Volvo P 120 User manual

P 120
DESCRIPTION
P 120, 4-DOOR
Body frame
The Volvo P 120 has an integral body so that there
A
i s
no chassis frame. The body is composed of a
number of pressed steel plates, each of which forms
part of the supporting construction.
The body can be suitably divided up into the floor,
side sections, rear section, scuttle, roof, front mud-
guards, doors, luggage compartment and bonnet.
The floor and frame sections (Fig. 1) consist of a
front and rear floor plate (1 and 4) and an inner
cantrail (2), front and rear cross-members (8 and 6),
tunnel (3) and scuttle (Fig, 2). The floor plates are
welded together with the rear seat support. The
tunnel (3), which accommodates the propeller shaft
i s spot-welded to the floor plates. The rear floor
plate has a longitudinal reinforcing member (5)
on each side at the bottom and between these a
number of cross-members. One of the cross-mem-
bers (6) is provided with an attachment (7) for the
rear axle tie rod, There is a flanged hole in the rear
floor plate for mounting the fuel tank, the upper
part of which forms part of the floor in the luggage
compartment. The scuttle section (Fig. 2) consists
of the bulkhead (7), wheel arches (5), front upper
cross-member (4) and side plates (3), as well as
l
ower cross-members (1 and 2). The bulkhead forms
the front transverse wall of the body and is shaped
with welded end pieces. Two front side members
(8) project from the front floor. At the front they
are joined together by means of a cross-member
(2) and at the rear they are connected to the front
cross-member under the front seats. Upper side
members (6) project from the upper corner between
the bulkhead and front pillar. These are spot wel-
ded to the front pillar, the front side plate and
wheel arch plates. The front axle member and
bumper support bars are attached to the side
members.
Fig. 2.
Scuttle section
Fig. 1. Floor section (2- and 4-door)
1. Front floor plate
2. I nner cantrail
3. Tunnel
4. Rear floor plate
5. Reinforcing member
6. Rear cross-member
7. Attachment for rear
8.
axle tie rod
Front cross-member
2.
Front lower
cross-member
Front lower
3.
cross-member
Side plate
4. Front upper
5.
cross-member
Wheel arch
6. Upper side member
7. Bulkhead
8.
Front side member

P 120
The front end is bolted to the upper side mem-
bers, front cross-member and front pillar. The front
mudguards are pressed in one piece and bolted
to the wheel arch plate. The front section forms
the front part of the front end as well as the air
duct to the radiator. The body is noise- and heat-
i
nsulated. The insulation consists of "waffle" board
which is stuck on to the plate.
Bonnet
The bonnet is pivoted at the rear on two hinges.
I
n the closed position, the bonnet is secured by a
bonnet lock fitted on the front section. The lever
for the bonnet lock is operated by means of a
control placed underneath the dashboard inside
the vehicle.
Doors sand openings
The doors are built up of an outer and inner plate
together with door arch which is flanged and spot-
welded in one unit. The hinges are fitted to the
i nner plate. The doors are adjustable both longitu-
dinally, vertically and laterally. The doors are
provided with a door check. This consists of a flat
bar attached to the door pillar and runs against a
roller in the door. In the open position the flat
bar obstructs the movement of the roller and thus
li mits the movement of the door. The door checks
are fitted to the doors with screws. The press-
button of the outside door handles operates a lever
which in turn disengages a rotating toothed roller
(tumbler). The inside door handles are fitted to the
remote control which is attached to the inner door
plate with screws. The handle transmits the move-
ment to the toothed roller by means of a link rod.
The lock insert is fitted in the press-button on the
door handle. The doors can be locked from inside
the vehicle by pressing down the locking knobs.
The window winders are of the cable and chain
type. The movement of the window winding handle
i s transmitted to the window itself by a cable and
chain which are joined together forming an endless
"drive This is mounted on two pulleys and a
sprocket. The lower pulley is provided with a spring
device for tensioning.
The luggage compartment lid is built up of an outer
and inner plate. The catch for the locking device
i s fitted on the lower edge of the luggage compart-
ment lid. The hinges are fitted at the upper edge
of the lid. The hinges are bolted to the plate under
the rear window through a reinforcing plate. The Fig. 4. Roof section (2- and 4-door)
On 4-door models the side section (Fig. 3)
consists of the front pillar (9), intermediate pillar (11),
rear pillar (6), intermediate and outer cantrails (8
and 7), roof former (1), windscreen pillar (10), rear
wheel arch (2) with wheel arch member (5), rear
mudguard (4), back plate and joining plate (3). The
cantrail and wheel arch member are manufactured
of galvanized sheet metal.
The roof section (Fig. 4) consists of a number of
pressed steel plates. The roof plates form the
upper part of the scuttle section, windscreen open-
i
ng, the roof itself, the opening for the rear window
and the upper limit of the luggage compartment.
The front mudguards, front section and bonnet
make up the front end.
Fig. 3. Side section (4-door)

l uggage compartment lid is counter-balanced with
torsion rods and can be set in any position when
opening. On chassis up to number 20999, the lock-
i ng device is placed on the body below the lid,
and on vehicles with effect from chassis number
21000, the locking device is fitted on the lid.
Interior fittings and upholstery
FRONT SEATS, LATE PRODUCTION
The front seats are built up on a tubular frame. The
padding consists of foam plastic which is covered
by fabric-backed vinyl. The seat can be adjusted
l ongitudinally by releasing the catch (3, Fig. 5), and
sliding the seat. The seat can be adjusted vertically
at the attachment (4) which is provided with holes
at different heights. The seat can be tilted to the
desired position by means of the adjusting device
(5).
The backrest inclination is variably adjustable
by means of the handwheel (2) which operates an
eccentric. The seat is provided with an adjustable
l umbar support (see Fig. 7), the tension of which
Bild 5. Front seat (4-door)
1. Adjustment of lumbar support
2. Adjustment of backrest inclination
3. Longitudinal adjustment
4. Adjustment of seat height
5.
Adjustment of seat inclination
P 120
i
s adjusted with a screw (1, Fig. 5 and 3, Fig. 7)
on each side of the backrest. The seat cushions are
attached to the seat frame by means of press-
fasteners.
REAR SEAT
The rear seat and backrest are built up in principle
i n the same way as the front seats, although in this
case the seat frame consists of a wooden frame.
DOOR UPHOLSTERY
The door upholstery consists of wood-fibre sheeting
lined with non-woven padding and covered with
upholstery material. It is secured to the door by
means of clips. The front armrest is made of moul-
ded plastic and is screwed to the inner plate of the
door.
HEADLINING
The headlining consists of plastic material stretched
on roof ribs and secured in retainers fitted on the
upper limit of the body sides.
COVERING FOR BULKHEAD AND FLOOR
The sides of the bulkhead are lined with millboard
which is attached with clips. The bulkhead is
covered with plastic-lined felt matting. The floor is
covered with rubber mats.
Bumpers
The bumpers are composed of three parts and the
upper joints are provided with overriders. The bum-
pers are fitted on four support bars, of which the
front ones are attached to the front side members
and the rear ones to the rear side members.
8-3

P120
P 120,2-DOOR
Body frame
The body frame is largely similar to that of the
4-door model. However, the side part is altered
so that there is no longer an intermediate pillar
and the rear mudguard (3, Fig. 6) is extended. The
side section consists of front and rear door pillars
(7 and 4), intermediate and outer cantrails (6 and
5), roof former (1), windscreen pillar (8), rear wheel
arch (2) and rear mudguard (3).
Bonnet
See the 4-door model.
Doors and openings
See the 4-door model.
Interior fittings and upholstery
FRONT SEATS
The front seats on the 2-door vehicle can be
hinged forwards in order to facilitate entry to the
rear seats. They are provided with catches (4) in
order to prevent tilting forwards (see Fig, 7).
OTHER INTERIOR FITTINGS
Concerning other fittings and the bumpers, see the
4-door model.
P 120 STATION WAGON
Body frame
The front end is the same as that on the 2-door and
4-door models, The floor section (Fig. 8) consists of
the front (11), intermediate (3) and rear (4) floor
plates, tunnel, inner cantrail (1), side members (6),
front (10), intermediate (8) and rear (5) cross-mem-
bers.
The front and intermediate floor plates are welded
together at the rear seat support. The tunnel is
spot-welded to the front floor plate (11). Two rear
side members (6) are welded to the lower side of
the intermediate (3) and rear (4) floor plates, one
on each side, and between these a number of
cross-members.
One of the cross-members (8) is
provided with an attachment (9) for the rear axle
tie rod. Both the rear side members are provided
with attachments for the rear axle support arms.
The spare wheel well (7), which is provided with
a lid in the floor, is welded on the lower side of
the rear floor plate. There is a flanged hole in this
for the fuel tank.
Fig. 6.
Side section (2-door)
1. Roof former
2. Rear wheel arch
3.
Rear mudguard
4. Rear pillar
5. Outer cant rail
6. I ntermediate cant rail
7. Front pillar
8. Windscreen pillar

P 120
Fig. 9. Side section, Station Wagon
1. Roof former
2. I nner frame for side
window
3. Upper rear pillar
4. Rear mudguard
5. Rear intermediate
pillar
6. Rear wheel arch
7. Front intermediate
pillar
8. Outer cantrail
9. I
ntermediate cantrail
10. Front pillar
Fig. 7. Front seat (2-door)
1. Adjustment of seat inclination
2. Adjustment of seat height
3.
Adjustment of lumbar support
4. Longitudinal adjustment of seat
5.
Adjustment of backrest inclination
The scuttle section is similar to that on the 2- and
4-door models.
The side section (Fig. 9) consists of the front pillar
(10), intermediate pillar (7), rear section, interme-
diate (9) and outer (8) cantrails, inner and outer
roof formers (1) and windscreen pillar. The rear
section is composed of the rear wheel arch (6), rear
mudguard (4), inner frame (2) for rear side window
and upper (3) and lower rear pillar. The upper part
of the rear mudguard is extended upwards and
forms the outer frame for the rear side window.
Fig. 8. Floor section,
Station Wagon
1. I nner cantrail
2. Rear seat support
3. I ntermediate floor plate
4. Rear floor plate
5. Cross-member
6. Side member
7. Spare wheel well
8. Cross-member
9.
Attachment for rear axle
support arms
10. Cross-member
11. Front floor plate
8-S

P 120
Fig. 10. Roof section, Station Wagon
Fig. 11. Catch device for rear seat, Station Wagon
1. Eccentric
2. Pull rods
3.
Catch sleeve
4. Handle
The roof section (Fig. 10) consists of the roof
plate,
windscreen member, two roof arches and
rear member.
Doors and openings
The doors on the Station Wagon are similar to those
on the 4-door model. The tailgate consists of an
upper and lower part. The hinges of the upper
tailgate are attached to the rear edge of the roof
section and those of the lower tailgate are bolted
i n the rear cross-member. The inside of the lower
tailgate is provided with a cover plate and mat
which are attached by means of screws. Both tail-
gate sections are locked by means of a common
l
ock which is bolted on to the lower tailgate. Each
of the tailgate sections is provided with a support
for holding it in the open position. Opening of the
upper tailgate is facilitated by means of a gas
spring, i.e. a piston which runs in an enclosed gas-
filled cylinder. There are four different opening
positions.
Interior fittings and upholstery
FRONT SEATS
See the corresponding section for the 4-door
model.
REAR SEAT
The rear seat is built up of springs on a frame and
has foam plastic padding which is covered with
vinyl. The seat cushion is provided with two hinges
at the lower front edge and can if necessary be
tipped up against the front seats. It is covered with
a
mat underneath and forms the front limit of the
l
oading space when in the tipped-up position.
The backrest consists of a back plate fitted with
rubber bands. The padding consists of foam plastic
and the upholstery of fabric-backed vinyl. The rear
side of the back plate is provided with a mat and
when folded down forms an extension of the floor
i n the loading space. The backrest is locked in the
normal position by a spring-loaded catch device,
see Fig. 11, the handle (4) of which operates the
l atches through an eccentric (1) and pull rods (2).
The lower corners of the backrest rest partly on a
fixed catch and partly (on the left-hand side) on a
sprung catch.
Bumpers
The bumpers are the same as on the 4-door model
except that the rear overriders serve as footsteps,
the upper sides of which are rubber-covered.

P 120
REPAIR INSTRUCTIONS
FRONT END
Front mudguards
The front mudguard is removed by taking out the
following screws: the screw between the mudguard
and stay at the lower side member, the screw bet-
ween the mudguard and body side behind the
above-mentioned stay, the screws in the front side
section and the screws in the upper side member.
I n addition, the headlamp with leads must be re-
moved. Concerning removing the headlamp, see
Part 3. Fitting is done in the reverse order.
Front section
The front section is attached to the front mudguards,
wheel arch plates and the upper and lower cross-
members.
When removing, take out the headlamps, the screws
between the front section and splash guard under
the headlamp, the screws in the upper and lower
cross-members and the screws in the wheel arch
plates.
Bonnet and bonnet lock
The bonnet is attached by means of screws in each
hinge. The bonnet is removed by taking out the
screws between the hinges and bonnet. The hinges
are attached to the body with four screws each.
All the holes in the hinges are oval in order to
permit the bonnet to be adjusted.
There are two types of bonnet lock. The early pro-
duction lock (up to chassis number about 10 000)
i s illustrated in Fig. 12. The bonnet lock is adjusted
as follows.
When the bonnet is locked the U-shaped catch
should lie right inside the lock catch groove and
the measurement B, Fig. 12 must not exceed 3 mm
(0.12"). Any adjustment should be made on the
catch itself. It should be adjusted vertically so that
the gap between the bonnet and the front section
Fig. 13. Bonnet lock, late production
of the body is 4.5 ± 1 mm (0.18 ± 0.04"). The tension
of the safety catch spring should be at least 0.1 kg
(0.22 lb.) measured at D, Fig. 12, in order to move
it from its rest position.
8-- 7

P 120
8-8
Fig. 14. Door check
When the bonnet is closed, the U-shaped catch
should meet the safety catch as close to the top as
possible, but not so high as to cause the hook
to be pushed forwards, measurement C, Fig. 12.
A small adjustment of 1-2 mm (0.04-0.08") can
be made by bending the safety catch. If a larger
adjustment is found to be necessary, this means
that the whole locking device has been displaced.
I
n this case the complete bonnet lock must be reset.
The late production lock, with effect from chassis
number about 10000, is illustrated in Fig. 13.
The lock can be adjusted laterally and longitudinal-
l y since the holes in the front section are larger than
the diameter of the attaching screws. The length
of the latch is adjustable by means of nuts. The
l atch and spring are lubricated with grease.
DOORS
Removing front door
1. Remove the door check, see Fig. 14. The
attaching bolts for this are accessible after
the side insulation material on the body has
been removed. The door check can also be
removed by unscrewing the guide roller and
pulling it off. In order to get at the guide
roller, the door upholstery must be removed
see under "Removing the door handle and
upholstery".
2. Unscrew the four countersunk screws which
hold the door to the upper and lower hinges.
The door sealing strip must be moved in order
to get at the hinge screws. This is done by
releasing the two plates over the hinges
to which the strip is glued and carefully pulling
to one side, see Fig. 15. When doing this,
make sure that the rubber strip does not come
away from the plate or door. Fig. 16. Removing armrest
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25255
Fig. 15. Plate over hinge
Fitting the door is done in the reverse order
to removing. Since the holes in the door are
l arger than the diameter of the bolt, and the
nut plates are movable, the hinge attachment
can be adjusted both vertically and laterally.
The door is adjusted longitudinally at the
hinge attachments in the body.
Removing rear door
(See also under "Removing front door")
1. Remove the door check. The attaching bolt
for this is accessible after the rubber plug in
the centre pillar has been removed.
2.
Remove the plates over the hinges.
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P 120
Fig. 18. Window winder with circlip
3. Remove the screws in the hinges and lift off
the door.
The holes in the centre pillar are larger than
the diameter of the bolts. When running nuts
are used, this enables the door to be adjusted
both vertically and laterally.
Removing door handle and upholstery
1. Remove the armrest, which is attached with two
screws accessible from underneath the armrest,
see Fig. 16.
2. Remove the door handle and window winding
handle. These are removed by prising out the
l ocking washer which holds them with tool
SVO 2297, see Fig.
1
7. The window winder,
l ocking washer and circlip are illustrated in
Fig. 18.
3. Remove the upper trim moulding. This is
attached to the door edges by four screws,
see Fig. 19.
Fig. 19. Removing the upper trim moulding
Fig. 17. Removing and fitting the window winder

P 120
8- 1 0
Fig. 22. Removing the lock handle
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23210
Fig. 20. Removing the door upholstery
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23211
Fig. 21. Removing upper screw for guide rail
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23256
4. Remove the door upholstery by carefully app-
l
ying a screwdriver or similar under the pad-
ded edge and then prising outwards, when
the upholstery will come away, see Fig. 20.
5. Remove the paper protectors which are fitted
over the holes in the inner plate of the door.
Door locks and door handles
REMOVING DOOR LOCKS AND LOCK HANDLES
Carry out operations 1-5 under "Removing the
door upholstery".
1. Unscrew the two screws which hold the guide
rail for the window. The screws are accessible
from the edge of the door as shown in Fig.
21. Lift out the guide rail.
2. Unscrew the three screws which hold the inner
handle mechanism (remote control).
3. Lift off the link arm between the lock knob
roller mechanism and disconnect the link for
the outer handle from the roller mechanism.
4. Unscrew the four screws on the edge of the
door which hold the toothed roller mecha-
nism.
5. Lift off the door with remote control.
6. The door handle is removed by unscrewing the
t wo screws which hold it, see Fig. 22. The
screws are accessible from the inside of the
door and are most easily removed after the
window has been let down or taken out, see
under "Window winder with mechanism".
Fig. 23. Dismantling the lock handle
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23212

DISMANTLING THE DOOR HANDLES
1.
Unscrew the two screws which hold the press-
button and lock plunger to the door handle,
see Fig. 23.
2. Press out the locking pins as shown in Fig. 24.
3. Turn the key backwards and forwards a few
ti mes in the press-button at the same time as
pulling outwards, when the lock plunger will
release and can be pulled out as shown in
Fig. 25.
FITTING AND ADJUSTING THE LOCKS
Front door
1. Fit the lock (10, Fig. 26) with remote control
(12) in the door without tightening the screws.
2. Adjust measurement A, Fig. 28 to 15±0.5 mm
(0.59 ± 0.02") by turning the lock. Tighten the
l
ock hard. If it is not possible to obtain the
correct measurement for A by turning the lock
after it has been tightened up as near to A as
possible, the remaining adjustment is done
by bending the lever (5). Measurement A must
be checked within the specified tolerances.
3. The remote control (12) with split pin (11)
fitted is pushed backwards so that the lever
(9) stops against the lock (10). The remote
control is screwed on in this position. Remove
the split pin (11).
4.
Fit the lever (7) for the inner locking knob (15).
Fig. 26.
Adjusting the front door lock
1. Outer handle
2. Lock nut
3.
Adjusting screw
4. Pin (for checking)
5. Lever
6. Link
7. Lever.
8. Lever
9.
Lever
1 0. Lock
11. Split pin
12. Remote control
13. Locking spring
14. Lever
15. Locking knob
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23244
Fig. 25. Press-button dismantled
P 120
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23243
Fig. 24. Pressing out the locking pin
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1
01 44
8-11

P 120
Rear door
1. Fit the lock (11, Fig. 27) with remote control
(13) in the door without tightening the screws.
2. Adjust measurement A, Fig. 28 to 17±0.5 mm
(0.67 ± 0.02") by turning the lock. Tighten the
l ock hard. If it is not possible to obtain the
correct measurement for A by turning the lock
after it has been tightened up as near to A as
possible, the remaining adjustment is done by
bending the lever (5). Measurement A must be
checked within the specified tolerances.
3.
The remote control (13) with split pin (12)
fitted is pushed backwards so that the lever
(10) stops against the lock (11). The remote
control is screwed on in this position. Remove
the split pin (12).
4. Fit the lever (17) and connect the link (16)
to the lever (1).
5. Set the lever (7) in the locked position, i.e.
backwards against the lock and lever (14) in
the rear catch position. Check through the
control hole (12) that the lever moves fully
to the catch position. In this position the lever
(14) is locked to the link (16) with screws at
the clips (15). Check that the link (16) does
not rub against the inner plate of the door.
On the other hand it must not be bent out so
much that it rubs against the screws of the
i nner trim moulding.
Fig. 27. Adjusting the rear door lock
1. Outer handle
2. Locknut
3. Adjusting screw
4. Pin (for checking)
5. Lever
6.
Link
7. Lever
8. Lever
9. Locking spring
10. Lever
11. Lock
12. Split pin
13. Remote control
14. Lever
15.
Clip
16. Link
17. Lever
18. Locking knob
8- 1 2
Fig. 29. Striker block
' Fig. 28. Adjusting measurements for lock

FITTING AND ADJUSTING THE OUTER HANDLES
Front door, early production
1. Check that measurement B, Fig. 28=15± 1 mm
(0.59±0.04"). Adjust if necessary. Tighten the
l ocknut (2) on the screw (3), Fig. 26.
2. Fit the outer handle (1) with link (6) fitted on.
3. Connect the link (6) to the lever (14). Adjust-
ment is done by selecting one of the three
holes so that the recess and hole in the outer
handle coincide. This is done by inserting a
pin (4) into the hole in the outer handle as
shown in the figure. They should come in
line
when the locking knob (15) is pressed
down, i.e. the lever (7) is pressed down and
the lever (8) moved backwards against the
l ock.
Late production
1. Check that the measurement B, Fig. 28=
1 5± 1 mm (0.59 ± 0.04"). Adjust if necessary.
Tighten the locknut (2) on the screw (3), Fig.
26.
2. Fit the outer handle (1) with link (6) fitted on.
3. Connect the link (6) with the lever (14). The
l ever in the handle is set in such a position
that a pin (4) (3 mm=0.12") can be inserted
i n the hole in the handle. Adjusting is done
by screwing the link up or down so that the
l
oop of the link (6) comes in line with the
l ever (14) on the lock.
Rear door
Late production
1. Check that the measurement B, Fig. 28= 15±
1 mm (0.59±0.04"). Adjust if necessary.
Tighten the locknut (2) on the screw (3), Fig.
27.
2. Fit the outer handle (1) with link (6) fitted on.
3. Connect the link (6) with the lever (8). The
l
ever in the handle is set in such a position
that a pin (4) (3 mm=0.12") can be inserted
i n the hole in the handle. Adjusting is done
by screwing the link up or down so that the
l oop of the link (6) comes in line with the
l ever (8) on the lock.
P 120
Inner locking knob
With the locking knob in the pressed-down posi-
tion,
measurement C, Fig. 28 should be 12± 1 mm
(0.47 ± 0.04") for both the front and rear door.
STRIKER BLOCK
The striker block (Fig. 29) is made of steel and
fitted with a floating nut plate. The block is
adjustable since the holes in the body have a
l arger diameter than that of the attaching screws.
The vertical position of the striker block is checked
by closing the door with the press-button of the
outer handle pressed in, when the dowel pin should
slide correctly into the striker block. N.B. This should
be done immediately after the striker block has
been fitted.
Ventilation windows
REMOVING AND FITTING
The ventilation window is built in with one of the
guide rails for the winding window. A suitable pro-
cedure for removing the ventilation window with
sealing strips is as follows:
1. Carry out operations 1-
5 under "Removing
the door upholstery".
2. Unscrew the five screws which hold the win-
dow to the door and door arch, see Figs. 30
and 31.
VOLVO
1 01 040
Fig. 30.
Attaching screw for ventilation window
8 1 3

P 120
8-
1 4
Fig. 31.
Upper attaching screw for ventilation
window
3. Unscrew the screws which hold the guide rail
for the winding window, see Fig. 32. This only
applies to the extended guide rail on the front
doors.
4. Remove the upper guide strip with a screw-
driver as shown in Fig. 33.
5. Lift up the window as shown in Fig. 34.
Fig. 33. Removing upper guide strip
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1
01 039
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23250
Fig. 32. Attaching screw for winding window
guide rail
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23246
Fig. 34. Lifting out the ventilation window
Window winder with mechanism
REMOVING AND FITTING
Carry out operations 1-5 under "Removing the
door upholstery".
Carry out operations 1-5 under "Ventilation win-
dows, removing and fitting".
1. Remove the clip which holds the carrier on the
winding cable to the rail under the window
and lift it up as shown in Fig. 35. On the rear
doors there is no carrier and the clip fits
directly on the winding chain.
2. Release the cable tensioning device by
slackening the nut for the catch screw on the
l ower pulley. Lift off the cable and chain.
3. If necessary remove the upper pulley, lower
pulley with tensioning device and winding
sprocket itself. The winding sprocket is remov-
ed by unscrewing the four screws, Fig. 36,
after which the sprocket with shaft is lifted out.
Before fitting the winding window, make sure
that the guide strips and seals are in good
condition. Worn or
,
damaged parts must be
replaced.
The cable for the winding mechanism should
be tensioned well but not too hard. Lubricate
the cable and chain with grease and the pulley
and winding sprocket with oil.
After fitting, check that the window runs easily
i
n the guide rails.

VOLVO
23248
Fig. 35. Removing clip for carrier
Sealing strips
A. BONDED STRIPS
The following procedure is recommended when fitt-
i ng new rubber strips:
1. Remove the old strips.
2. All traces of old adhesive should be care-
fully removed from the metal surfaces with
petrol or similar. It is most important to carry
this out carefully since no residue from old
adhesive must be left on the metal, but at the
same time care must be taken to make sure
that the paintwork is not damaged by the
solvent used. (Requirements: clean rags,
wooden putty knife).
3. The new rubber strips should be thoroughly
cleaned with petrol, methylated spirit or simi-
l ar. (Requirements: clean rags, fibre brush).
4. After they have dried, the rubber strips should
be
coated with Dekalin TH or equivalent and
then allowed to dry to a non-tacky state, which
usually takes about 15 minutes. (Requirements:
thick hair brush).
5.
The metal surfaces to which the rubber strips
are to be attached are then coated with
Dekalin TH. (Requirements: thick hair brush).
6. The treated and non-tacky rubber strips are
then pressed on to the newly-coated adhesive
on the metal.
7. The rubber strips should be pressed firmly
against the metal surfaces so that there is no
air trapped in the joints.
N.B.
Wait for at least 15 minutes after the strips
have been applied before closing the door.
P 120
VOLVO
23249
Fig. 36.
Removing sprocket
B.
STRIPS ATTACHED WITH FASTENING RAIL
On late production vehicles the sealing strip is
attached by means of a fastening rail which is spot-
welded to the door.
The sealing strip is removed by pulling it outwards,
when the ridge of the strip releases from the rail.
When fitting the sealing strip, one of the ridges is
placed in position in the rail, after which the other
ridge is pressed down into the rail with the help
of a screwdriver. This is moved along the rail as
shown in Fig. 37.
Fig. 37. Fitting sealing strip for door
8- 1 5

P 120
Luggage compartment lid, 2- and
4-door models
The luggage compartment lid is mounted on two
hinges, both of which are attached by means of
three screws to the inner plate of the lid and with
t
wo screws to the plate under the rear window.
The holes in the part of the hinges fitted in the lid
are oval so as to permit longitudinal adjustment. In
order to obtain lateral adjustment the holes in the
body under the rear window are made larger than
the diameter of the screws. These screws are access-
i ble after the insulating material round the edge of
the rear window has been removed.
When removing the luggage compartment lid, ten-
sion must first be removed from the torsion rods
which support the lid.
Apply tool
SVO 2572 as shown in Fig. 38 and prise
down the loop on the torsion rod until the catch
releases. Move aside the catch and let the torsion
rod move back. Remove the torsion rod attachment
i
n the body. The other end of the tool is used as
shown in Fig. 39. Prise upwards with the tool so
that the bent part of the torsion rod slides out of
the groove. Hold the tool in this position and grasp
the middle of the torsion rod with one hand and
pull it outwards as shown in Fig. 39 so that it
releases from the bracket when the tool is moved
back and the torsion rod is relieved of tension.
The locking device on vehicles with chassis num-
bers lower then 21000 i s attached with two screws
and a circlip on the body under the luggage
compartment lid. The locking device is released
by pressing in the lockable press button. The lock-
i ng clamp on the lower edge of the luggage com-
partment lid is adjustable in order to permit varia-
tion of the tightness with which the lid can be
l ocked.
When removing the lock, the two screws at the
edge of the luggage compartment opening in the
body are removed as well as the circlip round the
l ock press-button, see Fig. 40. When fitting, the
circlip is first fitted and then the screws. Make sure
that the rubber washer round the lock button seals
properly.
The locking device on vehicles with effect from
chassis
21000
i s attached to the luggage compart-
ment lid by means of screws. The catch fitting is
attached to the body with two screws. The lock is
adjusted by screwing the link (5, Fig. 41) up or
down. The lock cylinder (2) is attached to the
handle with a nut. The catch fitting is provided
with oval holes in order to permit adjustment.
8- 1
6
Fig. 38. Releasing the torsion rod
Fig. 39. Removing the torsion rod
VOLVO
1 01 060
VOLVO
1 01 061
VOLVO
23235
Fig. 40.
Removing circlip for lock press-button

TAILGATE, STATION WAGON
Upper tailgate
REMOVING THE UPPER TAILGATE
1. Unscrew the upper support from the tailgate.
2. Late production. Unscrew the gas spring from
the tailgate.
3. Carefully pull down the headlining at the rear
edge beginning in the middle and continuing
outwards towards the corners. The teazel strip
at the corners is bent out slightly with a putty
knife. The fabric is then carefully lifted off the
projection of the teazel strip with the help
of the putty knife. Remove the headlining
fabric up to the rear stretcher as shown in
Fig. 42.
P 120
4. Unscrew the nuts for the hinges and remove
the latter.
FITTING THE UPPER TAILGATE
1.
Place the hinges with packings in position.
Screw on the nuts, adjust the position of the
tailgate and tighten the nuts.
2. Fold the plastic strip for the headlining as
shown in Fig. 43 and press it up into position
with the help of the putty knife. Attach the
fabric at the corners as shown in Fig. 44.
3. Adjust the teazel strip against the body with
a hammer and piece of rubber as shown in
Fig. 45.
VOLVO
1 00 954
Fig. 42.
Headlining fabric removed to expose
upper tailgate hinge nuts
Fig. 43. Folding and fitting rear plastic strip
VOLVO
1 00 951
8 1 7
Fig. 41. Lock for luggage compartment
li d,
l
ate production
1. Handle
5. Link
2. Lock cylinder
6. Guide spring
3.
Lock mechanism 7. Lock
4. Rubber bush
8. Catch fitting

P 120
VOLVO
100 953
Fig. 44. Fitting headlining fabric in corner
8-
1 8
Fig. 45. Adjusting teazel strip
Fig. 46. Window moulding
A. Indentations
B.
Rubber strip
C. Sealing compound
D. Rubber strip
VOLVO
1
00 952
TRIM MOULDINGS
Waist mouldings
The waist mouldings, and the upper trim moulding
for the door on the P 120 2-door model, are
attached with clips. The mouldings are removed
with the help of a putty knife with which they are
carefully unfastened. Before fitting the mouldings,
the holes should be filled with sealing compound.
Window mouldings
REMOVING
Wind down the window. Apply masking tape or
similar as shown in Fig. 47 i n order to protect the
paintwork. From inside, place a screwdriver under
the rear edge of the moulding in line with the in-
dentations which secure it, see Figs. 46 and 48. Prise
carefully upwards with the screwdriver and at the
same time pull outwards and downwards with the
hand so that the rear retaining spring can be hooked
off with SVO 2297, see Fig.
49. Carefully pull out
the moulding backwards.
FITTING
Stick the profile rubber strips at both ends of the
window moulding and apply sealing compound
along the inner section of the moulding, see Fig.46.
Place the retaining springs in position and apply
sealing compound as shown in Fig. 50. Push the
window moulding in position under the rubber strip
of the ventilation window as shown in Fig. 51. Lift
the inner ridge of the moulding over the metal
edge of the door and press down so that the inden-
tations, Fig. 46, locate in the holes in the sheet
metal edge. Press up the retaining springs with
SVO 2297, see Fig. 52.
Moulding for rear side window,
Station Wagon
When fitting the clips for the moulding, one of the
l egs is inserted in the recess in the moulding, the
clip pressed together and the other leg inserted.
Apply sealing compound over the fastenings and
press the moulding into position.

Fig. 47.
Application of masking tape
Fig, 48.
Removing window moulding
Fig. 49.
Removing spring
P 120
Fig. 50. Position of springs
Fig. 51.
Fitting window moulding
Fig. 52. Fitting spring
8-- 1 9