Service Manual Section 2, B1-B15. 1991
Contents
1. B1 Engine gearbox check for leakage from underneath Check that there is no leakage from the engine or ge arbox If there is leakage from the gearbox the oil level should be checked and the gearbox topped up if necessary Oil quality manual gearbox 200 700 940 960 M 45146147 ATF oil type F or G M 90 Volvo P N 11 61 423 7 400 gearbox final drive Volvo P N 33 43 922 5 850 gearbox final drive Volvo synthetic gearbox oil 11 61 423 7 Note Always use new gaskets Note On automatic gearboxes oil level inspection and topping up if necessary are carried out later in the programme D5 Automatic gearbox top up oil B2 Drain engine oil and replace oil filter Drain engine oil Remove the drain plug Remove the drain plug Replace the washer Refit the drain plug and tighten Tightening torque 400 22Nm 740 940 65 Nm 960 40Nm 800 35Nm Replace the oil filter Remove the filter with the filter removal tool 999 2903 850 Use tool 999 5458 for removal of the oil filter Insert the new filter and hand tighten see the instructions on the filter B3 Automatic gearbox drain the oil Topping up see D5 200 400 700 940 960 AW 50 42 850 and AW 30 43 960 Oil chan ge every 75 000 km only for cars in taxi traffic and cars which spend a large proportion of their operational life towing trailers caravans 400 Remove the drain plug in the oil sump On the ZF also the plug2. PI GL 5 MIL L 2105 B or C rec Volvo s final drive oil P N 11 61 329 6 0 5 lit res Note Fit a new seal B15 Exhaust system check Check from underneath e Leakage e Attachment e Condition
3. ecified in the table Min thickness A B mm 200 700 9401960 400 800 Front solid disc 11 0 10 35 Front ventilated disc 20 0 19 3 23 0 Rear 8 4 7 5 8 4 B9 Brake hoses check leakage damage Check that the brake hoses do not leak are firmly attached at their anchorage points are not chafed are not in contact with sharp corners or other surfaces which can cause chafing or wear that there is no abnormal leakage from the shock ab sorbers B10 Brake and fuel lines check leakage damage Check for leakage that all the brake and fuel lines are correctly clamped and are undamaged that the pipes are not in contact with any sharp edges the handbrake wires and attachments B11 Fuel filter replace ga 240 400 700 940 960 Ga Petrol engines A N l A 240 700 9401960 The fuel filter is located on a ec bracket beside the fuel pump under the car Note On a SEZ the 240 with the B 230 E engine it is located in the x engine compartment n f eS eR 400 injection engines The fuel filter is located to VOLVO the right of the fuel tank 5413 Connect the puncturing tool and fluid suction pump Undo the filter from the bracket Clean the connec tions Connect puncturing tool 999 5413 Connect the hose from the puncturing tool to the fuel suction unit 981 2270 2273 and 2282 This method is descri bed in detail in service b
4. hey are replaced soon Check that there is no leakage at the brake caliper or connections If there is any uncertainty about lining thickness the wheels must be removed 700 Place an extended slide gauge between points A and B The distance should not exceed 35 mm with brake discs of normal wear Check that there is no leakage at the brake caliper or connections 800 Place an extended slide gauge between A and B The distance should not exceed 35 mm with brake discs of normal wear Check that there is no leakage at the brake caliper or connections TIE 184 Rear brake linings With rear disc brakes Minimum lining thickness 2 mm If lining thickness is close to this value the owner should be advised to replace the linings soon Check that there is no leakage at the brake caliper or connections 240 740 940 850 Min lining thickness 2 mm If lining thickness is close to this value the owner should be advised to replace the linings soon Check that there is no leakage at the brake caliper or connections 760 780 960 Place a slide gauge between point C and the protecti ve plate plane between the attachment lugs of the be aring housing and caliper holder Maximum permitted dimension with brake discs of normal wear 25 mm For replacement of brake linings Check the brake disc thickness Measure the brake disc thickness The value is not to be less than the minimum sp
5. in the differential housing Drain the oil Refit the drain plugs Always use new gaskets Tightening torque ZF 15 Nm CVT 30 Nm AW 70 71 72 ZF 4 HP 22 Remove the drain plug and drain the oil Refit the drain plug Warning The oil may be very hot if the car has been driven recently Refit and tighten the plugs Tightening torque 15 Nm Always use new gaskets B4 Clutch check adjust Check adjust the clutch play Press the fork rearwards 5mm Play 1 3 mm Adjust at the release fork B5 Driveshafts check play wear Check that there is no abnormal wear in the CV joints B6 Driveshafts check the rubber bellows Check that the rubber bellows seal completely and X n Dn P that they are undamaged 5146810 B7 Tyres check Check tread depth wear pattern indication of imbalance faulty camber toe in or wrong inflation pressure that the type of tyre is the same on both wheels Radi al cross ply For studded tyres check that all the tyres are stud ded 1 Tyre inflation pressure too low 2 Tyre inflation pressure too high 3 Wrong toe in 3 4 4 Imbalance B8 Brake linings check Always check both the front and rear brake linings Front brake linings Use a mirror Minimum lining thickness BAO ki 6 ee Gow ee ey oes re we op HT MD cs bw we Sle ewe amp Ss oe Ss TT If the lining thickness is close to these values the workshop should recommend that t
6. let it hang down into the con tainer Open the bleeder screw 3 on the fuel pump Undo the bleeder screw 1 and tighten it again when clean fuel comes through Bleed the system Move the hose to the air screw 3 on the fuel pump Use the filter s manual pump to pump fuel until clean fuel comes through the air screw Shut the air screw and remove the hose Pump a few more times until a slight resistance is felt Start the engine and check that there is no leakage B13 Fuel filter replace Replace the fuel filter Use tool 2903 For fitting Apply diesel oil to the rubber seal Tighten by hand until the seal is properly in place Tighten ad ditionally one 1 4 turn Start the engine and check for leakage Replace the fuel filter Drain the fuel as per B 12 Tighten the drain plug and remove the hose Undo the centre screw and remove the filter housing and its insert Remove the insert Clean the compo nents Lubricate the O rings with diesel oil Note always use new O rings Fit all the O rings Place the new insert in the filter housing and tighten the housing with the help of the centre screw Torque 10 Nm Bleed the system as per B 12 B14 Final drive Check for leakage oil level 240 700 940 960 Check that there is no leakage from the final drive If there is any leakage the oil level must be checked and the final drive topped up if necessary Top up with oil quality A
7. ulletin 2 23 713 Drain the fuel Insert a new fuel filter The direction of flow is marked with an arrow on the fuel filter 800 Empty the fuel system Remove the cover above the throttle control pulley the cover over the fuel distribution pipe the cover for the valve on the fuel distribution pipe Connect tool 999 5484 hose nipple to the fuel suction unit 981 2270 2273 and 2282 Start the suction pump Connect the nipple from the suction pump to the val ve on the distribution pipe Raise the car 9812270 2273 2282 Remove the cover above the fuel filter previous version the cover for the valve beside the fuel filter Connect tool 999 5480 nipple to the valve ahead of the fuel filter Drainage of the system takes about 2 minutes Reinstall the equipment in the reverse order Important Do not forget to refit the covers above the valves Replace the fuel filter Undo the quick release couplings from the fuel filter with the help of a 17 mm wrench by pushing the slee Undo the screw which retains the clamp around the filter Replace the filter Refit in reverse order B12 Fuel filter drain water 128 253 Drain water Undo the bleeder screw 1 a few turns Undo the drain screw 2 Tighten the screw when cle an fuel comes through Tighten the bleeder screw Drain the water Place a container below the filter Connect a hose to the drain screw 1 and
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