TWO- AND FOUR-DOORCARS(121/122 S M)

DESCRIPTION DRIVING

SERVICING

BEFORE YOU START DRIVING YOUR NEW VOLVOPLEASE READ THROUGH THISINSTRUCTION BOOK CAREFULLY. IT CONTAINS ALLTHE INFORMATION YOU NEED TO BE ABLE TODRIVE AND SERVICE YOUR VEHICLE IN THE BESTPOSSIBLE WAY. BY FOLLOWING THE INSTRUCTIONSGIVEN IN THIS BOOK, YOU WILL FIND THATYOUR VOLVO WILL COME UP TO ALL THEEXPECTATIONS CONCERNING ECONOMICALOPERATION AND EXCELLENT PERFORMANCE THATYOU HAVE EVERY RIGHT TO EXPECT OFA TOP-QUALITY VEHICLE.THIS INSTRUCTION BOOK IS NOT INTENDED TOBE A COMPREHENSIVE TECHNICAL MANUAL ANDDOES NOT CLAIM TO MAKE THEREADER INTO A PERFECT CAR MECHANIC. IT WILL,HOWEVER, SHOW YOU HOW TO LOOK AFTER YOURVEHICLE SO THAT TROUBLE IN THE FUTURECAN BE AVOIDED

AB VOLVO

DO NOTWAIT UNTIL SOMETHING GOES

WRONG BEFORE YOU START READINGTHIS BOOK. READ IT NOW.

THE SHORT TIME THIS TAKES WILL MORE THANREPAY YOU IN THE LONG RUN.

THE BETTER YOU KNOW YOUR VOLVO, THEBETTER SERVICE IT CAN GIVE YOU.

THIS BOOK CAN CONTAIN SOME VALUABLEINFORMATION EVEN FOR AN EXPERIENCED

MOTORISTFINALLY, WE WOULD LIKE TO EXPRESS OUR

APPRECIATION FOR THE CONFIDENCEYOU HAVE SHOWN IN THE NAME OF VOLVO

BY CHOOSING A VOLVO VEHICLE.WE ARE SURE THAT THE DEMANDS YOU MAKE

ON YOUR VOLVO WILL BE MORE THANSATISFIED, APART FROM THE FACT THAT YOU

WILL ENJOY DRIVING IT, AND THAT IT WILLGIVE YOU FAITHFUL SERVICE FOR MANY,

MANY MILES.

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CONTENTS

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CONTENTS

VOLVO SERVICE

Volvo Service OrganizationIn order to get the most out of the invested capital represented by a car,it must be looked after and serviced rationally. Volvo has gone to a greatamount of trouble in the design and selection of material to ensure thatthe car in question only requires a minimum of servicing. All this workwill be in vain unless we can count on your co-operation - that is tosay, that you make sure that your vehicle gets the regular 'servicing itneeds. In order to help you, Volvo has built up a world-wide serviceorganization. All Volvo dealers have specially trained personnel andreceive a continuous supply of technical information from the VolvoService Organization concerning repair and adjustment work. They havealso special tools, designed at the Volvo factory.All Volvo dealers have a comprehensive stock of spare parts which isyour guarantee for genuine Volvo spares. This is why our dealers are inthe very best position to give your vehicle first-class service concerningboth maintenance operations and repairs. You should also refer to yourdealer if you need information about your Volvo that is not includedin this instruction book.It is not only in your own country that there is a Volvo workshop withineasy reach but Volvo also has a widely distributed service network inother countries too.

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VOLVO SERVICE

Warranty and Service BookletA warranty and service booklet accompanies each vehicle when it isdelivered. This book contains a coupon entitling you to a cost-free ser-vice inspection after 2 500 km (1 500 miles) running. If possible, let thedealer who supplied the vehicle carry out this service inspection. If nec-essary, however, any of our dealers can do this.I f our six-month guarantee is to apply, we make one absolute conditionand that is that the above-mentioned cost-free inspection is carried outat roughly the mileage shown and that the vehicle has been looked afterin accordance with the instructions in this book.

Service InspectionsAfter the cost-free service inspection has been carried out, you shouldmake an agreement with your dealer concerning continued, regular ser-vice inspections in accordance with the suggestions made in our ServiceBook. Thorough and regular servicing is o f vital importance for the per-formance and length o f life o f the vehicle.Always use genuine Volvo spares.

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DESCRIPTION

GeneralThe Volvo 121/122 S is a two- or four-door, five-seater car. Manycolours are available and in each particular case the colour of the internalfittings and upholstery harmonizes with the external finish of the car.In addition to a spacious luggage compartment, where the spare wheeland tool kit are stowed, there is also plenty of storage space inside thecar itself, such as a shelf with its own lighting under the dashboard,a recessed hat shelf below the rear window and roomy pockets on theinside of the front doors. Standard equipment on the car includes a tripmeter in the speedometer, a windscreen washer and a back-up light whichgoes on automatically when the reverse gear is engaged. Both front seatsare fitted with safety belts. The car is of the integral construction typeso that there is no separate frame. The front and rear suspensions aswell as the engine and transmission are attached directly to the body.The surface finish of the body is synthetic and the primer used rust-proofs the body. The car is also thief-proof since the connection betweenthe ignition switch and the ignition coil is in the form of an armouredcable.

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Type designations

In all correspondence con-cerning your vehicle withthe dealer and when order-ing spare parts, the typedesignation, chassis and en-gine number should alwaysbe quoted.

On the USA market, 12234 and 13234 have desig-nations 12244 and 13244 respectively.Moreover, the letter M is not included in thetype designation for the models on the USA market.1. The type designation and chassis number arestamped on the cowl under the bonnet.2. Stamped on a plate to the left under the bonnetis the type designation together with the code num-bers for colour and upholstery.3. The engine type designation, part number andserial number are given on the left-hand side ofthe cylinder block. The last figures of the partnumber are stamped on a tab. The serial numberfollows this with all the figures stamped on. Fori dentifying the engine, both the part number andserial number should be quoted, for example496801-12345.:j.) See separate supplement.

This instruction book deals with vehicles having thefollowing type designations:

Type designation Engine Gearbox121341 M or 121342 M B 18 A M 40121361 M or 121362 M B 18 A BW 35*122341 M or 122342 M B 18 D M 40122351 M or 122352 M B 18 D M 41122461 M or 122462 M B 18 D BW 35*131211 M or 131212 M B 18 A M 30131341 M or 131342 M B 18 A M 40131361 M or 131362 M B 18 A BW 35*132341 M or 132342 M B 18 D M 40132461 M or 132462 M B 18 D BW 35*

DESCRIPTION

The engine is a four-cylinder carburettor unit with overhead valves.The pistons are made of light-alloy and the upper compression ring oneach piston is chromed. The main bearings and connecting rod bearingsare replaceable. The crankshaft is statically and dynamically balanced.Engine type B 18 A has an output of 85 h.p. (SAE) and is equipped withZenith-Stromberg horizontal carburettor.Engine type B 18 D has an output of 100 h.p. ( SAE ) and is equippedwith twin SU horizontal carburettors.

Fuel systemThe fuel system is fed from the tank to the carburettor by a fuel pumpwhich is driven by a cam on the engine camshaft. There is a filter in thefuel pump which traps water and other impurities in the fuel.

Lubricating systemThe engine lubrication is taken care of by a gear pump which sucks upoil from the sump on the bottom of the engine and forces it through theoil filter out to the lubricating points in the engine. A relief valve isbuilt into the oil filter which prevents the oil pressure from reachingexcessively high values.

Cooling systemThe 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 thermo-stat with an opening temperature of about 76 ° C (169 ° F) prevents thecooling water from passing through the radiator before the engine hasreached its normal working temperature.

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1. Carburettor (B 18 D) 12. Oil dipstick 21. Relay for back-up light2. Float chamber (B 18 D) 13. Distributor 22. Relay for headlight3. Air cleaner (B 18 D) 14. Heater flasher4. Expansion tank with 15. Starter motor 23. Motor for windscreen

filler cap for coolant 16. Ignition coil washers5. Charging control 17. Plate with type desig- 24. Fluid container for6. Dynamo nation and code for windscreen washers7. Oil filler cap colour and upholstery 25. Oil trap8. Air cleaner (B 18 A) 18. Fusebox 26. Fuel pump9. Carburettor (B 18 A) 19. Brake fluid container 27. Steering box

10. Battery 20. Clutch fluid container 28. Horn11. Hoses for heater system

DESCRIPTION

Electrical systemThe electrical system is of the 12-volt type and is fitted with a volt-age control dynamo. The starter motor is controlled from the instrumentpanel by means of the ignition key. This key also forms the main switchfor the rest of the electrical system. The cables to the headlights, parkinglights and internal lighting, however, are not taken over the ignitionswitch but can be switched on and off without the ignition key being inposition.

LightingThe lighting on the vehicle consists of two headlights (full and dipped)together with two combined flasher and parking lights. At the rear thelighting consists of two tail lights including flashers, combined lamps forthe tail lights and brake warning lights, and the back-up light. Internallighting consists of a roof light above the rear view mirror and a lightfor the parcel shelf.See pages 42-44 concerning replacement of bulbs.

FusesThe electrical system is protected by means of fuses fitted in a fusebox tothe left on the bulkhead under the bonnet. When replacing a fuse, be surethat you use a one of the right rating. If one of the fuses should blowrepeatedly, do not fit a more powerful fuse. Instead, take the vehicle toa workshop for a check of the electrical system.

1) Applies only to cars equipped with overdrive1 2

1. Flasher and parking 22. Battery screen wiper andlight, left 23. Fusebox washer

2. Headlight, left 24. Brake contact 43. Lighting switch3. Horn 25. Door contact, left 44. Ignition switch4. Headlight, right 26. Light signal device 45. Cigarette lighter5. Flasher and parking 27. Relay for horn 46. Control for

light, right 28. Overdrive switch') ventilation fan6. Connector 29. Roof light 47. Glove compartment7. Junction block 30. Switch for roof lighting8. Relay for headlight light 48. Switch for glove

signal 31. Flasher unit, direc- compartment9. Reversing light tion indicators lighting

contact 32. Door contact, right 49. Fuel gauge10. Distributor 33. Control lamp for impulse unit11. Dynamo charging 50. Rear lamp, left, with12. Charging control 34. Control lamp for rear light, stop light,13. Relay for reversing fullbeam headlights flasher and back-up

light 35. Control lamp for light14. Relay for over- direction indicators 51. Number plate

drive') 36. Control lamp for lighting15. Overdrive contact') oil pressure 52. Rear lamp, right,16. Ignition coil 37. Fuel gauge with rear light,17. Oil pressure 38. Windscreen wiper stop light, flasher

warning indicator 39. Instrument lighting and back-up light18. Foot dipper switch 40. Ventilation fan A = White E = Grey19. Solenoid for 41. Control lamp for B=Black F =Yellow

overdrive') overdrive C= Blue G=Brown20. Starter motor 42. Control for wind- D = Green H =Red21. Windscreen washer I = Spare lead

DESCRIPTION

Power transmissionClutch

The function of the clutch is to transmit the power from the engine tothe gearbox. The clutch is of the single dry plate type with diaphragmspring. The diaphragm spring 'functions partly as a lever when declutch-ing and partly as a pressure spring when engaging.

GearboxThe gearbox is used to regulate the speed ratio between the engine and therear axle so that the engine always operates in its most favourable speedrange. The gearbox is synchronised on all the forward gears; this meansthat gear-changing can be carried out without double declutching. Sincethe gearbox is fitted with helical gears and the gear lever is rubber in-sulated, excellent sound insulation is obtained. See page 57 for data.

Propeller shaftThe propeller shaft, which is the connecting link between the gearboxand the rear axle, is divided into two sections. The forward section isjournalled at its rear end in a bearing housing suspended in a rubberizedring.

Rear axleThe driving power of the engine is transmitted from the propeller shaftto the rear wheels through the rear axle. The rear axle is of the hypoidtype, i.e. drive pinion is below the centre line of the drive shafts. Seepage 57 for data.

BrakesThe vehicle is equipped with disc brakes at the front and drum brakesat the rear as standard. The brake system is also provided with a re-ducer valve, which prevents involuntary locking of the rear wheels.The footbrake system is hydraulic and influences all four wheels. Thehydraulic system consists of a 'fluid-filled master cylinder which, whenthe brake pedal is depressed, transmits the brake pressure through thebrake fluid in the lines to the wheel unit cylinders. The plungers in theseare then pressed outwards and apply the brake shoes or brake pads res-pectivly.Vehicles fitted with the B 18 D engine are also provided with vacuumtype servo brake cylinders.The handbrake system operates mechanically on the rear wheels.

Wheels and tyresThe vehicle has pressed steel wheels with lugs for the attachment of thehub caps. All wheels are carefully balanced and the tyres are of the tube-less type.

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Gearbox

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DESCRIPTION

BodyBonnet

The bonnet is fitted with a catchwhich is operated from the drivingseat through a handle located to theleft under the instrument panel. Thebonnet catch is released by pullingthe handle out.

When the bonnet catch handle hasbeen released inside the car, thebonnet is still retained by a safetycatch. After this is pressed in asshown, the bonnet can be liftedup. When the bonnet is closedthe bonnet catch is automaticallylocked and cannot be lifted untilthe handle inside the car has beenpulled again. Check to make surethat the bonnet is properly securedwhen it is closed.

Luggage compartment

The door key is used to lock theluggage compartment, which is open-ed by pressing the handle upwardsas shown. The luggage compartmentlid is balanced and does not needto be held up. To the left in thecompartment there is room for thespare wheel and tool kit. Alwaysmake sure that the spare wheel isfastened securely and that the toolkit is firmly stowed, otherwise irri-tating rattles can occur.

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Doors and locks

There is a lock with a keyhole oneach of the front doors. All thedoors can be locked from insidethe car by pressing down the lockbuttons on the window ledge. Onthe rear doors, this button mustfirst be pulled up before the doorscan be opened from the inside. Thisis an important safety factor ifchildren are alone in the back. Allthe doors can be locked by pressingdown the internal lock button andthen closing the doors. Do not leavethe keys in the car, otherwise youcan easily lock yourself out.Many people make it a habit ofpressing down all the lock buttons.In itself this is not an extra safetyprecaution. On the other hand,however, the passengers are lockedin and this might be dangerousshould an accident occur, especiallyinvolving fire. For this reason youshould always leave at least onedoor (for example, one or bothfront doors) "unlocked" when driv-ing.

The doors are opened from the in-side by turning the handle to therear. The ventilation windows forthe doors are opened by unscrewingthe lock stud, after which it can bepressed in and the handle turned up-wards. With the stud in the screwed-i n position, the handle is locked.

The rear side windows of two-doorcars can be partly opened by settingthe handle at the rear edge in diffe-rent positions (does not apply to13121).

In order to prevent freezing-up ofthe locks, a suitable anti-freeze agentshould be used in cold weather. Ifthe locks are already frozen, donot exert undue force on the keyotherwise you might break it. Instead,heat it with a match or similar andplace it quickly into the keyhole.

DESCRIPTION

Front seats

The front seats can be slid back-wards or forwards after the knobon the outside of the seat is presseddown. Exert leverage with your feeton the floor and slide the seat tothe desired position.If necessary, the seats can be moved25 mm (1") further to the rear thanpermitted by the slide rails by usingthe extra holes in the seat frames.The backrest inclination of the frontseats is smoothly adjusted by meansof an adjuster knob located at theoutside of the seat frame at thebottom.

On the two-door model the backrestis locked in the raised position bymeans of a catch. In order to tipthe backrest forwards the catch atthe rear edge of the seat frame mustbe lifted backwards and upwards.

The front seat is also provided withan adjustable lumbar support. Foradjusting this, the backrest is pro-vided with holes on both sides. Totension the lumbar support, turn thescrew clockwise and vice versa.

The inclination of the whole seatcan be adjusted with the eyeletscrew at the front under the seat.Remove the screw which goesthrough the eyelet and tip the seatbackwards as shown in the figure.Then slacken the locknut on thefloor and screw the eyelet screwupwards or downwards to the de-sired height. Then secure the eyeletscrew with the locknut.The whole seat can also be raised orlowered, which is done as followsRemove the seat cushion, unscrewthe two bolts on the seat frameattachment and then place them inone of the other holes in the bracket.

The front seat backrest has built-inattachments for fitting a headrest.

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Safety beltsStandard on this vehicle includessafety belts for both the frontseats. Utilize this simple but effectivesafety device. Even when drivingslowly, for example, in town traffic,a sudden, unexpected stop can causeserious injury. For this reason, thesafety belt should always be onwhen driving.

The length of the belt can be ad-justed at the outer, lower attach-ment.When the belt is to be used, it isremoved from the retaining hookon the door pillar and then placedwith one band round the waist andthe other band over the shoulderand chest and then locked in theanchorage between the front seats.

The belt is released by moving thelever in question to the rear.Make a habit of always hanging upthe belt when not in use. If it isallowed to lie on the floor it willbecome dirty and frayed and willobstruct getting in and out of thevehicle.Check now and then that the boltswhich hold the belt are properlytightened. If the belt has becomedirty it can best be cleaned withwater and synthetic washing agent.Petrol and similar must not be usedsince this can cause stains.As the safety belts lose much o ftheir strength when exposed tostretching, they should be replacedafter a collision even though theymay appear to be undamaged.

Rear seatThe rear seat is provided with afolding armrest in the middle.

DESCRIPTION

I nstruments and operating controlsBefore you start the engine, sit behind the wheel and carefully checkthrough all the instruments and controls. The location of these is shownin the illustration. The instruments and operating controls are describedin more detail on the following pages with reference to the numbers inthe illustration.Immediately after starting, and now and then while driving, you shouldglance at the instruments and check that they are showing normal readingsaccording to the values stated.

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1. Temperature gauge2. Warning lamp, , battery

charging3. Trip meter4. Speedometer5. Control lamp, full

headlights6. Control lamp,

directional signals7. Mileometer8. Warning lamp, oil

pressure9. Fuel gauge

10. Control for windscreenwipers and washers

11. Choke control

12. Ignition switch andstarter contact

13. Cigarette lighter14. Heater controls15. Grab handle16. Switch for glove box

lighting17. Clutch pedal18. Brake pedal19. Accelerator pedal20. Lighting switch21. Direction indicator switch22. Steering wheel23. Horn ring24. Gear lever

DESCRIPTION

I Temperature gaugeThe temperature gauge shows the temperature of the cooling system andthus indicates the working temperature of the engine. The indicator onthis gauge should remain within the green marking. If it should show anexcessively high temperature for a long time, this can depend upon thefact that the channels in the cooling system are blocked and circulationis thus being hindered. In such cases the cooling system should be cleaned(see page 40).

2 Battery charging control lampThis lamp lights up when the battery is discharging, this being normal atidling speed. If you accelerate a little, this lamp should go out. Shouldthe lamp light up while you are driving, this generally means that thereis some fault in the electrical system or that the fan belt is not sufficient-ly tensioned and is slipping on the pulley, thereby causing poor charging.

3 Trip meterThis trip meter, which is graduated in tenths of a mile, can be used tomeasure even short distances. The meter can be reset to zero by means ofa twist knob placed under the instrument panel to the left of the steeringcolumn. The knob is turned first to the right and then back to the leftagain.

4 SpeedometerThe speedometer has a horizontal indicator, the right hand point showingthe speed at which you are travelling. Since the length of the red strip isproportional to the speed, this is in itself a safety factor - the more redyou can see, the more dangerous your speed.

7 MileometerThe mileometer shows the total distance covered in miles. At a reading of99 999 miles the mechanism returns to zero and starts to go round again.

8 Oil pressure warning lampWhen you switch on the ignition, this lamp should light up and then goout again when the engine has been started. Should the lamp light upwhile you are driving, the engine should be stopped immediately and thecause for this determined. In most cases it means that the oil level is toolow. After hard driving it may happen that the warning lamp lightswhen the engine goes down to idling speed. This is normal providing thatit goes out again when the engine speed is increased.

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DESCRIPTION

10 Control for windscreen wipers and washersThe control for the windscreen wipers and washers has four positions.When pressed in, the control is shut. When pulled out one step, the wind-screen wipers operate at normal speed. When pulled out two steps, thewindscreen wipers move more quickly. When pulled out fully, the wind-screen washers are also operated. (Not standard on USA cars.) Whenthe control is pressed in again, the wiper blades stop when they havereached their normal position.The liquid container for the windscreen washers is placed under thebonnet and holds about 1 1 /2 litres (2 3 /4 Imp. pints = 3'/4 US pints).Never allow the wiper blades to operate on a dry and dusty surface sincethe glass and blades can then easily be scratched.

11 Choke controlThe choke control is used when the engine is started from cold. Whenpulled out about 10-15 mm (3/8-5/8"), the control influences thethrottle flap and increases idling speed. When pulled out further, thecontrol enriches the fuel - air mixture.

12 Ignition switch

1. "Radio" positionIn this position, the completeelectrical system of the vehiclewith the exception of the enginei gnition system, is switched on.2. Neutral position

3. Driving position

4. Starting positionTo start the engine, turn the keyto this position which engagesthe starter motor.

13 Cigarette lighterTo use the cigarette lighter, push it in. As soon as it has heated up suffi-ciently, it will automatically spring out backwards.

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DESCRIPTION

14 Heater and ventilation system

Switch for fresh-air fan

Pushed right in - closedInterco. pos. - full outputFully out - half output

Air-flow

AIR _ Air to front seat floorDEFR = Air to windscreenand to rear seat floor

Sliding control for air temp.

This control is used to regulate thetemperature 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 elementto a distributing chamber where it is distributed to the floor and wind-screen by means of the controls. NOTE: During normal condition thereis sufficient air-flow due to the fact of the overpressure at the air inletof the vehicle. If greater quantities of air are required, use the fan.The heater element is connected with a thermostat which keeps the tem-perature constant. When the temperature control is moved, there will bea slight delay before the heater element adjusts itself to the desiredtemperature.

The figure shows the air duct to therear seat and the air distribution in thevehicle when both the "AIR" and"DEFR" controls are used.

Misting on the windowsDuring cold or damp weather mist caneasily form on the windows, particu-larly with a full number of passengers.The best way of getting rid of this orto avoid it altogether is to open theventilation windows partly or fully andto set the fan and defroster controlsat max. output.

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DESCRIPTION

20 Lighting switch

Parking lights

(Lighting switch pulled out onenotch)

Dipped headlights

(Lighting switch fully out andfoot dipper switch in dippedposition)

Full headlights

(Lighting switch fully out andfoot dipper switch in fullposition)

The headlights are switched from full to dipped and vice versa by de-pressing the dipper switch with your foot.

Instrument lighting

The instrument lighting is regulated by turning the lighting switch knob.The more this knob is turned clockwise, the stronger the instrumentlighting will be.

Interior lighting1. The lamp lights when the left-hand

door is opened.2. The light is off all the time.3. The light is on all the time.

Direction indicator switch leverThe direction indicators are controlled bymeans of the switch lever to the leftunder the steering wheel.

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DRIVING

Starting i n a garageIf you start your vehicle in a garage, always open the garage doorsbefore starting the engine. The exhaust gases from the engine contain thepoisonous gas carbon monoxide which is particularly dangerous since it isboth invisible and odourless.

Driving with the luggage compartment lid openWhile driving with the luggage compartment lid partly or fully open, ex-haust gases (and consequently also carbon monoxide) can be sucked intothe car through the luggage compartment, particularly if a window isopen. Normally this involves no risk for the passengers, but for thegreatest safety the following advice should be followed:1. Keep all windows closed.2. Set the fresh air and defroster levers to fully open and the fan control

to full speed.

BrakingSteady acceleration and gentle braking are characteristic of a good driverand also result in the most economic running. Apply the brakes beforegoing into a curve and use your gearbox on downhill gradients so thatyou save unnecessary wear on both brakes and tyres.Violent :braking is only justified in dangerous situations.

TowingIf the vehicle is to be towed,the tow-line should not beattached directly to the bum-pers, but should be takenround the bumper supports.While the vehicle is beingtowed, the tow-line shouldbe kept evenly stretchedsince violent jerks candamage the bumpers.

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SERVICING

GeneralBefore the vehicle was delivered from the factory it was subjected to avery thorough inspection. Your dealer, in his turn, carried out a furtherdelivery inspection in accordance with the specifications of the Volvofactory. In addition to this there is the cost free service inspection after2 500 km (1 500 miles). After this inspection the servicing of the vehicleshould follow the routine in the service book which is based on a systeminvolving an oil change and oil level check after every 5 000 km(3 000 miles) and service inspections after every 10 000 km (6 000 miles)running.The simplest (and in the long run most profitable) way to give thevehicle the servicing it requires is to have all the servicing done by aVolvo workshop. You will then have all the work shown in the servicebook carried out in accordance with fixed prices and the workshopstamp in the service book will show how the vehicle is being serviced- this is also extremely important as far as second-hand value is con-cerned.When designing the car, particular attention has been paid to the "safetydetails" (e.g. suspension, brakes and steering). They are calculated towithstand the severest stresses with a wide safety margin. However, ifyou use your car for hard driving, you should take the precaution ofchecking these parts for fatigue cracks sometime during the car's usefullife, for instance when the parts concerned are reconditioned.If you prefer to carry out the simpler servicing procedures yourself or ifyou are sometimes obliged to have them done by a workshop outside theVolvo organization, this chapter contains some advice as to when andhow they should be carried out.For the sake of convenience, the servicing procedures have been summa-rized in a maintenance scheme on the following pages.

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SERVICING

Maintenance schemeIn the maintenance scheme below the servicing procedures have beengiven certain numbers which refer to the detailed descriptions on thefollowing pages.Some of the work must be carried out by skilled mechanics or requiresthe use of special tools and these have been marked in colour.

Operation

SERVICING

In addition to the servicing procedures mentioned in this scheme youshould also regularly check the following from the point of view oftraffic safety:

a) lighting, including brake warning lightsb) direction indicator flashersc) horn

Operation

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SERVICING

LubricationLubrication is the most important procedure in servicing a vehicle. Thecost of lubricant is insignificant compared with the cost of repairs causedby neglected lubrication.All metallic surfaces, no matter how finely ground they are, consist ofextremely small uneven points. If two ground surfaces are pressed to-gether and rubbed, the uneven surfaces will engage in each other andresult in friction and wear. If these two surfaces are separated by a thincoating of oil, however, the friction disappears and with it the wear.This is exactly what happens when bearings, pistons and gears in thevehicle are lubricated. The oil or grease actually prevents the metallicsurfaces from coming into direct contact with one another.This means that from a purely theoretical viewpoint the metallic surfacesin a motor vehicle are never subject to wear and it should be sufficientto lubricate them once. Unfortunately this is not so in practice. The un-even surfaces are worn down more and more and the minute particlesreleased contaminate the oil which also becomes partially carbonized.It is thus impossible to avoid wear completely, but wear can be de-creased and prevented to a very large extent by regular and carefullubrication.

Chassis maintenanceTo simplify maintenance of your Volvo, the vehicle has been equippedwith ball joints, steering rods and propeller shaft of such a design thatthey do not require regular lubrication. This has been possible due to thefact that points which normally require lubricating have been packed withvery durable grease at the factory and then carefully sealed, thus ob-viating the need for lubrication.However, in order to be certain that these parts are functioning pro-perly, it is necessary to inspect thoroughly their seals and rubber sleevesafter every 10 000 km (6 000 miles) or at least once a year.Oil should be changed or the oil level checked after every 5000 km(3000 miles) in accordance with the lubricating chart at the -end of thebook. After every 10 000 km (6 000 miles) the vehicle should undergothe 10 000 km (6 000 miles) inspection at a Volvo workshop. The meas-ures taken during this inspection are also to be found in the lubricatingchart.You should follow the recommendations of the Service Booklet, whichare based on Volvo's own investigations. Use only first-class lubricants of awell-known make. The right lubricant in the right quantity at the righttime will increase both the lifetime and reliability of your car.

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SERVICING

1 Body lubricationIn order to avoid squeaks and unnecessary wear, the body should belubricated about every 10 000 km (6 000 miles) or at least once a year.

During the winter season the door locks and luggage compartment lockshould be treated with a suitable anti-freeze agent to prevent them fromfreezing up.

No. Lubricating point Lubricant

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1 Bonnet catch Paraffin wax2 Bonnet hinges oil3 Ventilator window catches and hinges oil4 Catches Paraffin wax5 Door handle lock buttons Paraffin wax

6KeyholesDoor locks

Silicon oilSilicon oil

7 Luggage compartment hinges oil8 Luggage compartment lock Oil9 Door stops Paraffin wax

10 Door hinges Oil11 Driving seat rails and catches Paraffin wax12 Window lifts and oil

Locks( Accessible after removal of door panels).

Oil and greaseSilicon grease

SERVICING

2 Check the oil level in the engine

The oil level in the engine should bechecked each time the fuel tank is filled.Carry out the check with the engineswitched off by using the oil dipstickwhich is on the left-hand side of theengine.The oil level should be between the twomarks on the dipstick. It must never bepermitted to go down below the lowermark, but on the other hand the oil levelshould not be above the upper mark sinceoil consumption will then be abnormallyhigh.If necessary top up with new oil o f thesame type already in the engine.

3 Changing the engine oilFor lubrication of the engine, oil "For Service MS" should be used. Theviscosity should be selected according to the table below. Multigrade oilSAE 10 W-30, which covers the entire temperature range, is recommen-ded.The intervals between oil changes depend to a great extent on the drivingconditions to which the engine is subjected, as can be seen from thetable below.Light driving conditions concern long-distance driving on motorways withthe engine thoroughly warm and with infrequent stopping and starting.Normal driving conditions concern relatively short distances (not inter-rupted by frequent stopping and starting), when the engine is able tobecome warm but cools down between individual journeys.Unfavourable driving conditions concern continuous driving in congestedtraffic with much stopping and starting and long periods with the engineidling.

Oil change intervals,Oil grade Oil capacitykm (miles) *)

Operating Summer Winter Multigrade SAE 10 W-30 For oil ( IncludingConditions or motor oil "For Service MS" changing oil filter

Light 5000 (3000) 5000 (3000) Viscosity : below 0'C(32*F)SAEl0W 3.25 litres 3.75 litresNormal 5000 (3000) 2500 (1500) between 0*C and + 30° C (5'/4 Imp. pints (6'/ 8 Imp. pintsUnfavourable 2500 (1500) 2500 (1500) (32-90 °F) SAE 20

above +30'C (90'F) SAE 30= 7 US pints) = 8 1

/4 US pints)

*) During the running-in period the oil should be changed after the first 2 500 km (1500 miles).36

SERVICING

4 Gearbox5 The oil in the gearbox should be checked after every 5 000 km (3 000

miles). The oil level should be up to the filler hole. If necessary top upwith new oil. The oil in the gearbox should be changed after every 40 000km (25 000 miles). In the case of a new or reconditioned gearbox theoil should also be changed after the first 5 000 km (3 000 miles). The oldoil should be drained off immediately after the vehicle has been run.

6 Rear axle7 The oil level in the rear axle should be checked after every 5 000 km

(3 000 miles). The oil level should be up to the filler hole. If necessarytop up with new oil.The oil in the rear axle should be changed after the first 5 000 km (3 000miles), when the rear axle should be flushed thoroughly with flushingoil before being filled with the new oil. The old oil should be drainedoff 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 toppingup take place with new oil if necessary.

8 Steering boxThe oil level in the steering box should be checked after every 5 000 km(3 000 miles). The oil level should be up to the filler plug. If necessary,top up with new oil of the same grade and viscosity as that alreadyused. The oil in the steering box does not usually need to be changed.

3 7

SERVICING

9 Brake fluid10 Clutch control fluid

The fluid level in the brake andclutch control hydraulic systemsshould be checked after every 5 000km (3 000 miles). The fluid shouldbe up to the level marks in thecontainers. Use brake fluid for bothsystems.

Engine11 Oil filler cap

The oil filler cap is fitted with afilter. If this filter becomes blockedthere will be excessive pressure inthe crankcase and this can lead tooil leakage. This filter must there-fore be cleaned after about every40 000 km (25 000 miles).

12 Crankcase ventilationSome models are provided with po-sitive crankcase ventilation whichprevents crankcase gases from beingreleased into the atmosphere. Thevalve (4) should be replaced at In-tervals of 40 000 km (25 000 miles).The oil trap (6), the hoses (3 and 5),the nipple (1) and the filter (2)should be removed at the same timeand thoroughly cleaned. If the rub-ber hoses should be in a poor con-dition, then replace them.

13 Oil filterThe oil filter traps any impuritiesi n the oil so that the filter becomesblocked after a time. For this reasonit must be replaced regularly, forexample after every 10 000 km(6 000 miles), and preferably by aVolvo workshop. If the filter isreplaced without the oil beingchanged, 0.5 litre (A Imp. pints =1 1

/4 US pints) of oil should be ad-ded.

38

Brake fluidThe brake fluid used in the hydrau-lic brake system must meet thestandards laid down in SAE 70 R 3.From the point of view of trafficsafety it is extremely important toensure that poor quality brake fluidis not used in the hydraulic brakesystem. A top-quality brake fluidmust satisfy strict conditions con-cerning resistance to cold and heatand must have no detrimental effecton the rubber components in thebrake system.

14 Fuel filterThe fuel filter should be cleanedafter every 10 000 km (6 000 miles).Loosen the screw and remove thecover and strainer and clean these.When refitting the cover make surethat the gasket seals properly.

15 Air cleaner (B 18 A)The air cleaner should be replacedwith a new one after every 40 000km (25 000 miles). With continuousdriving in dusty conditions replace-ment must be carried out more fre-quently. When changing the aircleaner the sealing ring against thecarburettor should be checked.NOTE. On no account must theelement be moistened or oiled.

16 Air cleaners (B 18 D)The air cleaners of the SU carbur-ettors should be replaced with newones after every 20 000 km (12 500miles).

17 ValvesLet you Volvo workshop check theengine valve clearances after every10 000 km (6 000 miles). Too nar-row clearances can cause burntvalves.

18 Compression testEvery 10 000 km (6 000 miles) acompression test should be carriedout to get some idea of the condi-tion of the engine. The test shouldbe carried out at a Volvo work-shop.

19 Fan beltThe fan belt tension should bechecked at a Volvo workshop afterevery 10 000 kin (6000 miles). In-correct tension can result in poordynamo output.

SERVICING

20 Check the coolant level

To be able to function with maximumefficiency, the cooling system must bewell filled and must not leak.Check the coolant level when tanking.The level should be between the "Max"and "Min" marks on the expansion tank.When the engine is new or the coolingsystem has been emptied, this checkshould be carried out with particularthoroughness.

Topping up the coolant.Topping up the coolant is carried out by filling the expansion tankwhen its level drops down to the "Min" mark. Top up with sufficientfluid so that the level reaches up to the "Max" mark. Use genuineVolvo coolant.Note: Do not top up only with water, especially in the wintertime.Water alone reduces both the rust-proofing qualities of the coolant aswell as its anti-frost effectiveness.

21 Change coolantThe coolant retains its properties for about one year, when it shouldbe changed. When draining the cooling system, open the cock on theengine and loosen the plug under the radiator. The expansion tank isemptied by lifting it up from the brackets and holding it up so highthat the water runs into the radiator.Before filling with new coolant, the entire system should be flushedwith clean water. The coolant is filled through the opening on the radia-tor, but the heater control must be set at "Max" heat so that theentire system can be filled. Fill the radiator to the top and put on thecap. Then fill the expansion tank to the "Max" mark or just above.Run the engine warm and then check to make sure that the radiatoris completely full and that the level in the expansion tank lies betweenthe "Min" and "Max" marks.The capacity of the cooling system is 8.6 litres (15 1 /s Imp. pints =

4018 1/s US pints), when the coolant in the expansion tank is at the "Max"mark.

SERVICING

22 Check, replace the sparking plugs23 The sparking plugs should be removed after every 10 000 km (6 000

miles) and the electrode gap checked. The gap should be 0.7-0.8 mm(0.028-0.032"). After 20 000 km (12 500 miles) the plugs should bereplaced. This replacement should preferably be carried out at a Volvoworkshop where the sparking plugs are tightened with a torque wrenchto about 3.5 kgm (25 lb.ft.). When fitting new sparking plugs, be sureto fit the right type (see page 56). Consult a Volvo workshop if youconsider fitting another type of plug.

24 Ignition system25 The distributor contact breaker gap and the engine ignition timing set-

ting should be checked in a Volvo workshop after every 10 000 km(6000 miles). All adjusting work should be done by the workshop whichhas the necessary equipment for this purpose. The distributor is one ofthe most sensitive units in the engine and careless handling can lead todecreased engine output and high fuel consumption or even serious damageto the engine.

PetrolThe fuel used should be petrol with an octane value of at least 97".If petrol with too low an octane value is used, knocking or glow ignitioncan result.When delivered from the factory, the engine is adjusted for fuel havingan octane rating of at least 97 *.* Research Method Rating

26 CarburettorAfter every 10 000 km (6 000 miles), the vehicle should be taken to aVolvo workshop for a check on the carburettor or the carburettors.At every engine oil change check that the oil level in the centre spindleof the carburettor or carburettors reaches up to about 6 mm (

1/4") from

edge of the spindle. If it does not, top up to this level with oil ofthe same type as that used in the engine. Where the temperature is con-tinously below -20 ° C (-4 ° F) the use of hydraulic oil SAE 5W/l0Win the centre spindle is recommended.

SERVICING

Electrical system27 Check the battery electrolyte level

The electrolyte level should be checked when the fuel tank is being filled.The electrolyte level should be 5-10 mm ( 3/16- 3 /8") over the top ofthe cell plates. Top up with distilled water if necessary. Never add toomuch distilled water since this can cause the acid to splash over andresult in corrosion on the parts of the engine around the battery. Nevercheck the electrolyte level by lighting a match. The gases formed in thecells are very explosive.

28 Check the state of charge of the batteryThe state of charge of the battery should be checked after every 10 000km (6 000 miles). This check is carried out with the help of a hydro-meter, this showing the specific gravity of the electrolyte which varieswith the state of charge, see page 57. During the winter the state ofcharge must be checked more often since a fully charged battery is moreresistant to frost damage than a half charged one.

29 Check headlight alignmentThe alignment of the headlights should be checked in a Volvo workshopafter every 10 000 km (6 000 miles). Remember that the section of theroad lit up by the headlights can vary depending on the loading of thevehicle.

Replacement of bulbsTo obtain maximum lighting power and to ensure against lamps goingout, the headlight lamps should be changed every year, suitably in theautumn. Some of the bulbs have two functions, for example the headlightbulbs which have filaments for both full and dipped lights. The guidepins on the sockets of these bulbs are either of different thickness orthey are staggered so that the bulbs can only be fitted in one definiteposition. Certain makes of bulbs have a "Top" mark on the socket andthis should be turned upwards.

Replacing the roof light bulbWhen replacing the roof light bulbthe lamp shade is pulled straightout.

When fitting headlight bulbs do not touchthe glass with your fingers. The reasonfor this is that grease, oil or any otherimpurities can be carbonized onto thebulb and this can cause damage to thereflector.

Replacing the headlight bulbsLoosen the screw on the undersideof the rim with a screwdriver.Pull out the bottom part of the rimslightly and then lift upwards sothat the retainer catch releases itsgrip. (Do not pull the headlight rimso far forwards that the catch at thetop becomes bent, otherwise watercan penetrate and damage the re-flector.)Loosen the three screws retainingthe insert. It is not necessary toremove these screws completely. Thei nsert can now be removed by turn-i ng it in an anti-clockwise direction.Loosen the small springs retainingthe above holder and remove it.Take out the bulb holder and loosenthe bulb by pressing it inwards andturning it in a clockwise directionat the same time. When fitting anew bulb, remember that the socketpins have different widths. Whenrefitting the bulb holder in the insertmake sure that the small retainerengages in its notch.(In the case of Sealed Beam head-lights, follow the instructions shownin the pictures 1-5 and disconnectthe contact for the bulb holder,after which the bulb and holder arereplaced.)

SERVICING

Replacing the bulbs in the front parking lights/flashers

Unscrew the two screws by means of aPhilips screwdriver and lift off the glass andthe metal frame. The bulbs can now be re-moved by pushing in and twisting anti-clockwise.

The larger one is the flasher and the smallerone the parking light. See that the glassseats properly on the gasket.

Replacing the bulbs in the rear flashers,stop/tail lights and back-up lights

Replacing the bulbs inthe number plate lighting

Unscrew the two screws,one at the. upper and oneat the lower end of thelighting fixture, by meansof a Philips screwdriverand lift off the glass andthe metal frame. The bulbscan now be removed bypushing in and twistinganti-clockwise. The top bulb

is the flasher, the middleone the combined stop/taillight, and the bottom onethe back-up light. See thatthe glass seats properly onthe gasket when assemblingthe fixture. The untintedpart of the glass should beat the bottom.

The number plate lighting isbuilt into the handle on thel uggage compartment lid withone bulb on each side of theemblem. The bulbs are access-i ble from the underside of theemblem.

44

SERVICING

Power transmission30 Checking the free travel of the clutch yoke

In order to prevent the clutch from slipping, the free travel of the clutchyoke must be checked regularly and adjusted if necessary after 10 000km (6 000 miles) of operation. If the clutch does not disengage in a satis-factory way, the free travel of the clutch pedal must be checked. See thedata on page 57.The clutch should be checked and adjusted at a Volvo workshop sincethese workshops have the necessary equipment.

31 Check the propeller shaftEvery 10 000 km (6 000 miles) the rubber seal on the spline shaft shouldbe checked as well as the universal joints. If the rubber seal is damaged,it should be replaced and the new seal filled with molybdenum disulphidegrease before fitting.

Brakes32 Check and overhaul the brakes

After every 10 000 km (6 000 miles) running the vehicle should be takento a Volvo workshop for controlling the function of the brakes.As the rear wheel brake linings become worn the brake shoes must beadjusted in order to obtain satisfactory braking effect.The disc brakes on the front wheels are self-adjusting.In connection with this check the brakes should also be inspected forwear. The filter on the servo cylinder should be replaced in connectionwith the changing of the rear brake shoes.

Front end33 Check the front wheel alignment

Correct front wheel alignment is of vital importance for the steering ofthe vehicle. Faulty adjustment can also mean heavy wear on the tyres.Have the front wheel alignment checked at a Volvo workshop at regularintervals, for example after every 10 000 km (6 000 miles). If the vehiclehas been involved in a collision or heavy impact and it is suspected thatthe front end may have been affected, take the vehicle to a workshopfor a check of the front wheel alignment as soon as possible. The frontwheel alignment angles are shown on page 58.

34 Check the ball joints, tie-rod, etc.After every 10 000 km (6 000 miles) the vehicle should be taken to aVolvo workshop for a check of the front end concerning excessive playin the ball joints, steering gear, etc. Also check the ball joint seals fordamage and leakage. When new seals are fitted they should be filled withchassis grease.

45

SERVICING

Wheels and tyres35 Air pressure

Make a habit of checking the airpressure in the tyres regularly. Thebest way to do this is to check thepressures every time you fill the fueltank. See page 58 for the correctair pressures. Do not forget thespare wheel when you check the airpressure. Even if this wheel is notused, the air pressure can go downand you may find that the tyre isflat just when you need it.During driving the temperature ofthe tyre rises and that also of theair pressure in relation to the ve-hicle's speed and load. Normallythe air pressure should only bechecked when the tyres are cold. Ifthe tyres are warm, any alterationshould be only made in those caseswhen the tyres must be pumpedwith air.Size 165 S15 tyres are intended forspeeds up to 175 km.p.h. (110m.p.h.).For prolonged driving at speedsabove 140 km.p.h. (90 m.p.h.) theair pressure in the tyres should bei ncreased by 0.3 kg/cm2 (4.5 lb/sq.in.). The pressure must not exceed2.1 kg /cm2 (30 lb./sq.in.).

If inspection of the tyres shows thatthere are particularly worn spotsand unusual wear on the tread, takethe vehicle to a Volvo workshopfor the wheels to be balanced.

4 6

Excessively low air pressure is oneof the most usual reasons for wear.If pressure is too low, the outeredges of the tread take the wholeloading and wear down very quick-ly. Insufficiently inflated tyres alsoresult in difficult steering and highfuel consumption.Excessively high air pressure meanstyre wear along the centre of thetread.

Changing a wheelBefore the vehicle is jacked up, thehandbrake should be applied andone of the gears engaged to makesure that the vehicle stands still.Lay a couple of stones or chocksi n front of and behind the wheelsthat remain on the ground.

Removing1 Lever off the hub cap with the

help of the spade-shaped lever.2 Loosen the wheel nuts slightly

with the help of the box spannerand tommy bar. All the wheelshave nuts with right-handthreads which are loosened byturning in an anti-clockwisedirection.

3 Insert the lifting claw of thejack in the appropriate jackattachment of the wheel to bechanged. Lift up the side of thecar far enough for the wheel toturn freely.

4 Unscrew the wheel nuts com-pletely and lift off the wheel.Be careful when lifting off thewheel so that the threads of thestuds are not damaged.

FittingFit the new wheel and tighten thenuts until the wheel is in good con-tact with the hub flange. Thenlower the vehicle and tighten thenuts finally. Tighten the nuts alter-nately.Fit the hub cap by striking it smart-ly with the hand opposite the lastof the lugs to engage.

SERVICING

Body36 Washing

When the vehicle is new it should be washed often to harden the surfacefinish. If dust and dirt are allowed to remain in contact with the surfacefinish for any length of time, damage can result. Washing and polishingare also important from the viewpoint of rust protection. Special careshould be taken particularly during the wintertime that all residues ofroad-salt are washed off as soon as possible otherwise corrosion caneasily occur. Another point, if the paintwork of a car is well lookedafter, the car will have a higher trade-in value, should the owner decideto sell it.While the vehicle is being washed it should stand where it is not in directsunshine since this can cause drying patches. First rinse off the undersideof the body with a jet of water and use a soft brush if necessary. Thenrinse down the entire body with a fairly light jet until the dirt hasloosened up. Then wash off the dirt with a sponge using plenty of water.If washing with water alone is not sufficient, washing agents can beused. Be very careful when choosing a washing agent since some of themare detrimental to the surface finish.Spots of tar, etc. can be removed by using paraffin before washing withwater. If the vehicle has white side-wall tyres, these can be cleaned byscrubbing them with washing agents, scouring powder or, in the worstcases, fine sandpaper. After washing, clean the vehicle carefully with asoft, clean chamois leather.Use a different leather for the windows, otherwise greasy smears can becaused.

37 Polishing (waxing)The vehicle does not need polishing until the surface finish begins to loseits lustre and normal washing is not sufficient to make it shine again.Polishing will also remove any deposits on the surface finish. Undernormal conditions it is sufficient to polish the vehicle a couple of timesa year on condition that it is carefully looked after and thoroughlywashed as soon as it has become dirty or dusty. During the wintertime,in coastal regions or industrial areas, it may however be necessary topolish the vehicle more often to avoid attacks from rust.The vehicle should be carefully washed and dried before being polished.If polishing is carried out on a dirty or dusty surface, the surface finishcan easily be scratched. Do not polish in direct sunshine since this canresult in a smeary surface.Polishing a couple of times a year is generally sufficient to give the sur-face finish the maintenance it needs. I f you want to wax the vehicle, bevery careful to ensure that the surface is absolutely clean before a layerof wax is applied. Be very careful when using solvents since in manycases these can damage the surface finish. Waxing may not be carried outuntil at least six months after the vehicle has been delivered.

Use a good quality polish intended for synthetic finish. Neverpolish or wash the vehicle in direct sunshine since the result canbe a smeary surface. Be careful when choosing washing agents.

48

Touching-up damageon the surface finish

The touching-up of any extensivedamage to the synthetic finish re-quires the use of special equipmentand skill, so that the repairing ofany such damage should be entrustedto a Volvo workshop. Any minordamage caused by flying stones, etc.and small scratches can, however, beattended to by the owner himself.

Damage caused by flying stones re-quires immediate treatment. There-fore make a habit of checking thefinish and carrying out touching-upwork regularly - for example whenwashing the car.Volvo dealers can supply suitabletouching-up paint. Always checkthat you get exactly the rightcolour.

1 Scrape the damaged surface ab-solutely clean with a penknife orother sharp object. Carefully re-move any loose flakes of paintand "chamfer off" the edgesround the damaged surface.

2 The figure shows a damaged spotscraped clean with "chamfered"edges ready for touching-up.

3 In the event of severe damagedue to flying stones it is necessaryto treat the spot with anti-rustprimer. This can be applied witha matchstick or fine brush. Theprimer should cover the wholeof the scraped and "chamfered"surface.

4 When the anti-rust primer hasdried, genuine Volvo paint is ap-plied. Stir the paint well (notwith the brush). Apply severalthin coats of the paint, allowingit to dry thoroughly between eachapplication.

SERVICING

Chromed partsThe chromed parts should be washed with clean water as soon as theyare dirty. This is particularly important if you drive a lot on gravelroads which are treated with chemicals to keep the dust down andduring the wintertime when salt is used on the roads to melt the snow orif you drive near the sea. After washing you can apply wax or anti-rust preparation.

38 Anti-rust treatmentThe Volvo 121/122 S is anti-rust treated at the factory.The door sills are made of galvanized sheet metal and do not require anymaintenance. The lower part of the body is treated with underbody seal-ing compound on those places which are subjected to flying stones fromthe wheels, i.e. the wheel arches, the entire floor plate and the undersideof the sills. Anti-rust fluid is sprayed on the chassis parts.Inspection and any touching-up of the anti-rust protection should bedone at regular intervals, and at least once a year.If any touching-up 'of the anti-rust protection is necessary, this should bedone immediately to prevent moisture from seeping under it.

39 CleaningCleaning the upholstery

The upholstery consists of vinyl-coated fabric and is very resistant todirt so that it does not really require any maintenance. If it becomesstained, the upholstery can easily be cleaned with a synthetic washingagent and lukewarm water.

Cleaning the floor matsThe floor mats should be taken out at least twice a year and cleaned.Particularly during the winter when there can be snow and ice on themats, they should be taken out and dried.If the mats are stained they can be cleaned with methylated spirits whichare then rinsed off with water.

50

SERVICING

Servicing before long-distance drivingIf you're thinking of travellingabroad with your vehicle or makingany other long journey, you shouldhave your vehicle thoroughly check-ed at a Volvo workshop. You will en-joy your journey better if you knowthat your vehicle is in perfect trim.You drive in a more relaxed wayif you're certain that everything isfunctioning perfectly. You thus avoidirritating incidents and expensiveand time-making stoppages. Evenif something unforeseen should hap-pen, your journey does not needto be spoiled. Wherever you go youknow you have Volvo workshops

within reach and these workshops can take care of your vehicle veryquickly. Do not forget the regular servicing during your trip abroad. AllVolvo workshops abroad are equipped to give your vehicle the serviceit needs.

If you prefer to look over your vehicle yourself, thefollowing hints are worth noting

1 Check the brakes, front wheel alignment and steering gear.

2 Check the engine and drive unit for fuel, oil and coolant leakage.

3 Examine the tyres carefully. Replace worn tyres.

4 If you are not sure whether the engine is functioning perfectly andthe fuel consumption is normal, you can save both time and moneyby doing a thorough overhaul.

5 Examine the state of charge of the battery and clean the terminals.

6 Check the tool kit and spare wheel.

7 Check the lighting.

5 1

SERVICING

Procedure in cold weatherWhen cold weather is in the offing,it is time to think of the winterservicing of your vehicle. The firstheavy night frosts can come as anunpleasant surprise unless preventiveprecautions have been taken.

Engine cooling systemGenuine Volvo coolant should be used all the year round. Therefore thecoolant should not comprise only of water plus a rust-proofing agent,not even during the summertime.The coolant retains its properties for about 1 year, when it should bechanged. A suitable time for doing this is during the autumn, as maxi-mum security against possible damage by frost during the winter months.When changing the coolant, flush the cooling system with clean water.Otherwise, see page 40. If the coolant has to be topped up during thewinter, use only genuine coolant. Water alone weakens both the anti-rustproperties of the coolant as well as its rust-proofing effectiveness. Whentopping up with coolant, it is a good idea to check the concentration toensure that it is strong enough to provide sufficient protection againstdamage by frost.Experience has shown that too thin glycol mixtures (10-20 %) areextremely unfavourable from the viewpoint of rust protection. Theamount of glycol added should be at least 40 °/o, that is 3.4 litres(6 Imp. pints = 7 1 /4 US pints), which is effective below -24 ° C(-12 ° F).Radiator alcohol is not recommended as an anti-freeze agent becauseit has the disadvantage of evaporating at normal engine temperature.

Drain cocks for cooling system

1. Right side of radiator. 2. Right side of engine.

5 2

SERVICING

Engine lubricating system

During the winter multigrade oil SAE 10 W-30 or engine oil with a vis-cosity of SAE 10 W should be used for the engine lubricating system.These oils reach the lubricating points in the engine more easily at lowtemperatures and also facilitate cold starting. If you drive mainly shortdistances during the winter, the engine oil should be changed more oftenthan usual, for example after every 2 500 km (1 500 miles). See page 36.

Electrical system

The electrical system in the vehicle is subjected to greater stresses duringthe winter than during the warm summer months. The lighting and thestarter motor are used more and since the capacity of the battery is alsoconsiderably lower with low air temperatures, the state of charge mustbe checked more often. If the specific gravity of the electrolyte is ex-cessively low there is risk of frost damage to the battery.

Brake system

During the winter the brakes are subjected to splash and condensationwater to a greater extent than during the summer and the result of thiscan be that the handbrake cable may freeze up if the handbrake is lefton. When you park the car, do not apply the handbrake but engagebottom gear or reverse.

Windscreen washer

In the same way as anti-freeze is added to the cooling system during thewinter to prevent frost damage, anti-freeze should also be added to thewindscreen washer water container. This is particularly important duringthe wintertime when the car is often exposed to dirt and water whichcan rapidly freeze on the windscreen and necessitate the frequent useof the windscreen washers and wipers. Your Volvo dealer can supplyyou with a suitable anti-freeze for this purpose.

Anti-freeze for door locks

A frozen door lock is one of the most irritating things that can happento a car-owner. Many valuable minutes early in the morning can bewasted warming up keys and melting ice in locks. Remember this in goodtime and lubricate the lock with some anti-freeze preparation.

5 3

FAULT TRACING

The information given below is only intended to serve as a guide in loca-lizing and temporarily correcting minor faults. After having carried outany such measures, have them checked and adjusted by an expert me-chanic.

The engine does start although the starter motorturns it round at normal speed

1 Check that there is fuel in the tank.2 If the engine is warm, starting should be done with the accelerator

pedal slowly depressed as far as it will go.3 In wet weather the sparking plug insulators should be wiped clean and

the distributor cap removed and wiped dry if flash-over is suspected.4 Check that the fuel line connections on the pump and carburettor are

not leaking and that fuel is supplied to the carburettor.5 If the engine is turned round for a while without having started, too

rich a fuel mixture can enter the cylinders resulting in the sparkingplugs becoming moist. Blow the cylinders clean by screwing out thesparking plugs and turning round the engine with the starter motor.Dry the sparking plugs before fitting them.

If the engine still does not start1 Remove the ignition cable from each plug in turn. Hold the end of the

cable about 1/4" from the cylinder block while turning round the engine

with the ignition switched on. If there is a strong spark the fault isprobably in the sparking plugs, so they should be changed.

2 If only a weak spark is obtained or none at all, check to see whetherthe ignition cables are properly inserted -in the distributor and ignitioncoil. Remove the cables and clean the contact surfaces.

3 Remove the distributor cover and check and clean all contact surfaces.Check that the contact breakers close properly when the engine isturned round. If the contact breaker arm shaft binds, oil it very spa-ringly.

If the engine misfires, the reason can be:1 That one of the ignition cables has loosened in the distributor cover or

from the sparking plug.2 That one or more of the sparking plugs is coated with soot or oiled up,

in which case the plug concerned should be cleaned or changed andthe sparking plug gap adjusted.

3 That the distributor cover and rotor arm can be cracked or damp.4 That one of the ignition cables is in a poor condition.5 That the contact breaker gap in the distributor is insufficient or non-

existent.6 That the contact breakers are badly burnt.

5 4

SPECIFICATIONS

5 5

Dimensions and weights

SPECIFICATIONS

Engine

Fuel system

Cooling system

I gnition system

5 6

57

SPECIFICATIONS

5 8

SymbolsBrake fluidSee page 38

Rear axle oilGrade : Hypoid oilViscosity : See page 37

Lubricant see notes

Light engine oil

Engine oilGrade : For Service MSViscosity : Multigrade SAE 10 W-30

See page 36.

Gearbox oilViscosity : See page 37

Notes for lubricating chartNote 1 Check that the oil reaches up to the filling plug.Note 2 The wheel bearings are packed at the factory with a special type of

grease intended to last for the lifetime of the bearings, which, there-fore, do not require a change of lubricant or additional grease. Thisalso applies after the bearings have been reconditioned or changed, pro-vided that they have been lubricated with a high-class multi-purposegrease.

Note 3 Check that the fluid reaches up to the level mark.Note 4 Lubricate the felt wick under the rotor and fill a few drops of light

engine oil into the lubricating cup.Note 5 Check the oil level when filling up with petrol. Change the oil every

5 000 km (3 000 miles) and in spring and autumn when changing overto another viscosity, if multigrade oil is not used. In unfavourable ope-rating conditions the oil should be changed after every 2 500 km(1 500 miles), see page 36.

Note 6 Have the handbrake cable lubricated with graphite grease a couple oftimes a year.

Note 7 Check every 5 000 km (3 000 miles) that the oil reaches up to the fillingplug. Concerning oil change, see page 37.

Note 8 Fill the lubricating cup with light engine oil. The lubricating cup isopened by turning the outer cap. Use an ordinary oil can, not a pres-sure can.

Note 9 At every engine oil change check that the oil level in the centre spindleof the carburettor or carburettors reaches up to about 6 mm (1/4") fromedge of the spindle. If it does not, top up to this level with oil ofthe same type as that used in the engine. Where the temperature is con-tinously below -20° C (-4° F) the use of hydraulic oil SAE 5W/10Win the centre spindle is recommended.

Note 10 The oil filter should be changed every 10 000 km (6 000 miles), seepage 38.

62

Dynamo (B 18 A)Note 8

Wheel bearingsNote 2

CarburettorNote 9

Oil filterNote 10

GearboxNote 7

Handbrake cableNote 6

Rear axleNote 7

Wheel beringsNote 2

Steering boxNote I

Wheel bearingsNote 2

Clutch fluidNote 3

Brake fluidNote 3

DistributorNote 4

EngineNote 5

Handbrake cableNote 6

Wheel bearingsNote 2