery should be checked after every 10 000 km 6 000 miles The check is carried out with the help of a hydro meter this showing the specific gravity of the electrolyte which varies with the state of charge See page 55 When checking the battery check also the terminals and terminal bolts to make sure they are well tight ened and smeared with rustproofing agent If necessary wipe off the terminals and terminal bolts with a rag or brush them with a wire brush and apply rustproofing 30 Check headlight alignment The alignment of the headlights should be checked in a Volvo workshop after every 10 000 km 6000 miles Remember that the section of the road lit up by the headlights can vary depending on the load in the vehicle Replacement of bulbs To obtain maximum lighting effect and to forestall the chances of lights going out the headlight bulbs should be changed every year suitably during the autumn Some of the bulbs have two functions for example the headlight bulbs which have filaments for both mainbeam and dipped lights The guide pins on the sockets of these bulbs are either of diffe Replacing the headlight bulbs Loosen the three screws retaining the ri m with a screwdriver Pull out the bottom part of the rim slightly a
15. aps any impurities in the oil so that it becomes blocked after a time For this reason it must be replaced for example after every 10 000 km 6 000 miles and preferably by a Volvo work shop If the filter is replaced without the oil being changed 0 5 litre approx 1 pint of oil should be added Fuel filter The fuel filter should be cleaned after every 10 000 km 6000 miles Loosen the screw and remove the cover and strainer and clean these When re fitting the cover make sure that the gasket seals properly Air cleaner B 20 A The air cleaner should be replaced with a new one after 40 000 km 25 000 miles Replacement should be more frequent if the driving conditions are dusty NOTE On no account must the element be moistened or oiled 17 Air cleaner B 20 B SERVICING The air cleaner consists of a plastic cover with a replaceable paper insert The insert should be replaced every 40 000 km 25000 miles Where driving conditions particularly dusty it should be changed more often Between the interval just mentioned the insert must not be cleaned To replace the insert undo the hose clamp for the preheating hose as well the clamps securing the top of the cleaner Then remove the top so that the insert is accessible for removal 22 SERVICING Check the coolant level The cooling system must be well filled with coolant and not leak if it is to ope rate at maximum efficiency Check the coo
16. arburettors The engine is water cooled and the cooling system is of the pressure type Water is circulated by means of a pump fitted on the fan shaft A wax type thermostat with an opening temperature of about 82 180 F prevents the cooling water from passing through the radiator before the engine has reached its normal working temperature On certain markets a fan with a slip type coupling is fitted Fuel system Fuel is fed from the tank to the carburettor by a fuel pump which is driven by a cam on the engine camshaft There is a filter in the fuel pump which traps water and other impurities in the fuel Exhaust emission control The engine is fitted with exhaust emission control that is a system as a result of better mixing and distributing of fuel and air provides a more complete combustion and thereby cleaner exhaust gases On the B 20 A engine the exhaust emission control is obtained through the carburettor which is specially designed for this purpose On the B 20 B engine the exhaust emission control is provided partly through carburettors specially designed for this purpose and partly by the engine having a special in duction manifold with throttles and preheating chamber When driving at regulated alternator The starter motor is operated from the instrument low speeds the throttles are closed so that the fuel air mixture is forced panel by the ignition key which also switches on the rest of the electrical to pass the preheatin
17. asions the following advice should be followed 1 Keep all windows closed 2 Set the fresh air and defroster levers to fully open and the fan control to full speed 25 OPERATING INSTRUCTIONS Braking Steady acceleration and gentle braking are characteristic of a good driver and also result in the most economic running Apply the brakes before going into a curve and use your gearbox on downhill gradients so that you save unnecessary wear on both brakes and tyres Violent braking is only justified in dangerous situations The handbrake should be used sometimes even if it is not necessary to hold the car in position because the rear brake units undergo any necessary adjustment each time the handbrake is applied Driving in rain or through water pools even when washing the car will cause water to be splashed up onto the brake discs and brake linings This might alter the frictional properties of the linings Since the brake linings heat up during braking they dry very quickly but a certain delay in the braking effect will sometimes be noticed If you should happen to drive long distances in the rain or slush lightly depress the brake pedal now and again to heat up the linings and thus dry them This should also be repeated after washing the car Towing 26 If the car is to be towed the tow line should not be attached directly to the bumpers but should be taken round the bumper supports as shown in the picture oppos
18. by softening up to dirt on the underside of the body with a jet of water and use if necessary a soft brush Then rinse downthe whole body with a light jet until the dirt has loosened up Use plenty of water After this wash off the dirt with a sponge using plenty of water A washing agent can be used to facilitate washing Special washing agents are now available on the market ven dish washing fluids can be used A suitable mixture is about 5 10 cl of fluid dish washer to 10 litres 2 2 Imp galls 2 6 US galls of water Asphalt spots and tar pittings can easily be removed with white spirit or equivalent but this should be done after the washing Whenever a washing agent is used the car should be well rinsed down with clean water afterwards After washing dry the car with a soft clean chamois leather Use diffe rent leathers for the windows and the remainder of the car otherwise using the same leather can cause greasy smears on the windows 39 Polishing waxing 46 The car does not need polishing until the surface finish begins to lose its lustre and normal washing is no longer sufficient to make it shine again Under normal conditions it is sufficient to polish the car a couple of times a year on condition that it is carefully looked after and thoroughly washed as soon as it has become dirty or dusty During the winter and in coastal or industrial areas it may however be necessary to polish the car more often in order to avoid rus
19. ce the screw in one of the other holes in the attaching bracket Safety belts Always use the safety belt when driving Place one strap across the lap and the other over the shoulder and chest and fasten the belt by inserting the buckle tongue into the locking device between the front seats A loud clicking noise indicates that the belt is locked Make sure that the parts of the belt in contact with the body are not twisted Always ensure that the belt is so ad justed that it fits well against the body If the belt requires lengthening make sure that the upper part of the lap strap is slack and take hold of the adjusting grip with one hand and with the other hand pull out to the desired length Tidy up any slackness by pulling in the upper part If the belt is to be shortened pull in the upper part of the lap strap The belt is released from the locking device by moving to the rear the lever concerned on the locking device Do not let the belt lie on the floor otherwise it will become dirty and probably be a hind rance when getting in and out of the car Now and again check that the bolts anchoring the belt are properly tighten ed and that the belt is in good condi tion Use water mixed with a synthetic washing agent for cleaning the belt As the safety belts lose much of their strength when exposed to violent stretching they should be replaced after a collision even though they may appear to be undamaged Never modi
20. changed after the first 2 500 km 1 500 miles Subsequent oil changing is according to the intervals given below The intervals will depend to a great extent on the type of oil used For engine lubrication oil grade For Service MS is to be used As far as viscosity is concerned multigrade oil is recommended These oils are better suited for demanding driving conditions for example continuous driving in city traffic with incessant stopping and starting or with lengthy idling periods For engine oil with viscosity SAE 10 W 30 multigrade 10 W 40 10 W 50 or 20 W 50 the oil should be changed every 10 000 km 6 000 miles or at least once a year If engine oil with viscosity SAE 10 W singlegrade 20 20 W or 30 is used the oil should be changed every 5 000 km 3 000 miles or at least twice a year At very low temperature below 20 C 4 F multigrade oil SAE 5 W 20 is recommended However this oil should not be used when the temperature is continuously above 0 C 32 F Oil change Viscosity Temperature range intervals Oil capacities Oil grade km miles SAE 10 W 30 I 1 0000 No oil filter 10 W 40 all year round 6000 3 25 litres 5 72 10 W 50 J 20 W 50 at temperatures above orar least once Imp pints 6 86 For Service MS 10 C 14 F year US pints SAE 10 W nid E 5 T 5000 With oil filter 3000 i 20 20 W 14 and 90 F d c ER 3 75 Berto 30 above 30 C 90 F Imp pints 7 91 For Service MS a year US
21. d Fill the The fan belt tension should be checked every 10 000 km 6000 miles radiator to the top and re fit the cap Then fill the expansion tank to the Due to wear or dirt this belt can start slipping with poor cooling and Max level or somewhat above this Re fit the expansion tank cap Run poor alternator output asa result the engine warm switch off the ignition and allow the engine to cool A way to test the tension is to press in the fan belt at a point midway Then check the radiator to make sure that it is completely filled and that between the alternator and the fan It should be possible to press down the level in the expansion tank is at the Max mark The capacity of the belt about 10 mm 35 with normal pressure the cooling system is 8 6 litres 1 9 Imp galls 2 3 U S galls when The check can suitably be carried out by a Volvo workshop the level is at the Max mark in the expansion tank 36 37 SERVICING 24 Check replace the sparking plugs 25 The sparking plugs should be removed every 10000 km 6000 miles and the electrode cap checked The gap should be 0 7 0 8 mm 0 028 0 032 After 20 000 km 12500 miles the plug s should be changed This replacement should preferably be carried out by a Volvo workshop where the plugs should be tightened with a torque wrench When fitting new plugs be sure to fit the right type see page 54 Consult a Volvo workshop if you intend changing to a harder or softer type
22. d to be spoiled Wherever you go there should be Volvo workshop within easy reach to take care of your car if necessary Do not forget the regular servicing during trips abroad All Volvo workshops abroad are equipped to give your vehicle the service it requires If you prefer to look over your vehicle yourself the following hints are worth noting 1 Check the brakes front wheel alignment and steering gear 2 Check the engine and drive units concerning fuel oil and coolant leakage 3 Examine the tyres carefully Replace worn tyres 4 Check that the engine is running perfectly and the fuel consumption is normal 5 Examine the state of the battery and clean the terminals 6 Look over the tool equipment and check the spare wheel 7 Check the lighting 49 SERVICING Procedure in cold weather Engine When cold weather is on the way it is time to think of the winter ser vicing of your car The first night of frost can come as a very un pleasant surprise unless preventive precautions have been taken cooling system A good quality anti freeze should be used all the year round Thus the cooling system should always contain water plus anti freeze and rust Inhibitor even in the summertime The coolant keeps its properties for approximately 2 years when it should be changed A suitable time for doing this is during the autumn This would ensure against possible damage caused during the winter months When th
23. e coolant is being changed the cooling system should be flushed out with clean water For further details see page 37 If the coolant has to be topped up during the winter use only a good quality coolant Water alone weakens both the anti rust properties of the coolant as well as its rust proofing effectiveness It is a good idea when topping up with coolant to have the concentration checked in order to be certain that there is always sufficient protection against damage by frost Experience has also shown that extremely weak anti freeze solutions 10 2096 are very unfavourable from the viewpoint of rust protection For this reason the quantity of anti freeze should amount to 50 of the coolant that is 4 3 litres 7 57 Imp pints 9 10 U S pints which is effective below 35 C 31 F The maximum freezing point 56 59 F is obtained when 5 2 litres 9 15 Imp pints 10 97 U S pints of anti freeze is in the cooling system Radiator alcohol is not recommended as an anti freeze agent since it evaporates at normal engine temperatur Location of drain tap for cooling system 50 d or gt D ILT 5 FILTER 3 2 1 Right side of radiator 2 Right side of engine SERVICING Engine lubricating system During the winter multigrade oil or engine oil with a viscosity of SAE 1 W should be used for the engine lubricating system At continuous temperatures below 20 C 4 F use multigrade
24. earances can cause burnt valves 20 Compression test Every 10000 km 6000 miles a compression test should be carried out to get some idea of the condition of the engine The test should be carried out at a Volvo workshop 23 dropped to the Min mark Use a good quality anti freeze for cars 50 anti freeze and 50 water and top up to the Max mark NOTE Do not top up with water only Water by itself reduces both the rust protective and anti freeze qualities of the coolant Topping up with water only in the winter can also damage the cooling system due to ice forming in the expansion tank NOTE In countries with very warm climate where there is little risk of frost water without anti freeze can be used in the cooling system Change coolant The coolant retains its properties for approx 2 years when it should be changed To drain off the coolant open the cock on the right hand side of the engine Also disconnect the hose between the lower part of the radiator and the water pump as this empties the radiator The expansion tank is emptied by lifting it up from its brackets and holding it so high that the coolant runs down into the radiator Before filling with new coolant flush the entire system with clean water The cooling system is filled with coolant through the filler opening on top of the radiator When this has been done the heater control should 21 Fan belt be set to max to ensure that the entire system will be fille
25. equipped with ball joints steering rods and propeller shaft of such a design that they do not require regular lubrication This has been possible due to the fact that points which normally require lubricating have been packed with very durable grease at the factory and then carefully sealed thus obviating the need for lubrication However in order to be certain that these parts are functioning properly it is necessary to inspect their seals and rubber sleeves thoroughly after every 10 000 km 6 000 miles or at least once a year Oil should be changed or the oil level checked after every 10 000 km 6000 miles in accordance with the lubricating chart at the end of the book This can be done in connection with the 10 000 km 6000 miles inspection at a Volvo workshop The measures taken during this inspection are also to be found in the lubricating chart You should follow the recommendations of the Service Booklet which are based on Volvo s own investigations Use only first class lubricants of a well known make The right lubricant in the right quantity at the right time will increase both the lifetime and reliability of your car Body lubrication To avoid rattle and unnecessary wear the body should be lubricated once a year Every 10 000 km 6000 miles the hinges on the bonnet doors and boot lid as well as door stops should be lubricated During the winter months the locks and handles on the doors and boot lid should also be pro
26. er transmission Brakes Front end Wheels and tyres Body Servicing before long distance trip Procedure in cold weather Lubricating chart FAULT TRACING SPECIFICATIONS page page 22 23 24 25 page 27 28 30 34 39 43 43 43 44 46 49 50 60 page 52 page53 VOLVO SERVICE VOLVO SERVICE Warranty and Service Booklet A warranty and service booklet accompanies each vehicle when it is delivered This book contains a coupon entitling you to a free service inspection after 2 500 km 1 500 miles If possible let the dealer who supplied the vehicle carry out this service inspection If necessary however any of our dealers can do this If our six month guarantee is to apply we make one absolute condition and that is that the above mentioned free inspection is carried out at roughly the mileage shown and that the vehicle has been looked after in accordance with the instructions in this book Service Inspections After the free service inspection has been carried out you should make an agreement with your dealer concerning continued regular ser vice inspections in accordance with the suggestions made in our Ser vice Book Thorough and regular servicing is of vital importance for the performance and length of life of the vehicle Always use genuine Volvo spares Volvo Service Organization In order to get the most out of the invested capital represented by a car it must be looked after and serviced regular
27. es not start 1 Remove the ignition cable from each plug in turn Hold the end of the cable about 14 from the cylinder block while turning round the engine with the ignition switched on If there is a strong spark the fault is probably in the sparking plugs so these should be changed 2 If only a weak spark is obtained or none at all check to see whether the ignition cables are properly inserted in the distributor and ignition coil 3 Remove the distributor cover check and clean all contact surfaces Check that the contact breaker points close properly when the engine is turned round If the contact breaker arm shaft binds oil it very sparingly If the engine misfires the reason can be That one of the ignition cables has loosened in the distributor cover or from the sparking plug 2 That one of the sparking plugs is coated with soot or oiled up in which case the plug concerned should be cleaned or changed and the sparking plug gap adjusted 3 That the distributor cover and rotor arm are cracked or damaged 4 That one of the ignition cables is in poor condition 5 That the contact breaker gap in the distributor is insufficient or non existent 6 That the breaker contacts are badly burned 52 SPECIFICATIONS Measurements and weights Length Width Height unladen ready to drive Wheelbase Ground clearance unladen Ground clearance driver and 3 passengers Track front Track rear Turning circle Weight ready
28. frozen door lock is one of the most irritating things that can happen to a car owner Many valuable minutes early in the morning can be wasted warming up keys and melting ice in locks Remember this in good time and lubricate the lock with some anti freeze preparation These are now available in small handy tubes which can be kept in a handbag or coat pocket 51 FAULT TRACING The information given below is only intended to serve as a guide in localizing and temporarily correcting minor faults After having carried out any such measures have them checked and adjusted by an experi enced mechanic The engine does not start although the starter motor turns it round at normal speed 1 Check that there is fuel in the tank 2 If the engine has been warm starting should be done with the accele rator pedal slowly depressed as far as it will go 3 In wet weather the sparking plug insulators should be wiped clear and the distributor cap removed and wiped dry if flash over is suspected 4 Check that the fuel line connections on the pump and carburettor are not leaking and that fuel is supplied to the carburettor 5 If the engine is turned round for a while without starting too rich a fuel mixture can enter the cylinders resulting in the sparking plugs becoming moist Blow the cylinders clean by screwing off the sparking plug and turning round the engine with the starter motor Dry the sparking plugs before fitting them If the engine still do
29. fy or repair the belt on your own but have this done by a Volvo workshop Rear seat On certain markets two rear safety belts are fitted as standard These are of the 2 point lap type The belts are fastened by pushing the buckle tongue on one part of the belt into the lock of the other To release simply lift up the spring loaded cap on the lock In principle the belts are adjusted in the same way as for the front seat belts DESCRIPTION Instruments and controls Before you start the car sit behind the wheel and carefully check through all the instruments and controls The location of these is shown in the illustration opposite The instruments and controls are described in more detail on the following pages with reference to the numbers in the illustration Note that variations may occur on different markets Immediately after starting and now and then while driving glance at the S instruments to make sure they are showing normal readings according e Cm to the values given in the following text lt 1 Temperature gauge 15 Cigarette lighter 2 Warning light battery charging 16 Fan switch heater ventilation 3 Trip meter controls 4 Speedometer 17 Grab handle 5 Mainbeam control light 18 Switch for glove locker light 6 Turn indicator control light 19 Bonnet release handle 7 Mileometer 20 Foot dipper switch 8 Oil pressure warning light 21 Clutch pedal 9 Fuel gauge 22 Brake pedal 10 Warnin
30. g chamber system The cables to the headlights parking lights and internal lighting however are not taken over the ignition switch but can be switched on and off without the ignition key being in position Electrical system The electrical system is of the 12 volt type and is fitted with a voltage When higher output is required the throttles open so that the fuel air mixture flows directly to the cylinders DESCRIPTION Lighting Fuses The lighting on the car consists of two headlights mainbeam and dipped together with two combined flasher and parking lights The rear lighting consists of two tail lights including flashers combined lamps for the tail lights and brake warning lights as well as the reversing light Internal lighting consists of a roof light above the rearview mirror and a light for the parcel shelf See pages 40 42 concerning replacement of bulbs The electrical system is protected by means of fuses fitted in a fusebox to the left on the bulkhead under the bonnet When replacing a fuse be sure that you use one with the right rating If any fuse should blow i check the electrical system Power transmission Clutch The clutch is of the single dry plate type with diaphragm spring The diaphragm spring functions partly as a lever when declutching and partly as a pressure spring when engaging Clutch pedal pressure is transmitted mechanically to the release fork Gearbox 10 The gearbox is used to
31. g lamp handbrake 23 Accelerator pedal brake system 24 Lighting switch 11 Windscreen wiper and washer 25 Turn indicator switch switch headlight flasher 12 Choke control 26 Steering wheel 3 Horn ring 27 Gear lever 14 Ignition switch and steering wheel lock DESCRIPTION 18 Temperature gauge The temperature gauge shows the temperature of the coolant and thus indicates the working temperature of the engine The pointer on this gauge should remain within the green sectors Battery charging warning light This light goes on when the battery discharges If it goes on during driving this means either that there is some fault in the electrical system or that the fan belt is not sufficiently tensioned and is thus slipping the pulley causing poor charging Trip meter The trip meter which is graduated in tenths of a mile can be used to measure even short distances The meter can be reset to zero by means of a reset knob placed under the instrument panel to the left of the steering column The knob is turned first to the right and then to the left Speedometer The speedometer has a horizontal red ribbon indicator the ribbon point showing the speed at which you are travelling Since the length of the red ribbon is proportional to the speed this is in itself a safety factor the more red shown the more dangerous your speed Mileometer The mileometer shows the total distance covered in miles After 99999 mi
32. g the extra holes in the seat frames The backrest inclination of the front seats is smoothly adjusted by means of a knob B on the outside of the seat A catch automatically locks the backrest and thus prevents it from falling for wards To fold the backrest backwards release the catch C The front seats are provided with head rests Before driving always make sure that the headrest is at the proper height To adjust slacken the plastic nuts on the headrest holders The car is delivered with the headrests adjusted to a stan dard height After adjusting lock them by turning the plastic nuts clockwise The front seats are also provided with an adjustable lumbar support To tension the lumbar support and thus exert more pressure against the small of the back turn the knob clockwise Turning it anti clockwise slackens the tension on the support and reduces the pressure against the small of the back The inclination angle of the entire seat can be adjusted with the eyelet screw at the front under the seat Remove the screw which goes through the eyelet and tip the seat backwards as shown in the picture Then slacken the locknut on the floor and screw the eyelet screw up wards or downwards to the desired height Then secure the eyelet screw with the locknut The whole seat can be raised or lowered which is done as follows Remove the seat cushion also the screw and nut on the seat frame attachment on the floor Then pla
33. h underbody sealing compound on those places subjected to flying stones from the wheels that is the wheel arches the entire floor and the underside of the sills Anti rust fluid is sprayed on the chassis parts Inspection and touching up of the anti rust protection should be done at regular intervals and at least once a year If any touching up of the anti rust protection is necessary this should be done immediately to prevent moisture from seeping in and conse quently damaging it Cleaning Cleaning the upholstery The upholstery consists of vinyl coated fabric which is very resistant to dirt so that it rarely requires any maintenance If it becomes stained the upholstery can easily be cleaned with a synthetic washing agent and lukewarm water Cleaning the floor mats The floor mats should be taken out at least twice a year and cleaned and dried particularly during the winter The floor under the mats can be cleaned at the same time If the mats have become stained they can be cleaned with methylated spirit and then rinsed off with water SERVICING Servicing before a long distance trip If you are thinking of taking your car abroad or on a long trip have it checked at a Volvo workshop You will enjoy your journey better if you know that your car is in perfect trim Irritating incidents can be avoided as well as expensive time absorbing stoppages Even if some thing unforeseen should happen your journey does not nee
34. ite While the car is being towed the tow line should be kept even ly stretched since violent jerks can damage the bum pers SERVICING General Before the car was delivered from the factory is was subjected to a very thorough inspection Your dealer in his turn carried out a further deli very inspection in accordance with the specifications of the Volvo fac tory In addition to this there is the free service inspection after 2 500 km 1 500 miles Subsequent servicing of the car should follow the routine in the service book which is based on a system involving an oil change oil level check and service inspections after every 10 000 km 6 000 miles The simplest and in the long run most profitable way to give the car the servicing it requires is to have all servicing done by a Volvo work shop You will then have all the work specified in the service book carried out in accordance with recommended prices and the workshop stamp in the service book will show when the car was serviced this is also extremely important as far as second hand value is concerned During the designing of the car particular attention was given to the safety details e g suspension brakes and steering They are calcu lated to withstand the severest stresses with a wide safety margin How ever if you use your car for hard driving you should take the precau tion of checking these parts for fatigue cracks sometime during the car s useful life for
35. lant level when filling up with fuel The level should be between the Max and Min marks on the ex pansion tank When the engine is new or the cooling system has been emptied this check should be carried out with particular thoroughness The cooling system filler caps on the radiator and expansion tank should not be removed other than for topping up with coolant More frequent removal may impede the circulation between the expansion tank and the engine when the latter is warming up and cooling 18 Cleaning the air cleaner with Topping up with coolant foam plastic sleeve Top up the coolant by filling the expansion tank when its level has Cars intended for markets where dusty conditions are prevalent are fitted with air cleaners provided with a foam plastic sleeve This sleeve is normally washed or changed after every 20 000 km 12500 miles After every 80000 km 50000 miles the paper filter must also be re placed The foam plastic sleeve is removed from the air cleaner and washed in paraffin kerosene fuel oil or warm water mixed with a washing agent Squeeze the sleeve until it is clean and then rinse it in clean water When the sleeve is dry dip it in engine oil SAE 30 Squeeze the sleeve in the oil and remove surplus oil by rolling the sleeve in a clean cloth Fit the sleeve on the paper filter 19 Valves Let your Volvo workshop check the engine valve clearances after every 10 000 km 6000 miles Too narrow cl
36. le the engine too long but start driving with a light load on the engine as soon as the oil pressure warning light goes out Gear changing 24 The gearbox has synchromesh on all for ward gears It gear changing is to func tion satisfactorily the clutch pedal must be fully depressed To obtain good acceleration it is impor tant that gear change timing is adapt ed to the speed in such a way that the engine speed is within suitable limits neither too high nor too low The gear positions are shown in the pic ture opposite it Gear positions for 4 speed gearbox OPERATING INSTRUCTIONS Recommended speed ranges km p h m p h for the different gears Engine Gearbox 1st gear 2ndgear 3rd gear 4th gear B20A M 40 0 45 15 70 25 100 35 0 28 10 45 15 50 22 B20B M 40 0 50 20 80 30 115 40 0 30 15 50 20 70 25 Points Worth Noting Starting in a garage If you start your car in a garage always open the garage doors before starting the engine The exhaust gases from the engine contain poison ous carbon monoxide gas which is particularly dangerous since it is both invisible and odourless Driving with the boot lid open While driving with the boot lid partly or fully open exhaust gases and consequently also carbon monoxide can be sucked into the car through the boot particularly if a window is open Normally this involves no risk to the passengers However on such occ
37. les it returns to zero and starts going round again DESCRIPTI ON 10 Handbrake warning light This lights red when the handbrake is applied and the ignition is on The light also functions as a warning light should a failure arise in one of the brake service circuits If the light goes on when driving the car should be taken without delay to a workshop for a check on the brake system Observe due care when driving on such occasions 1t Windscreen wiper and washer switch The windscreen wiper and washer switch has four positions When pressed fully in the switch is switched off When the switch is pulled out to the first position the windscreen wipers operate at normal speed When it is pulled out to the second position the wipers operate more quickly Pulling the switch out fully also operates the windscreen washers The liquid container for the windscreen washers is placed under the bonnet and holds about 1 5 litres 2 6 Imp pints 3 2 US pints Never allow the wiper blades to operate on a dry and dusty surface since this can easily scratch the glass and blades 12 Choke control The choke control is used when the engine is started from cold When pulled out about 10 15 mm the control operates the throttle flap and increases idling speed Pulling the control out further enriches the fuel air mixture and this steps up the idling speed 14 Combined ignition switch and steering wheel lock POPO connected up except
38. lish Car washing fluid Revolution counter Towing hitch Your dealer will willingly help you to find the accessories which you are looking for but which are not mentioned here Moreover he will be supplying you with genuine Volvo accessories with factory guarantee 64 Fuel octane rating B 20 A 97 B20B 100 For mainly highway driving however fuel with an octane rating of minimum 97 can be used even for the B 20 B engine ROT Research Method Recommended tyre pressures kg cm p s i cold tyres Tyre size 165 S 15 6 85 15 165 SR 15 Front Rear Front Rear 1 2 persons 1 4 20 1 6 23 1 8 26 24 30 Full load 1 5 22 2 0 28 For prolonged driving at speeds above 140 km p h 90 m p h the pressure should be increased by 0 3 kg cm 4 5 p s i This also applies to the 165 SR 15 tyre when driving at speeds near that of the maximum for the vehicle Maximum pressure for a 165 S 15 tyre must not however exceed 2 1 kg cm 30 p s i The specifications and design details given in this book are not binding We reserve the right to carry out modifications without previous notice AB VOLVO GOTEBORG SWEDEN AB VOLVO GOTEBORG SWEDEN
39. lling out the switch next to the heater controls 25 Turn indicator switch lever be a slight delay before the heater element adjusts itself to the desired The turn indicators controlled by means One lover mounted temperature on the left hand side of the steering column under the steering wheel Interior lighting Mainbeam flasher The illustration shows the air duct 1 The light goes on when the front doors Moving the turn indicator switch up to to the rear seat and the air distri are opened wards the steering wheel switches on bution in the vehicle when both the 2 The light is off all the time the mainbeam lighting which remains on FLOOR and DEFR controls are 3 The light is on all the time until the switch lever is released used During cold or damp weather mist can easily form on the windows particularly with a full number of passengers The best way of getting rid of this or to avoid it altogether is to open the ventilation windows partly or fully and to set the fan and defroster control at max out put 20 21 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Warranty inspection After 2 500 km 1 500 miles the car should be taken to a Volvo work shop for the free warranty inspection The procedure then carried out also includes an engine oil change It is very important to ensure that this oil change is carried out since during the first period the engine oil usually collects a lot of impurities Af
40. ly Volvo has gone to a great deal of trouble in the design and selection of material to ensure that the car in question only requires a minimum of servicing All this work will be in vain unless we can count on your co operation that is to say that you make sure that your vehicle gets the regular servicing it needs In order to help you Volvo has built up a world wide service organization All Volvo dealers have specially trained personnel and receive a continuous supply of technical information from the Volvo Service Organization concerning repairs and adjustment work They have also special tools designed at the Volvo factory All Volvo dealers have a comprehensive stock of spare parts which is your guarantee for genuine Volvo spares Our dealers are therefore in the very best position to give your vehicle first class service concerning both maintenance operations and repairs You should also refer to your dealer if you need information about your Volvo that is not included in this instruction book Not only is there a Volvo workshop within easy reach in your own country Volvo has also a widely distributed service network in other countries DESCRIPTION Type designations This instruction book deals with cars having the following type designations note that some varia tions are not to be found on certain markets Type designation Engine Gearbox 13 134 B20A M 40 13 334 B 20 B M 40 13 344 B 20 B M 40 1 car ty
41. nd then lift upwards so that the re tainer catch releases its grip Do not pull out the headlight rim so far forwards that the catch at the top becomes bent otherwise water can penetrate into and damage the reflector It is not necessary to remove these screws completely The insert can be removed by turning it in an anti clock wise direction Remove the bulb holder contact and take off the rubber sleeve Remove the spring fixing the lamp holder in the cor rect position rent thickness or they are staggered so that the bulbs can only be fitted in one definite position Certain makes of bulbs have a Top mark on the socket and this should face upwards bulb and holder are changed com pletely as one unit When fitting the bulb holder into the insert make sure that the small spring retainer engages in the notch Replacing the roof light bulb When replacing the roof light bulb the lamp shade is pulled straight out When fitting headlight bulbs do not touch the glass with your fingers The reason for this is that grease oil or any other impurities can be carbonized onto the bulb and this may damage the deflector SERVICING Replacing the bulbs in the front parking lights flashers Unscrew the two screws by means of a Philips screwdriver and lift off the glass and the metal frame The bulbs can now be removed by pushing in and twisting anti clockwise Replacing the bulbs in the rear flashers stop
42. oil SAE 5 W 20 These oils reach the lubricating points mentioned more easily at low temperature and also facilitate cold starting See page 31 Electrical system The electrical system in the vehicle is subjected to greater stresses during the winter than during the warm summer months The lighting and starter motor are used more and since the capacity of the battery is a so considerably lower at low air temperature the state of charge must be checked more often and if necessary the battery charged If the specific gravity of the electrolyte is excessively low there is risk of frost damage to the battery Brake system During very cold weather the brakes are subjected to splash and con densation water which can result in the handbrake freezing up if left on Therefore never park the car with the handbrake applied engage instead 1st gear or reverse and if possible place blocks behind the wheels Windscreen washer In the same way as anti freeze is added to the cooling system during the winter to prevent frost damage anti freeze should also be added to the water container for the windscreen washer This is particularly important because the windscreen during the winter frequently becomes dirty and is often splashed with water which rapidly freezes and thus necessitates the frequent use of the windscreen washer and wipers Your Volvo dealer can supply you with a suitable anti freeze for this purpose Anti freeze for door locks A
43. otation Contact breaker gap 54 B20A B20B 82 h p 4700 100 h p 5500 90 h p 4800 118 h p 5800 16 kpm 15 5 kpm 116 1b ft 2300 112 Ib ft 3500 16 5 kpm 17 0 kpm 119 Ib ft 3000 123 Ib ft 3500 4 88 9 mm 3 5 80 mm 3 15 1 99 litres 87 1 o 93 1 Overhead 40 45 mm 50 55 016 018 020 022 700 r p m 800 r p m Horizontal Horizontal Zenith Stromberg SU HS 62 175 CD 2 SE 1 2 97 ROT 100 ROT Positive pressure approx 0 7 kg cm 10 p s i approx 82 C 180 F approx 90 C 195 F 1 3 4 2 21 23 B T D C 10 B T D C at 1500 r p m at 600 800 r p m Bosch W 175 354 Bosch W 200 T 35 Bosch W 175 T 354 1 8 mm 028 032 3 5 4 0 kpm 25 29 Anti clockwise 4 5 mm 016 020 1 On certain markets SU HS 6 On certain markets Zenith Stromberg 175 CD2 SE 3 ROT Research Method 4 Or corresponding Electrical system Voltage es sul ok we Battery type capacity electrolyte specific gravity when recharging is necessary Alternator max rating Output Starter motor output FUSES Lem Mui PCIe Lamp bulbs 12 V Headlights asymmetrical Parking lights front Flashers front and rear Stop parking lights tail lights Reversing lights
44. pe designation and chassis number are stamped on the cowl under the bonnet 2 Stamped on a plate to the left under the bonnet is the type designation together with the code numbers for colour and upholstery 3 The engine type designation part number and serial number are given on the left hand side of the cylinder block The last figures of the part number are stamped on a tab The serial number follows this with all the figures stamped on For identifying the engine both the part number and serial number should be quoted for example 496918 3456 all correspondence con cerning your vehicle with the dealer and when order ing spare parts the type designation chassis and engine number should al ways be quoted 9 8 7 6 5 4 3 2 0 Engine compartment B 20 A 0 d 99 d9 49 Engine B 20 B 1 Pwr Air cleaner 20 10 Floatchamber 20 Carburettors 20 11 Expansion tank with 12 filler cap for coolant 13 Voltage regulator 14 Hoses for air preheating 15 Alternator 16 Air cleaner B 20 A 17 Carburettor B 20 A 18 Hoses for positive crankcase ventilation Battery Hoses for heater system Oil dipstick Distributor Car heater Starter motor Ignition coil Data plate type upholstery colour code 19 20 21 22 23 24 25 26 27 28 18 19 Fusebox Oil filler cap Brake servo cylinder Relay for reve
45. pints Change the oil after the first 2 500 km 1 500 miles during running in 31 SERVICING 4 Carburettor s At each engine oil change check that the oil level in the centre spindle of the carburettor s is about 6 mm 14 from the top of the spindle If it is not top up to the level using oil approved as Automatic Trans mission Fluid Type A transmission oil The carburettors are adjusted and tested in a test bench at the factory with a CO meter No subsequent checking or setting of the carburettors is necessary other than in connection with repairs to or replacement of the carburettors Automatic Transmission Fluid Type A 5 Gearbox M 40 6 32 The oil in the gearbox be checked after every 10000 km 6000 miles The oil should be at the level of the filler hole Top up with the recom mended oil if necessary The oil in the gearbox should be changed after every 40 000 km 25000 miles In the case of a new or reconditioned gearbox the oil should be changed after the first 5 000 km 3 000 miles on which occasion the gearbox should be thoroughly flushed with oil of the same type to be subsequently used The old oil should be drained off immediately after the vehicle has been run when the oil is still warm Oil grade Viscosity Oil capacity SAE 80 i Gas oil At temperatures continuously 33 Imp plats below 30 C 90 F 1 am SAE 90 1 6 S pints Engine oil SAE 30 7 8 9 10 SERV
46. r push in the control more and more but oid speed 80 km p h x 50 m p h 2 far that the engine to run unevenly Drive for as short a period as possible with the choke out With the air preheating ar rangement the engine should run smoothly already some minutes Avoid driving at low speed in high gear after starting When the engine is thoroughly warm the control should be pushed right in After starting a cold engine do not race it immediately but run it at mo derate speed and do not subject it to heavy loading until engine tem perature has reached normal level 4th speed 110 km p h 70 m p h 130 km p h 80 m p h 23 22 OPERATING INSTRUCTIONS Starting a warm engine 1 Check that the handbrake is on and the gear lever is in neutral 2 Depress the clutch pedal 3 Lightly depress the accelerator pedal and turn the ignition key to the starting position Release the key as soon as the engine has started If the engine does not start immediately depress the accelerator pedal fully and hold it there until the engine has started Warming up the engine Experience has shown that engines in vehicles which are frequently stopped and started are subject to abnormally rapid wear The reason for this is that the engine is not given a chance to reach its normal working temperature When the engine is cold it should be taken up to its normal working temperature as quickly as possible Do not therefore id
47. re spindle of the carburettor s reaches up to about 6 mm 4 from the top of the spindle If it does not top up to this level Use oil ATF Type A transmission oil Note 9 The oil filter should be changed every 10000 km 6 000 miles see page 35 Note 10 Check the oil level every 10000 km 6 000 miles Concerning lubri cant for a final drive with differential brake see page 33 Note 9 Gearbox Note 7 Handbrake cable Note 6 Rear axle Note 11 Wheel bearings Note 2 61 Text for wiring diagram 62 Note that the electrical equipment can vary for the different models on different markets A White B Black C Blue 4 LX Elm m amp NM o 19 20 21 23 25 26 27 29 30 31 32 Flasher and parking light left Headlight left Horn Headlight right Flasher and parking light right Connector Junction block Relay for headlight signal Reverse light contact Distributor Alternator Charging regulator Brake warning switch Relay for reverse light Foot dipper switch 17 18 Ignition coil Oil pressure warning indicator Brake warning lamp Switch for handbrake control Fusebox Brake contact Starter motor Windscreen washer Battery Door switch left Light signal device turn indicators Horn ring Roof light 33 34 35 36 37 38 39 40 M 42 44 45 46
48. rear kg cm 1 6 2 0 PS 23 28 Tyre size 2 165 SR 15 Air pressure cold tyres front kg cm 1 8 p S ee arsine 26 rear kg cm 21 I ME RE 30 For prolonged driving at speeds over 140 km p h 90 m p h the pressure should be increased by 0 3 kg cm 4 5 p s i Capacities Fuel tank 0 000 cee eee ee eee approx 45 litres 9 9 Imp galls 11 9 US galls Cooling system approx 8 6 litres 1 9 Imp galls Oil capacity engine 2 3 08 galls when changing oil approx 3 25 litres 5 72 Imp pints 6 86 US pints including oil cleaner approx 3 75 litres 6 60 Imp pints 7 91 US pints Oil capacity gearbox approx 0 75 litre 1 32 Imp pints 1 58 US pints Oil capacity rear axle approx 1 3 litres 2 28 Imp pints 2 74 US pints Oil capacity steering box approx 0 25 litre 44 Imp pint 53 US pint 56 LUBRICATING CHART Symbols Brake fluid Grade SAE 70R3 Rear axle oil Grade Hypoid oil Viscosity See pages 33 and 34 Oil capacities ERI OLLI 3 25 litres Check the following when filling the tank 1 Check the engine oil level Be Light engine 0 Engine oil Grade For Service MS Viscosity Multigrade SAE 10 W 30 see page 31 b Special lubricant see resp notes Gearbox oil Bate 1 30 litres 2 28 Imp pints
49. right hand threads and are loosened by turning them anti clockwise nsert the lifting arm of the jack in the appropriate jack attachment of the wheel to be changed Jack up the side of the car far enough for the wheel to turn freely Unscrew the wheel nuts completely and lift off the wheel Be careful when lifting off the wheel that the threads of the wheel studs are not damaged Fit on the new wheel and tighten the nuts until the wheel makes good contact with the hub flange Then lower the car and tighten the nuts alternately Warning On cars fitted with a differen tial brake a jacked up rear wheel must not be turned if the other rear wheel is on the ground Because of the differen tial brake turning the jacked up wheel also moves the other rear wheel and this may cause the car to topple off the j ack SERVICING Body 38 Washing The car should be washed often since such things as dirt dust dead insects tar sports etc usually adhere firmly to the body and may dama ge the paintwork Washing also helps to counteract rusting During the winter make sure that all road salt residue is washed off as soon as possible otherwise corrosion can easily occur A car the bodywork of which has been well taken care of has of course a higher second hand value should the owner consider selling it When washing the car make sure that it is not exposed to direct sun light since this can cause drying patches Begin
50. rinting permitted if source quoted BEFORE YOU START DRIVING YOUR NEW VOLVO PLEASE READ THROUGH THIS INSTRUCTION BOOK CAREFULLY IT CONTAINS ALL THE INFORMATION YOU NEED TO BE ABLE TO DRIVE AND SERVICE YOUR VEHICLE IN THE BEST POSSIBLE WAY BY FOLLOWING THE INSTRUCTIONS GIVEN IN THIS BOOK YOU WILL FIND THAT YOUR VOLVO WILL COME UP TO ALL THE EXPECTATIONS CONCERNING ECONOMICAL OPERATION AND EXCELLENT PERFORMANCE THAT YOU HAVE EVERY RIGHT TO EXPECT OF A TOP QUALITY VEHICLE DO NOT WAIT UNTIL SOMETHING GOES WRONG BEFORE YOU START READING THIS BOOK READ IT NOW THE SHORT TIME THIS TAKES WILL MORE THAN REPAY YOU IN THE LONG RUN THIS INSTRUCTION BOOK IS NOT INTENDED TO BE A COMPREHENSIVE TECHNICAL MANUAL AND DOES NOT CLAIM TO MAKE THE READER INTO A PERFECT CAR MECHANIC IT WILL HOWEVER SHOW YOU HOW TO LOOK AFTER YOUR VEHICLE SO THAT TROUBLE IN FUTURE CAN BE AVOIDED FOR A MORE DETAILED MECHANICAL DESCRIPTION AND REPAIR PROCEDURES YOU ARE REFERRED TO THE SPECIAL SERVICE MANUAL FOR THE VEHICLE CONTENTS VOLVO SERVICE The Volvo Service Organization Warranty and Service Booklet Service Inspections TECHNICAL DESCRIPTION Type designations Engine Electrical system Power transmission Brakes Wheels and tyres Body Instruments and controls OPERATING INSTRUCTIONS Running in Starting the engine Gear changing Points worth noting SERVICING General Maintenance scheme Lubrication Engine Electrical system Pow
51. rsing lights Relay for headlight flasher Fuel pump Brake fluid container Steering box Windscreen wipers Horn DESCRIPTION DESCRIPTION Engine Air preheating Certain variations of the 120 models are provided with thermostatically controlled air preheating With this arrangement the induced air is maintained at a constant favour able temperature Air preheating counteracts ice formation in the car burettor and also contributes to a shorter warming up period after start ing from cold Lubricating system The engine lubrication is taken care of by a gear pump which sucks up oil from the sump on the bottom of the engine and forces it through the oil filter out to the lubricating points in the engine A relief valve is built It into the oil filter which prevents the oil pressure from reaching exces sively high values The engine is a four cylinder carburettor unit with overhead valves The pistons are made of light alloy and the upper compression rings on each piston are chromed The main bearing and big end bearing shells are replaceable The crankshaft is statically and dynamically balanced Engine type B 20 A has an output of 90 h p SAE and is equipped with a Zenith Stromberg horizontal carburettor On certain markets SU hori Cooling system zontal carburettor Engine type B 20 B has an output of 118 h p SAE and is equipped with twin SU horizontal carburettors On certain markets twin Zenith Stromberg horizontal c
52. s damaged it should be replaced and the new seal filled with molybdenum disulphide grease Brakes 33 Check the brakes After every 10 000 km 6000 miles the car should be taken to a Volvo workshop for a check on the functioning of the brakes The brakes should also be inspected for wear at the same time 34 Replacing the booster cylinder air filter and overhauling the brakes Normally the booster cylinder air filter should be replaced every third year When driving for the most part on dusty roads replacement should be more frequent An authorized Volvo workshop should be allowed to carry out the replacement Every third year or 60 000 km 36000 miles the brake system seals should also be replaced Front end 35 Check the front wheel alignment Correct front wheel alignment is of vital importance for the steering of the vehicle Faulty adjustment can mean heavy wear on the tyres For this reason have the front wheel alignment checked regularly at your local Volvo workshop for example after every 10 000 km 6 000 miles If the vehicle has met with a collision involving heavy impact and it is suspected that the front end may have been affected take the vehicle to a Volvo workshop for a check on the front wheel alignment as soon as possible Volvo workshops have special measuring equipment for this purpose and can therefore carry out this control very quickly The front wheel alignment angles are shown on page 56 36 Check the ball joints
53. sure lines to the rear wheels are fitted with relief valves which prevent involuntary locking of the rear wheels This system has a warning light located on the instrument panel The warning light shows if there is a failure in one of the circuits when braking It also serves as a warning light for the handbrake Wheels and tyres The car has pressed steel wheels with lugs for the attachment of the hub caps All wheels are carefully balanced and the tyres are of the tubeless type Tyre size 165 S 15 165 SR 15 or 6 85 15 11 DESCRIPTION Body Bonnet Boot The bonnet is fitted with a locking catch which is operated from the driving seat by means of a handle located to the left under the dashboard Pulling out the handle releases the bon net When the bonnet locking catch has been released the bonnet is still retained by a safety catch Press up this catch as shown in the picture opposite and the bonnet can be lifted up Closing the bonnet locks it so that it can only be opened by pulling out the release handle Always make sure that the bonnet locks properly when closed The boot is locked with the same key as that used for the doors The lid is opened by pressing the handle upwards as shown in the picture opposite The lid is balanced and will thus remain in the position opened In the boot to the left there is space sufficient for the spare wheel and a tool kit Always make sure that the spare wheel is fastened sec
54. tail lights and reversing light Unscrew the two screws one at the upper and one at the lower end of the lighting fixture by means of a Philips screwdriver Lift off the glass and the metal frame The bulbs can now be removed by push ing in and twisting anti clockwise 42 The top bulb is the turn indicator the middle one the combined _ stop tail light and the bottom one the reversing light Make sure that the glass fits pro perly on the sealing strip when assembling the fix ture The untinted part of the glass should be at the bottom The larger one is the turn indicator flasher and the smaller one the parking light Make sure that the glass fits well against the gasket Replacing the bulbs in the number plate light The number plate light is built into the handle on the boot lid with one bulb on each side of the em blem The bulbs are ac cessible from the under side of the emblem SERVICING Power transmission 31 Checking the clutch yoke free travel To avoid risk of the clutch slipping the clutch yoke free travel should be checked and adjusted if necessary every 10 000 km 6 000 miles For data see page 55 The clutch should be checked and adjusted at a Volvo workshop since these workshops have the proper equipment 32 Check the propeller shaft Every 10000 km 6000 miles or once a year the rubber on the spline shaft should be checked as well as the universal joints If the rubber seal i
55. ter 5 000 km 3 000 miles the oil in the gearbox and rear axle should be changed Subsequent changes should be carried out at approximately those intervals indicated in the maintenance scheme on page 28 and in the lubricating chart at the end of the book Before being delivered Volvo engines are test run on test benches and jn the cars on test tracks We are therefore assured that all clearances are satisfactory and thus accept no responsibility for damage caused by careless running in Running in Starting the engine Starting a cold engine As the car is new we recommend that a certain amount of caution be observed during the running in period for it is during this time that the 1 Check that the handbrake is on and the gear lever is in neutral movable parts of the car must be properly bedded in so as to obtain smooth and durable sliding surfaces During running in the following max permissible speeds apply 2 Pull the choke control out fully 3 Depress the clutch pedal to assist when starting especially in cold during the first between 1 000 and 2 000 km weather 1 000 km 600 miles 600 and 1 200 miles es 4 Turn the ignition key to the starting position Release the key as soon 1 st speed 30 km p h 20 m p h 50 km p h 30 m p h as the engine has started 2nd speed 55 km p h 35 m p h 75 km p h 45 5 Push in the choke control until the best idling speed is obtained As the engine becomes warme
56. ting Before the vehicle is poli shed it should be carefully washed and dried so that scratches do not occur in the paintwork Polishing a couple of times a year is generally sufficient to give the surface finish the maintenance it needs If you want to wax the vehicle be very careful to ensure that the surface is absolutely clean before application Often it is necessary to use white spirit for cleaning Waxing should neither be considered as a substitute for polishing nor as a necessary protection for the paintwork against unfavourable weather For the most part waxing is not necessary until one year after delivery of the car Use only a good quality polish intended for a synthetic finish Never polish or wash the vehicle in direct sunlight as this can easily result in a smeary surface Touching up surface finish damage The touching up of any extensive dama ge to the synthetic finish requires the use of special equipment and skill so that the repairing of any such damage should be entrusted to a Volvo work shop Minor damage caused by flying stones etc and small scratches can however be attended to by you your self Damage caused by flying stones requires immediate treatment Therefore make a habit of checking the finish and carrying out touching up work regularly for example when washing the car Volvo dealers can supply you with suitable touching up paint with brush Always check to make sure that you get exactly the right
57. to drive Permissible total weight Permissible load without driver Permissible axle pressure front rear Permissible roof load Max permissible trailer weight 4440 mm 175 0 1633 mm 64 3 1470 mm 58 0 2600 mm 10 2 4 210 mm 8 27 170 mm 6 69 1315 mm 51 77 1345 mm 51 77 9 5 m 31 4 1080 kg 2381 Ib 1600 kg 3520 Ib 440 kg 968 Ib 750 kg 1650 Ib 900 kg 1980 Ib 100 kg 220 Ib 1000 kg 2200 Ib 53 SPECIFICATIONS Engine Type designation Max output DIN at r p m Max output SAE at r p m Max torque DIN at r p m Max torque SAE at r p m Number of cylinders edv e A b Stroke skewed ex EDS Displacement Compression ratio Valves Valve clearance warm and cold inlet and exhaust Idling speed warm engine Fuel system Carburettor type designation number Fuel octane rating min Cooling system Thermostat begins to open at fully open at Ignition system Firing order Ignition setting stroboscope setting with vacuum regulator disconnected Sparking plugs normal driving hard driving Sparking plug gap Tightening torque Distributor direction of r
58. top up with the recommend ed oil The oil in the steering box generally does not need to be changed except when reconditioning takes place If the oil is to be changed the old oil can be sucked up by means of an oil syringe or similar which is inserted down through the filler hole Oil grade Viscosity Oil capacity AE 0 25 litre Hypoid oil SAE 80 all year round 0 44 Imp pint E pint 0 53 U Brake fluid The brake fluid level in the brake hydrau lic system should be checked after every 5 000 km 3 000 miles The brake system is provided with twin brake fluid con tainers one for each system Both con tainers have a common filler cap The level of the brake fluid should be be tween the Max and Min marks Only brake fluids which meet the re quirements according to the specifica tions under SAE 70 R 3 may be used for the hydraulic brake system Crankcase ventilation The engine is provided with positive crankcase ventilation which prevents the gases in the crankcase from being re leased into the atmosphere Instead they are sucked into the intake manifold and take part in the combustion process whereupon they are blown out through the exhaust pipe together with the other combustion gases Every 40 000 km 25000 miles remove and clean the nozzle 1 the hoses 2 and 4 and the flame protector 3 Rubber hoses should also be replaced if they are in a poor condition 15 16 Oil filter The oil filter tr
59. ttery with a voltmeter If extra batteries are used for starting they must be properly connect ed to prevent the rectifiers from being damaged The negative lead from the auxiliary battery for starting must be con nected to the negative terminal stud of the car battery and the posi tive lead from the auxiliary battery for starting to the positive terminal stud If a rapid charger is used to charge the battery the car battery leads should be disconnected The rapid charger must never be used as an auxiliary unit for starting 4 Never disconnect the battery circuit for example to change the bat tery while the engine is running as this will ruin the alternator im mediately Always make sure that all the battery connections are properly tigh tened If any electrical welding work is to be carried out on the vehicle the earth lead and all the connecting cables of the alternator must the removed The welding unit should be placed as near the welding point as possible N Check the battery electrolyte level To ensure that the battery functions properly the electrolyte level should be checked regularly A suitable time to do this is when the fuel tank is being filled The electrolyte level should be 5 10 mm 4 over the top of the cell plates Top up with distilled water if necessary Never add too much distilled water since this can cause the acid to splash over and cause damage in the engine compartment
60. urely and that the tool kit is firmly stowed otherwise irritating rattles can occur Doors and locks Both the doors are fitted with a lock and keyhole Both doors can be locked from inside the car by pressing down the lock button on the window ledge The lock button lifts automatically when the door is opened from the inside The doors can be locked from the outside by press ing the lock button on the window ledge and shutting the door Do not leave the keys in the car The doors are opened from the inside by pulling the door handle to the rear The ventilation windows for the doors are opened by unscrewing the lock stud pressing it in and then turning the handle upwards Screwing in the stud locks the handle The rear side windows can be partly opened by turning up the catch as shown in the picture To prevent the locks from freezing up in cold weather apply a suitable anti freeze agent If the locks are already frozen do not exert undue force on the key otherwise you might break it In stead heat it with a match or similar and place it quickly in the keyhole Should you lose the car keys contact your nearest Volvo dealer for new keys and quote the code number of the keys which have been lost DESCRIPTION Front seats The front seats can be moved back wards or forwards after the knob A is pressed down If necessary the seats can be moved further to the rear than permitted by the slide rail by usin
61. vided with some anti freeze to prevent them from freezing up No Lubricating point Lubricant 1 1 3 4 5 10 11 12 30 Bonnet catch Paraffin wax Bonnet hinges Ventilator window catches and hinges Oil Catches door Paraffin wax Door handle lock buttons Paraffin wax Keyholes Lock oil Door locks Lock oil Boot hinges Boot lid lock Oil Key holes Lock oil Door stops Paraffin wax Door hinges Driving seat rails Paraffin wax and catches and oil Window lifts Oil and grease Locks Silicon grease Accessible after removal of door panels Lubrication included in 10 000 6000 miles service 2 3 SERVICING Check the oil level in the engine The oil level in the engine should be checked each time the fuel tank is filled The check should be carried out with the engine switched off but warm and in order to obtain comparable values about 1 minute after the engine has been stopped Wipe the dipstick before meas uring The oil level should be between the two marks on the dipstick It must never be permitted to go down below the lower mark but on the other hand it should not be above the upper mark since oil consumption will then be abnormally high If necessary top up by filling through the oil filler hole on the rocker arm casing with new oil of the same type already in the engine Changing the engine oil With a new or reconditioned engine the oil should be

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