Volvo 240 1984 User manual

Seruice
Manual
Repairs
andmaintenance
Section1
(17l
7,500
Mile
Maintenance
Service
1984
DL,GL
GLE
(Canadal
Turbo,
Diesel

Contents
- Replacingtiming
gear
bells..............
lntroduction
Volvo7.500MileMaintenance
ServiceChart
7,500MileMaintenance
ServiceProcedures
Controls
and
lighting
In
car,.,,..,,..,,.,,,
Exterior,..,,.........
Onlift
- Tires,
wheels
- Frontend
-Brakes,,..,........
- Powertransmission
-Rearend...........
Exhaustsystem,Diese|.....................
-Rearaxle,manualtransmission...........
- Engine
oilandfilter:
'Gasoline
engines
'Diesel
engine
Underhood:
- Engine
coolingsystem...................
F|uids...............
- Replacing
automaric
l.ansmissionflLrid....
821and823
- lMiscellaneous
- Adiustvalves
Replacetiming
gear
belt...................
B2lNCanadai
- lMiscellaneous
- COemissionscheck
821F-Turbo:
B23F:................
D24
diesel:
- Miscellaneous
- Valve
clearanceadjustmert,.,,,.,,..,,..
ldlespeeds..........
- Settingenginecontrols..................
- Compression
test
Checkingadjust;ng
injecto's
............
Opeation Page
1
2
1 18 10
41-A6 15
81-83 1l
c1-c4 18
D1-Dl0 19
E1-E4 22
F1 F4 23
G1-G2 24
H1 25
t1 t2 25
J1-J2
J3-J4
K1-K2
K3-K5
L1-110
M1-M3
N1-N15
01-07
Pt-P15
01-016
R] R16
S1_
57
al- a7
h1-h12
cl c6
d1-d7
el
- e10
f1 f8
91 933
26
21
28
2A
29
33
34
31
39
44
49
55
Roadtest
58
60
63
64
61
10
73
a2
TP
30600n
7500.08.83
Printed
in
U.S.A.

G,e!PJf,lE99!]ls!e elviee
- Chaft-
lntroduction
These
maintenanceinstructionsare
presented
ina"Work Related
Sequence".Stepbystep
procedures
are
designedtoassistthetechnicianin
performing
thetasksinanefficientandlogicalmanner.
VolvoMaintenance
ServiceChan
TheVolvoMaintenanceService
procedures
arelisted
onthefollowing
pages(see
chart).Theyappearin
thesameorderasintheWarranties
and
MaintenanceRecordsManual
suooliedwitheachnewvehicle.
Thecertificatesin
the
manual
shouldbesignedbytheServiceManager,datedandstamped.
The
chart,aswellastheoperationsinsidethemanual,liststheactualmileagewhen
theservace
insoectionshouldbeoerformed.
Greatcarehasbeen
exercisedto makethecharteasyto read.Groupingofmileageandservicesfacilitate
finding
of intervals fortheserviceoperations.
7,500Mile12,500
km Maintenance
Service
EMTSSTOTVS
Seruiceevery7.500miles: 12.500km
Emissions
ItemsmarkedEMISSIONS
havebeen
determined
part
ofemissionrelated
ser-
vice
mainlenance
program.
Theseitemsreouire
servicemaintenan-
ceatmileageintervals
showntoensure
trouble-free
operation.
Seruiceat: IEMTSSTOTVS
15-30-45-
60-7' 90-t05-t
2, 50-7r, 0lr-12, 150-t75-2
0O-
th
ousa
n
d k m
Seruiceat: lEMrSSrOlrS
30-60-90-12o-thousand m
50-10O-t50-2
(n-t housand km

Volvo
7,500Mile
(12,500
km)Maintenance
Service
Chart
Contlolsand lighting
Hazardwarning
flasher
Blower
Heatercontrols
Reardemist
AIR
CONDcontrol
norn
Tu
rnsignals
Headlights
andLIGHTSswitch
Instrument
panel
lights
Group17,7,500
MileMaintenance
Service
- Chart-
l
2
3
4
5
6
7
I
9
Power
brakefunction
Pressuretestbrake
system
Parkingbrake
Warning
lights
Auto
transshift
control
Steering
Parking
lights
Brake
lights
Taillights
Back-up
lights
Reflectors
andlenses
Fill
washerfluid
Wiperblades
Wipercontrol
Washer
iets
Allitems
onthispage
should
beinspectedal 7,500
mile
=
= 12,500kmintervals:
miles km
7,500
= 12,500
15,000: 25,000
22,500: 37,500
30,000
= 50,000
37,500
= 62,500
45,000: 75,000
52,500: 87,500
60,000
= 100,000
67,500:112,500
75,000
--125,000
82,500 137,500
90,000
= I50,500
97,500
= 162,500
105,000
= 175,000
112,500
= 187,500
120,000
= 200,000
10
11
12
't4
17
18
In
car
A2
A3
A5
A6
Exterior
- lubrication
81 Hoodhinges
82 Door
hinges
83 Trunklid
Onlift
Tires.wheels
C1 Tires
C2 Tire
pressure
C3 Wheel
bearing
play
C4 Wheel
bearing
nojse
Frontend
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
Frontshock
absorbers
Front
springs
Steering
gear
Steeringrack
Control
armbushings,
strut
Steeringrodplay
Eall
toints
Steeringrod
ends
Control
arms
Stabilizer
barandlinks
O

Group17,7,500
MileMaintenance
Service
- Chart
-
ooos.,,SoBg"oB
"ss"-"te
.r"l€l$
*t1)'-s*'e= S*"".S
.Sg{'"'
k.
,.d"e"S "S"s"S ",88"",8o8.8o8
r"*r'O' oo
A f,' Eba'6' {)rd'bo' miles
aaa oaa aaa aoa E1
aoa aaa aoa aaa E2
aoa aao aoa aaa E3
OaOaaa:,1
aoa aaa aoa aaa Fl
aoa aaa aaa aaa F2
aoa aaa aao aaa F3
aao aaa ooa aaa F4
aaa aaa aaa aaa
aaa aoa aaa aoa
aoa
oaaa
aa
Brakes
Brake
hoses
Brakelines
Parkingbrake
Wheelbrakes
Powertransmission
Clutch
play
B2lFTurbo
andB23F:
clutchnegative
play
Autotrans:
shiftcontrol
Propeller
shaft
Rear
end
Rearshockabsorbers
Rear
suspension
Exhaustsystem
821-Turbo
B23F
D24
diesel
Fluids
Rearaxle
lvl46manual
transmission
aaa aaa aaa oaa c1
aoa aaa aoa aaa G2
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aaaaaaH2
aaaaaaH3
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aoa aao aaa aaa t2
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a
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a
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a
aaa
a
aaa
a
aaa
a
aaa
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aaa oaa
oaa aaa
a
aaa oaa
aao oaa
EMtSStONS
EMtSSTONS
EMtSStONS
EMtSStONS
Engine
oiland
filter:
J1-J2 Gasolineengines
INOTE:
Turbointervals!)
J3-J4 Diesel
engine
Enginecoolingsystem:
K1 Check
anti-freeze
K2 Replacecoolant
Fl!ids:
K3
K4
K5
L1-L10
Lt
1
M1
M2
M3
N1-N15
01-07
Brakefluidlevel
Power
steering
gear
Battery
Automatic
transmission
Replacefluid
Checkoillevel
821and823
(all)
Auto
trans:adjustkickdown
cable
Engine
controls
Drivebelttension
Adjustvalves
Replace
timing
gear
belt
EMtSSTONS
EMtSStONS
EMtSStONS
3

-r
Group
17,7,500MileMaintenance
Service
- Chaft -
o)
.sss&",SoS.,SoS
"SS."}S
.s"l€l$
S'g'a' ""-'s'.{r6*o'E ${}borm
,//// ,r4 //4// ,r,
^sos"sos",Bos
"Bos",s
oB.sos
"r*p:+ -".Al"g- *:a-'A p$ioY mles
aaa Pl
aaa P2
aaa P3
aaa P4
aaa P5
aaa P6
aaPT
aaPs
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aaP10
a a Pll
aaa
aaa
aoa
aaa
aaaaaa
aaa aaa aoa aaa
oaa aaa aaa aaa
aaa aoa aaa aaa
aoa aaa oaa aaa
aaa aaa oaa aaa
aaa aao oaa aaa
aoa aao aaa aaa
aoaaaa
aaa
aaa
aaa a
B21l'lcanada
Exhaust
system
Damper
oillevel
Chokecontrol
Breaker
points,
rotoretc
Dwellangle
Pulsair
Positive
crankkcaseventilation
Replace
spark
plugs
Lubricatedistributor
ChecUadjusttiming
EGRvalveoperation
P12 Cleanfuel
pump
strainer
P13 Replace
air
filter
cartridge
P14 Checkcentrifugaladvance
P15 Checkfuellines
01-O16 COemissions
check
821F-Turbo
Rl Tightennuts,exhaust
pipe
toturbo
R2 Checkturbo
seal
R3 Torque
clampscrews
Checkofturbosystem:
R4-R5 Connectinstrument
R6
R7
R8
R9
R10
R11
R12-R13
R14
R15
R16
aaa
aaa
aao
aaa
aao
aaa
a
a
a
a
a
aao
oaa
aaa
aaa
aaa
aao
aaa
aaa
aoa
aoa
aoa
aaa
a
a
a
a
a
EMtSStONS
EMtSSTONS
EMtSStONS
Checktimingretard
Checkfullloadenrichment
system
Checkoverload
protection
switch
Lubricatedistributor
Replace
airtiltercanridge
Replacespark
plugs
Replaceoxygen
sensor,
resetlight
Replacefuelfilter
Positive
crankcaseventilation
same:adverseconditions
Replacefueltankfilter
ao
O'
aa
aa
aa
a
aaaaaa a

Group17,7,500
MileMaintenance
Service
- Chart-
I'r
,J,
tod"i
so
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!\,' l
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//t
^o
a
O
a
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a3
a4
a5
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a7
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aaaaa
oaa
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aoa
aaa
oaa
aaaoo
aaa a
a
a
a
asl
os2
a s3-s4 EMtSStONS
EMtSStONS
EMtSStONS
EMtSStONS
EMtSSIONS
EMtSStONS
EMTSStONS
EMtSStONS
EMtSStONS
EMtSStONS
B23F
Replaceairfilter
cartridge
Replace
spark
plugs
Replaceoxygensensor,
resetlight
Replacefuelfilter
Positivecrankcase
ventilation
- same;adverseconditions
Replacefueltank
tilter
D24
diesel
Draincondensate
Positivecrankcaseventilation
Cooling
system
pressure
check
Replacing
airIiltercartridge
Replacefuelfilter
Checkluellines
Drive
belttension
Valve
clearanceadjustment
Enginecontrols
ob1-h12
c1-dj
Maintenance
servicesat75,000mile
intervals:
e'l-el0 Compressiontest
f1-f8 Checking/adjustinginjectors
g1-933 Replacingtiming
gear
belts
5

Group17,7,500
MileMaintenance
Service
- Chart-Roadtest
_---- I
Item
Engine
l
l
3
4
5
6
7
8
I10
l
2
3
4
l
2
Adjust
Startingability
Fastidle
(cold
engine)
ldle
(warm
engine)
No
stallsonaccelerationordeceleration
Nonoisefromengine
Normalwarmup
Normal
engineoperation
Normal
acceleration
Leaks
Reinstallhardwareremoved
atJactory
Staner/alternator
operation
lgnition
andsteeringlock
Instruments,controllights
Clutchadjustment
Clutchoperation
o
Elestrical
Drivetrain
Correctoperation
Manual
transmission

Group
17,7,500
MileMaintenance
Service
- Chaft-
o3
Automatic
transmission
1__
Steering
Gear
seloctor
play
Starter
operation
onlyin PandN
Run
tonormal
operatingtemperature
Noslippage
atstallspeed
Upshift
No
slippageduring
shifting
Kickdown
Upshiftwith kickdown
Gear
selectorin2,downshift
andbraking
Gear
selectorin1,downshift
andbrakino
Park
position
operation
Drive
shafts
andbearingnoises
Power
assist
No
pullwhen
brakinghard
Pedal
pulsatlon
"Spongy"
brake
pedal
Parking
brake
Correct
steering
Stoeringwheel
position
andreturn
Steeringwheel
effort
Steeringlooseness
Power
steeringlunction
Nosuspension
noises
Rearaxle
tight
Tireunbalance
Accessory
operation
Heater
andheatercontrols
Speednoises
Body
noises
Visibledefects
Cleansteering
wheel
etc
Note
faultsdetected
Checkoff
Remedyfaults
5
6
1
8
10
11
12
Biakes
1
3
I Serines
1
2
5
2
3
and
wheels
Body
and
equipment
't __
7

Group17,7,500
MileMaintenanceService
- Chaft-
Services
beyond90,000
milqq
- '150.0QQ
!m
Theseruicechartslistmileage
upto 90.000milos
= 150,000km.Spaceandreadability
setsalimit.
On
thefollowing
page
isa listthatgoes to 300,000miles
= 500,000
km.ltcrossreferences
actual
mileage
whenaserviceshouldbe
performed
andwhatintervalservicesshould
be
pedormed
atthat
mileage.
8

Gtoup 1/, /.500 Mile Mdinlenance
Service
- Chart-
Services
at the
ftileagesindicated
below
---------- --- includeservice
operat;ons
performed
attheseinteryals.
7,500 15,000
12,500 25,000 22.54O 30,000 45,000 60,000 75,000
100,000 125,000
37,500 50,000 75,000
7,500
=
15,000
=
22,500
=
30,000
=
37,500
=
45,000
=
52,500
=
60,000
=
67,500
=
75,000
,
82,500
:
90,000
=
97,500
-
105,000
=
112,500
=
120.000
=
127,500
=
135,000
:
142,500
:
150,000
=
157,500
=
165,000
:
172,500
=
180,000
=
187,500
:
135,000
=
202,500
-
210,000
=
217,500:
225,000
=
232,500
:
240,000
:
247,500
=
255,000
=
262,500
:
270,000
=
277,500
-
285,000
=
292,500
-
300,000
=
12,500
25,000
37,500
50,000
62,500
75,000
87,500
100,000
112,500
125,000
137,500
150,000
162,500
175,000
187,500
200,000
212,500
225,000
237,500
250,000
262,500
275,000
247,500
300,000
312,500
325,000
337,500
350,000
362,500
375,000
387,500
400,000
412,500
425,000
437,500
450,000
462,500
475,000
487,500
500,000
..:t
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9

Group17,7,500MileMaintenance
Service
- Controlsandlighting -Procedures
Controls
and
lighting
Hazardwarningflasher.
Pressinswitch.
Checkthatallfourturnindicator
lights
andswitchindicatorlightflash.
Turnoff
0l
@ID
l-!21n
l-ll EI
Etl
t,4l@
EBlower.
Turnonignition
switch.
Checkthat
blowerisoffwithFANcontrolin
posi'
tionOffandoperatesin positions
1-2-3-4.Allow
blowertorunfor
a
brief
period
atmaximumrpm
(position
4).
ry^E,
-11-
Heater
controls,
Setallcontfolsin
positions
where
airflowvents
areclosed.
Heatercontrol
onCOLD.
Depress
DEFcontrol.
Checkthat
airis blowing
from
delrostervent
openings.
Depress
FLOOR
control.
Checkthatairisblowing
fromfloor
ventopenings.
Alsocheck
thatairis
blowing
torearseat.
Run
engineuntil
atnormal
operatingtemperatu-
Check
thatairexiting
ventsisstill
cold.Setheater
control
toWARIM.
Checkthatheated
airnowexits
vents,
Checkthat
airexitsfrom
alloutletsoninstrument
panel.
Switch
offblower.
CheckthatREC
(recirculate)valve
operates.Listen
tovalvefunctioning
when
depressing
controt.
srop
engrne.
c
10

Group17,7,500
MileMaintenance
Service
- Controlsandlighting
-
Checkelectricallyheatedrearwindow
(demist).
Actuate
REARDEMISTswitchfor rearwindow
heater.Checkthatlightinswitchcomeson.
Switch
is
aspring-back
type.
System
remains
ON
for1G-15minutesunlesskeyisturnedOFF.
CheckAIRCONDcontrol.
Start
engine.
Actuate
AIRCONDswitch.Checkthat
maonetic
clutchfunctions,visually
andbysound.
Switchengineoff.
Checkhorn.
Depress
horncontacts
atalternate
places.
Check
thathornoperates
atall
points.
Check
turnsignals.
Checkthatleftandright
frontandrearturnindjca-
torlightsaswell
asindicatorlightsoninstrument
panel
flash.
Checkthatleverreturns
to neutral
afterturning
steeringwheel.
11

Group17,7,500
Mile Maintenance
Seyice
- Controls and lighting -
CheckheadlightsandLIGHTSswitch.
PlaceLIGHTSswitchinheadlight
position.
Switch
betweenhighandlowbeams.Checkinhighbeam
position
that
headlights
and
indicator
lightareon.
Checkinlowbeam
position
thatlowbeamlights
areonandhighbeamindicatorlightisout.
Checkinstrument
panel
lightsandlights
ingear
shiftcontrol.
Mustbeaccomplishedeitherinadarkenedareaor
bylookingdirectly
at
lamplens
(openingl
SwitchonLIGHTSswitch.Checkthatlightintensi-
ty increasesand decreasesby turning rheostat
firstclockwise,then
counterclockwise.
10Q
Check
parking
lights.
Checkthatalllights
areon. 0)
Qr
12
0r
11
Check
brakelights.
nonroc. hrrL6.6.lil
Checkthalbrake
lightscomeonwith light
pressure
onpeoar.

Group17,7,500
Mile
Maintenance
Service
- Controls
andlighting,
12
Checktail lights.
Check
thatalllights
areon.
Checkback-up
lights.
Set
shiftselectorto reverse.
Checkthatbothlights
areon.
Checkrearreflectors
andlenses.
Checkthatref
lectorsandlenses
are
not
damaqed.
Fillwasher
lluidreservoir.
Use
cleanwater
and
solvent,Inbelow
freezinq
conditions
use
washer
solventanti-Ireeze

GtouQt17,7,500
Mile
Maintenance
Service
- Controlsandlighting -
16
Checkwiperblades.
Check
bladealignment.
Checkthat
bladesarenot
damaged
and
a16
free
tromfor€ign
matter.
Wagons:
check
tail
gate
wip€r
blade.
-['
17
Checkwipers.
Turn
onighition
k€y.
Switch
onwipers.
usingWASHMIPE
controlon
sto6ringcolumn.
Check
spoed.in first
andsecond
position.ptus
rmervat
postflon.
Checkwiper
bladealignment
and
park
Dosition.
Forwagon
models:
Checktailgate
wiperbyactua-
tins REARA/VIPE/WASH.
18
Adiustwindshield
washer
discharge
nozzles.
Washsr
l'ets
shouldhit
windshield10-20
cm{4-8"}
fromupper
edgeandapprox.
35cm('12") from
door
pillar
Adjust
nozzlesbyinsening
a needlein metalin-
senandrotateinsert.
For
wagonmodels:
Alsochecktailgate
window
washeraltonm6nt.
14

Group17,7,500MileMaintenance
Sevice
- ln car -
In
car
Se,rvice
every7,500miles= 12,500km
A1
Check
power
braketunction,
Remove
vacuumby depressingbrake
pedal
5
trmes,
Depressbrake
pedal,
startengine.
Pedal
position
shoulddrop
slightlyif
power
brake
l!nctions.
Pressure
test brakesystem.
Keep
brake
pedal
deprcssed
20seconds
with low
oeoalDressure.
Repeat
withhigh
pedalpressure
for5seconds,
Pedal
position
must
notdrop.A drop
indicates
brakeIluidleakage
orboostervacuum
leak.
A3
Check
parking
brake.
Apply
parking
brake.Adjustifitisnotlully
applied
after
pulling
10-11notches.
Afteradjustment,
adequatebraking
power
should
beobtained
after
pulling
2-8notches,
pulling
force
approx.
65lbs. Adjustthroughrear
of parking
brake
console.
Checkthatcatchisoperatingcorrectly.
Checkthatindicatorlighton instrument
panel
goes
on.Releaseleverandcheckthatlight
isout
when
leverisinbottom
position.
Yoke
shouldbeat right
anglesto parking brake
lever.
lfyoke isaskew,
usenutsatcableendsto adjust.
There
shouldalwaysbeatleast2mmthread
pro-
rruotnq,
15

Group17,7,500MileMaintenanceService
-lncar-
[. r lI t ,t"
nftEIEIddLl z
tt tt
44
Check
warninglights.
Tuln
ignitionkey
to driving
position.
Check
that
warning
lightsforcharging,
oil pressure,
butb
failure
andbrakefailure
comeon.
Stanenoine.
Check
thatlights
gooff.
(
Automatic
transmission.
checkshift
control.
Clearance
in position
"D" toward
oosition
"N',
shall
bethe
sameasclearance
in position
"2,'
toward
Dosition"1".
ou0
Check steering.
Turnsteeringwheelbackand
fonhwithwheels
restingon
ground.
Checksteeringwheel
play
withwheels
pointing
straight
forward.
Jackupfrontendand
place
stands
undercontrol
armsclosetowheels.
Turnsteeringwheelfullyto rightandleft
posi-
tions.Checksteeringeffortandsteering
gear
for
play.
0)
0
0
16

Group17,7,500Mile
MaintenanceSeruice
- Exterior,lubication -
Exterior
- lubrication
Seflice everv7,5(n miles: 12.500km
..\
B1
Lubricatehoodhinges.
Useoilcanandheawoil.
82
Lubricatedoorhinges,doorstopsand
striker
plates.
Lubricatedoorhingeswith
heavyoil.Usedoor
waxto lubricatedoorstops.
Checkthatlatcheslockin bothouter
andinner
posrtrons.
Checkthatdoorstopsarein workingorderand
providepositive
locking
inintermediateandouter
oostt|ons.
BiJ
Lubricatetrunklid(tail
gate
forwagons).
Lubricatelid/gatehinges.
Useheavyoil.
17

Group17,7,500MileMaintenance
Service
- Tircs,wheels-
atr
pressure arr
pressure
too high
Onlift
Tires,wheels
Seruiceevety 7.500miles : 12,500km
o
0;
Check
tires.
Checktreaddepth.Minimum
allowableis1mm
l=1/32"1.
Checkwear
pattern.
lt mayindicateunbalance,
incorrect
camber,toe-in
or
incorrect
tire
pressure,
Checkthattiresmounted
onbothfrontandboth t^
rear
wheels
arethesame
(radial,
cross-ply,tread, U
studded).
0r)
0r)
a t- == =-1. Checktiresandtirepressure.
qca riro h16.."ra lrh6l
Generally:
Economy
andmax5
persons
invehicle:use
36
psi
frontandrear,
Comfort
and
max
3
persons
invehicle:use26
psi
front
and27-30
psirear.
18