Volvo 120 User manual

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VOLVO 120
2-DOOR
CARS
(120S)
DESCRIPTION
OPERATING INSTRUCTIONS
SERVICING
AB VOLVO GOTEBORG SWEDEN
Service
Cables: Volvo, Goteborg, Sweden
Reprinting permitted if source quoted
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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 ATOP-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 TI IAN REPAY YOU IN THE
LONG RUN. THIS INSTRUCTION BOOK IS NOT INTENDED
TO BE A COMPREH ENSIVE 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
I N FUTURE CAN BE AVOIDED. FOR MORE DETAILED
OPERATING INSTRUCTIONS AND ADJUSTMENTS, YOU
ARE REFERRED TO THE SPECIAL SERVICE MANUAL
FOR THE VEHICLE.
AB VOLVO
CONTENTS
3
VOLVO SERVICE

Page
The Volvo Service Organization

Warranty and Service Booklet

Service Inspections 
4
5
5
D E S C R I P T I O N

page
Type designations 
Engine

Electrical system 
Power transmission 
Brakes 
Wheels and tyres 
Body 
Instruments and controls

6
8
9
10
11
11
12
16
OPERATING INSTRUCTIONS

page
Running-in 
Starting the engine 
Gear-changing 
Points worth noting 
22
23
24
25
SERVICING

page
General 
Maintenance scheme 
Lubrication 
Engine 
Electrical system 
Power transmission 
Brakes 
Front end

Wheels and tyres

Body 
Servicing before long-distance trip 
Procedure in cold weather 
Lubricating chart 
27
28
30
34
39
43
43
43
44
46
49
50
60
FAULT TRACING

Pa
g
e
52
SPECIFICATIONS

page 53
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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 regularly. Volvo has gone to a great deal of trouble
i n 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. This is why our dealers are 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 infor-
mation about your Volvo that is not included in this instruction book.
Not only in your own country is there a Volvo workshop within easy reach.
Volvo also has a widely distributed service network in other countries.
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) running. 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 cost-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 cost-free service inspection has been carried out, you should make an
agreement with your dealer concerning continued, regular service inspections in
accordance with the suggestions made in our
Service Book. Thorough and regular
servicing is of vital importance for the performance and length of life of the vehicle.
Always use genuine Volvo spares.
4
5
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DESCRIPTION
Type designations
This instruction book deals with cars having the follow-
ing type designations (note that certain variations are
not to be found on certain markets):
1. The car type 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.
6
In all correspondence con-
cerning your vehicle with the
dealer and when ordering
spare parts, the
type designa-
tion, chassis and engine number
should always be quoted.
1. Air cleaner (B 20 B)
2. Floatchamber (B 20 B)
3. Carburettors (B 20 B)
4. Expansion tank with filler
cap for coolant
5. Voltage regulator
6. Hoses for air preheating
7. Alternator
8. Air cleaner (B 20 A)
9. Carburettor (B 20 A)
0. Hoses for positive crank-
case ventilation
1. Battery
2. Hoses for heater system
3. Oil dipstick
4. Distributor
5.
Car heater
6.
Starter motor
7. Ignition coil
8. Plate with type designa-
tion and code for colour
and upholstery
19. Fusebox
20. Oil filler cap
21.
Brake servo cylinder
22. Relay for reversing lights
23. Relay for headlight flasher
24.
Fuel pump
25. Brake fluid container
26. Steering box
27. Windscreen wipers
28. H orn
Type designation Engine Gearbox
13-134
B 20 A M
40
13 -334 B 20 B M 40
13-194 B 20 A M 40
13-394 B 20 B M 40
13-344 B 20 B M 40
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DESCRIPTION
Engine
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.
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 hori-
zontal carburettors.)
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 design-
ed for this purpose. On the B 20 B engine the exhaust emission control is pro-
vided partly through carburettors specially designed for this purpose and partly
by the engine having a special induction manifold with throttles and preheating
chamber. When driving at low speeds the throttles are closed so that the fuel-air
mixture is forced to pass the preheating chamber.
When higher output is required, the throttles open so that the fuel-air mixture
flows directly to the cylinders.
8
DESCRIPTION
Air preheating
Certain variations of the 120 models are provided with thermostatically con-
trolled air preheating.
With this arrangement the induced air is maintained at a constant, favourable
temperature. Air preheating counteracts ice formation in the carburettor and
also contributes to a shorter warming up period after starting 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 into the oil filter which
prevents the oil pressure from reaching excessively high values.
Cooling system
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°C (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.
Electrical system
The electrical system is of the 12-volt type and is fitted with a voltage-regulated
alternator. The starter motor is operated from the instrument panel by the igni-
tion key, which also switches on the rest of the electrical 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.
9
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DESCRIPTION
Lighting
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 rear view mirror and a light
for the parcel shelf.
See pages 40-42 concerning replacement of bulbs.
Fuses
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 repeatedly, do not fit
a more powerful fuse. Instead, have a workshop 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
The gearbox is used to 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.
10
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 centre line 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 pressure
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, or 165 SR 15.
11
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DESCRIPTION
Body
Bonnet
O
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 bonnet.
O
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.
Luggage compartment
O
The luggage compartment 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. To the left of the luggage com-
partment there is space sufficient for the
spare wheel and a tool kit. Always make sure
that the spare wheel is fastened securely and
that the tool kit is firmly stowed, otherwise
irritating rattles can occur.
12
Doors and locks
O Both the doors are fitted with a lock and
keyhole.
Both doors can be locked from inside the car
by pressing down the lock buttons on the
window ledge. The lock button lifts auto-
matically when the door is opened from the
i nside. The doors can be locked from the
outside by pressing the lock button on the
window ledge and shutting the door. Do not
leave the keys in the car.
O
The doors are opened from the inside by
turning the door handle to the rear. The ven-
tilation windows for the door are opened by
unscrewing the lock stud, pressing it in and
then turning the handle upwards. Screwing
in the stud locks the handle.
O
The rear side windows can be partially open-
ed by setting the handle at the rear edge in
different positions.
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. Instead, 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.
13
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DESCRIPTION
Front seats
•

The front seats can be moved backwards 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
using 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 automati-
cally locks the backrest and thus prevents it
from falling forwards. To fold the backrest
backwards, release the catch (C).
•
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 back-
wards as shown in the picture. Then slacken
the locknut on the floor and screw the eyelet
screw upwards 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 place
the screw in one of the other holes in the
attaching bracket.
The front seat backrests have built-in attach-
ments for mounting a headrest.
14
Safety belts
•

Always use the safety belt when driving. Re-
member that even when driving slowly in
city traffic, serious injury can arise from
sudden, unexpected stopping. The practical
design of the belt makes it very easy to use.
Place one strap across the lap and the other
over the shoulder and breast and lock 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 con-
tact with the body are not twisted. Always
ensure that the belt is so adjusted that it fits
well against the body.
•
If the belt requires lengthening, take hold of
the adjusting piece with one hand and with
the other hand pull out to the desired length
the lower part of the double section of the
lap strap.
•

If the belt is to be shortened, pull in the upper
part of the lap strap. After a certain amount
of practice, all belt adjustment can be carried
out with the one hand. 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
hindrance when getting in and out of the car.
Now and again check that the bolts anchor-
ing the belt are properly tightened and that
the belt is in good condition. 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 modify or repair the belt on your own
but have this done by a Volvo workshop.
Rear seat
As standard, the rear seat has anchorages for
safety belts. On certain markets, safety belts
are also fitted to the rear seat.
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DESCRIPTION
I nstruments 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 arc 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 instru-
ments to make sure they are showing normal readings according to the values
given in the following text.
1. Temperature gauge
2. Warning light, battery charging
3.
Trip meter
4. Speedometer
5. Mainbeam control light
6.
Direction indicator control light
7. Milometer
8. Oil pressure warning light
9. Fuel gauge
10. Warning lamp, handbrake,
brake system
11. Windscreen wiper and washer
switch
12. Choke control
13. Horn ring
14. Ignition switch and steering
wheel lock
16
15. Cigarette lighter
16. Fan switch, heater/ventilation
controls
17. Grab handle
18. Switch for glove compartment
light
19. Bonnet release handle
20. Foot dipper switch
21. Clutch pedal
22. Brake pedal
23. Accelerator pedal
24. Lighting switch
25.
Director indicator, switch
headlight flasher
26. Steering wheel
27. Gear lever
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DESCRIPTION
1 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 re-
main within the green sectors.
2
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 on the pulley, causing
poor charging.
3 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.
4 Speedometer
The speedometer has a horizontal red ribbon indicator, the ribbon point show-
ing 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.
7
Milometer
The milometer shows the total distance covered in miles. After 99 999 miles it
returns to zero and starts going round again.
8
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 re-
main on during driving, the engine should be stopped and the cause for this
determined. In most cases it means that the oil level is too low. After hard driv-
ing it may happen that the warning light comes on when the engine is at idling
speed. This is normal providing it goes out again when the engine speed is
increased.
18
DESCRIPTION
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.
11 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 (
1
/
a
") 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
The switch has four positions:
(0)
Locking position, (1) Garage
position, (2) Driving position and
(3) Starting position.
The key can only be inserted or
taken out of the lock in the Locking
or Garage position.
Removing the key when in the
Locking position automatically
locks the steering wheel.
If the key is removed from the lock
in the Garage position, the electri-
cal system is disconnected, except
for the radio. The steering wheel
is not locked.
During driving, the key should be
in the Driving position.
To start the engine, turn the key to
the Starting position and this auto-
matically engages the starter motor.
As soon as the engine starts, release
the key which automatically returns
to the Driving position.
If the car is parked in such a way
as to make it difficult to unlock the
steering wheel, unlocking can be
made easier by slighting turning
the steering wheel one way and
then the other.
15
Cigarette lighter
To use the cigarette lighter, push it in. As soon as it attains sufficient heat, it
will automatically spring out.
19
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DESCRIPTION
16 Heater and ventilation system
Fresh-air fan switch
Pushed right in - closed
Interm. pos. - full output
Fully out - half output
Air flow
FLOOR - - Air to front seat floor
DEFR = Air to windscreen
and to rear seat floor
Air temp.
This control is used to regulate
the temperature of the incoming
air.
The heating and ventilation system of the car is operated as shown 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 windscreen by means of the
controls.
NOTE: Under normal conditions there is sufficient air-flow due to
the fact of the 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 he a slight delay
before the heater element adjusts itself to the desired temperature.
The illustration shows the air duct to
the rear seat and the air distribution in
the vehicle when both the "FLOOR"
and "DEFR" controls are used.
During cold or damp weather mist can
easily form on the windows, partic-
ularly 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 controls at
max. output.
20
Parking lights
(Lighting switch pulled out one
notch)
Dipped headlights
(Lighting switch fully out and
foot dipper switch in dipped po-
sition)
Mainbeam
(Lighting switch out fully and
foot dipper switch in mainbeam
position)
Panel light switch
The panel light switch is regulated by rotating the small lighting switch knob.
Warning signal flashers
On certain markets, the car is fitted with warning signal flashers which are operat-
ed by pulling out the switch next to the heater controls.
25 Direction indicator switch lever
The direction indicators are controlled by means of the switch lever mounted
on the left-hand side of the steering column under the steering wheel.
Interior lighting
1. The light goes on when the front doors
are opened.
2. The light is off all the time.
3. The light is on all the time.
Mainbeam flasher
Moving the direction indicator switch up
towards the steering wheel switches on the
mainbeam lighting which remains on until
the switch lever is released.
21
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OPERATING INSTRUCTIONS
Running-in
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 movable parts
of the car must be properly bedded in so as to obtain smooth and durable sliding
surfaces.
Do not drive at full engine output
for more than short periods during
the first 500 km (300 miles) and avoid labouring in all gears.
Warranty inspection
After 2 500 km (1500 miles)
running, 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.
After 5 000 km (3 000 miles)
running, 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.
22
OPERATING INSTRUCTIONS
Before being delivered, Volvo engines are test-run on test benches and in 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.
Starting the engine
Starting a cold engine
1. Check that the handbrake is on and the gear lever is in neutral.
2. Pull the choke control out fully.
3.
Depress the clutch pedal to assist when starting especially in cold weather.
4. Turn the ignition key to the starting position. Release the key as soon as the
engine has started.
5. Push in the choke control until the best idling speed is obtained. As the
engine becomes warmer push in the control more and more but never so far
that the engine starts to run unevenly. Drive for as short a period as possible
with the choke out. With the air preheating arrangement, the engine runs
smoothly already some minutes after starting.
When the engine is thor-
oughly warm, the controls should be pushed right in.
After starting a cold engine, do not race it immediately but run it at moderate
speed and do not subject it to heavy loading until engine temperature has reach-
ed normal level.
Starting a warm engine
1.
Check that the handbrake is on and the gear lever is in neutral.
2.
Depress the clutch pedal.
3.
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.
23
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OPERATING INSTRUCTIONS
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 en-
gine 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 quick-
ly as possible. Do not therefore idle the engine too long but start driving with
a light load on the engine as soon as the oil pressure light goes out.
Gear-changing
The gearbox has synchromesh on all for-
ward gears. If this is to function satisfactorily,
the clutch pedal must be fully depressed.
To obtain good acceleration, it is important
that the gear-change timing is adapted 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 picture
opposite.
24
Gear positions for 4-speed
gearbox
Driving with the luggage compartment lid open
While driving with the luggage compartment lid partly or fully open, exhaust
gases (and consequently also carbon monoxide) can be sucked into the car
through the luggage compartment, particularly if a window is open. Normally
this involves no risk to the passengers. However, on such occasions, the follow-
ing 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
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 poisonous carbon mon-
oxide gas which is particularly dangerous since it is both invisible and odo-
urless.
OPERATING INSTRUCTIONS
Recommended speed ranges, km.p.h. (m.p.h.)
for the different gears
Engine
Gearbox
1st gear 2nd gear 3rd gear 4th gear
B 20 A M 40 0---45 15-70 25-100 35-
(0-28) (10-45) (15-G0) (22- )
B 20 B
M 40
0-50 20-80 30-115 40-
(0-30) (15-50) (20-70) (25- )
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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.
Towing
If the car is to be towed, the
tow line should not be attach-
ed directly to the bumpers,
but should be taken round the
bumper supports as shown in
the picture opposite. While
the car is being towed, the
tow line should be kept even-
ly stretched since violent jerks
can damage the bumpers.
SERVICING
General
Before the car was delivered from the factory it was subjected to a very thorough
i
nspection. Your dealer, in his turn, carried out a further delivery inspection in
accordance with the specifications of the Volvo factory. 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 servic-
i ng it requires is to have all servicing done by a Volvo workshop. 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 calculated to withstand
the severest stresses with a wide safety margin. However, if you use your car
for hard driving, you should take the precaution of checking these parts for
fatigue cracks sometime during the car's useful life, for 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 organ-
ization, 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 summarized
in a maintenance scheme in the next two pages.
27 26
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SERVICING
Maintenance scheme
In the maintenance scheme below the servicing procedures have been given
certain numbers which refer to the detailed descriptions on the following pages.
Some of the work must be carried out by skilled mechanics or requires the use
of special tools and these have been marked D.
SERVICING
In addition to the servicing procedures mentioned in this scheme, you should
also regularly check the following from the point of view of traffic safety:
a)
Lighting, including brake warning light
b) Direction indicator lights
c) Horn
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SERVICING
Lubrication
Chassis maintenance
To simplify maintenance of your Volvo, the vehicle has been 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 (6 000) miles
in accordance with the lubricating chart at the end of the book. This can be
done in connection with the 10 000 km (6 000 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 l ubricant in the
right quantity at the right time will
increase both the lifetime and reliability of your car.
1 Body lubrication
In order to avoid squeaks and unnecessary wear, the body should be lubricated
about every 10 000 km (6 000 miles) or at least once a year. During very cold
weather the door locks and luggage compartment lock should be treated with
a suitable anti-freeze agent to prevent them from freezing up.
30
SERVICING
2 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 switc-
hed off but warm and, in order to obtain
comparable values, about 1 minute after the
engine has been stopped. Wipe the dipstick
before measuring. 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.
3 Changing the engine oil
With a new or reconditioned engine, the oil should be 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 de-
manding 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 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).
31
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SERVICING
4 Carburettor(s)
The old oil is drained off by removing the drain plug on the sump. Draining
should take place after driving when the oil is still warm.
For lengthy motorway driving fuel with an octane rating of 97 (ROT*) can also
be used for the B 20 B engine.
At each engine oil change, check that the oil level in the centre spindle of the
carburettor(s) is about 6 mm (
1
/
4
") from the top of the spindle. If it is not, top
up to the level using oil ATF, 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.
* Research Method
5
Gearbox, M 40
6
The oil in the gearbox should be checked after every 10 000 km (6 000 miles).
The oil should be at the level of the filler hole. Top up with the recommended
oil if necessary. The oil in the gearbox should be changed after every 40 000
km (25 000 miles). In the case of a new or reconditioned gearbox, the oil should
be changed after the first 5000 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.
32
9
Rear axle with differential brake
10 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.
33
SERVICING
7 Rear axle
8 The oil level in the rear axle should be checked after every 10 000 km (6 000
miles). The oil should be up to the level of the filler hole. Top up with the re-
commended 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 top-
ping up. The used oil should be drained off immediately after the vehicle has
been run, when the oil is still warm.
After this oil change, only the oil level need be checked and topping up take
place if necessary.
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SERVICING
11 Steering box
The oil level in the steering box should be checked after every 10 000 km
(6 000 miles). The oil should be at the level of the filler plug. It necessary, top
up with the recommended 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
Hypoid oil
Viscosity
SAE 80 (all year round)
Oil capacity
0.25 litre
0. i-i Imp. pint
0.53 U. S. pint
12 Brake fluid
The brake fluid level in the brake hydraulic
system should be checked after every 5 000
km (3 000 miles). The brake system is pro-
vided with twin brake fluid containers, one
for each system. Both containers have a
common filler cap. The level of the brake
fluid should be between the "Max" and
"Min" marks.
Only brake fluids which meet the requirements
according to the specifications under .SAE 70 R 3
may be used for the hydraulic brake system.
Engine
13 Crankcase ventilation
The engine is provided with positive crank-
case ventilation which prevents the gases in
the crankcase from being released into the
atmosphere. Instead, they arc sucked into
the intake manifold and take part in the com-
bustion process whereupon they are blown
out through the exhaust pipe together with
the other combustion gases. Every 40 000
km (25 000 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.
34
14 Oil filter
The oil filter traps 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 workshop.
If the filter is replaced without the oil being
changed, 0.5 litre (approx. 1 pint) of oil
should be added.
15 Fuel filter
The fuel filter should be cleaned after every
10 000 km (6 000 miles). Loosen the screw
and remove the cover and strainer and clean
these. When refitting the cover make sure
that the gasket seals properly.
16 Air cleaner (B 20 A)
The air cleaner should be replaced with a
new one after 40 000 km (25000 miles).
Replacement should be more frequent if the
driving conditions are dusty.
NOTE. On no account must the element be
moistened or oiled.
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17 Air cleaner (B 20 B)
The air cleaner consists of a plastic cover
with a replaceable paper insert. The insert
should be replaced every 40 000 km (25 000
miles). Where driving conditions are partic-
ularly 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.
18 Cleaning the air cleaner with
foam plastic sleeve
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 (12 500 miles). After every 80 000 km
(50 000 miles) the paper filter must also be replaced.
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 (6 000 miles). Too narrow clearances can cause burnt valves.
20 Compression test
Every 10 000 km (6 000 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.
21
Fan belt
The fan belt tension should be checked every 10 000 km (6 000 miles). Due to
wear or dirt, this belt can start slipping with poor cooling and poor alternator
output as the result.
A way to test the tension is to press in the fan belt at a point midway between
the alternator and the fan. It should be possible to press down the belt about
10 mm (3/8') with normal pressure.
The check can be suitably carried out by a Volvo workshop.
36
SERVICING
SERVICING
22 Check the coolant level
The cooling system must be well filled with
coolant and not leak if it is to operate at
maximum efficiency.
Check the coolant level when filling up with
fuel. The level should be between the "Max"
and "Min" marks on the expansion tank.
When the engine is new or the cooling sys-
tem has been emptied, this check should be
carried out with particular thoroughness.
The cooling system filler caps on the radia-
tor and expansion tank should not be remov-
ed other than for topping up with coolant.
More frequent removal may impede the cir-
culation between the expansion tank and the
engine when the latter is warming up and
cooling.
Topping up with coolant
Top up with coolant when the level in the expansion tank drops down to the
"Min" mark. Top up to the level of the "Max" mark. Use a good quality
anti-freeze.
NOTE. Do not top up with water only, particularly during the winter. 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.
23 Change coolant
The coolant retains its properties for approx. 2 years when it should be changed.
To drain the coolant, open the tap on the right-hand side of the engine. Then
disconnect the hose between the lower part of the radiator and the engine.
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 be set to max. to
ensure that the entire system will be filled. Fill the radiator to the top and refit
the cap. Then fill the expansion tank to the "Max" level or somewhat above
this. Refit the expansion tank cap. Run the engine warm, switch off the ignition
and allow the engine to cool. Then check the radiator to make sure that it is
completely filled and that the level in the expansion tank is at the "Max" mark.
The capacity of the cooling system is 8.6 litres (1.9 Imp. galls. = 2.3 U.S.
galls.)
when the level is at the "Max" mark in the expansion tank.
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