V70 XC AWD L5-2.4L Turbo VIN 56 B5254T (1998)

volvo :: Volvo V70 XC AWD L5-2.
4L Turbo VIN
56 B5254T (1998)
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations
Alarm Horn Relay: Locations
Fuse/Relay Identification and Location
Fuses
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations > Page 7
V70 XC AWD L5-2.4L Turbo VIN 56 B5254T (1998)

Panel Locations
Fuses 11A/1 To 11A/9 & 11B/1 To 11B/5 In Relay Fusebox In Engine Compartment

Fuses 11C/1 To 11C/40 In The Central Electrical Unit
Relays

Panel Locations

Relays In The Relay/Fusebox In The Engine Compartment
Relays In Central Electrical Unit
Other Relays
2/11 Relay engine coolant fan (FC)
2/43 Relay heated rear seat (S70/V70)
2/54 Relay coolbox (V70)
2/74 Relay heating plugs coolant (Diesel)
7/1 Bulb failure warning sensor rear
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service Precautions
Alarm Module: Service Precautions
Control Modules
Connecting Disconnecting Control Modules
Always switch off the ignition before connecting or disconnecting a connector or the test box to a control module
Temperature
80 CThe control module must not be heated to above . Remove control module when stoving for example.
Arc Welding
Disconnect connector from control modules when arc welding. Remove control module before carrying out any a
Replacing
Do not replace a control module without checking its wiring and components. The new component may be dama
NOTE:
Make a note of the radio code before disconnecting the battery leads and the car is without voltage supply. Re-e
Alarm
When replacing the battery on cars with the new VGLA alarm, the siren does not need to be disconnected.
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service Precautions >
Page 14

Symbols
Figures and symbols are used instead of, or to supplement text to facilitate fault-tracing and make easier to read.
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service Precautions > Page 15
Alarm Module: Service and Repair
ZZI1. Removing Main Control Module
Remove:
Driver's side soundproofing panel Under side of Dashboard.Control module by pressing it to the left. Disconnect
ZZI2. Installing Main Control Module
In reverse order.
> Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations
Heated Mirror Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 20

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 28

List of Components By Component Number
1/1 Battery
2/1 Main headlamp relay with bulb failure warning sensor

2/2 Fog lamp relay
2/4 Relay, windshield intermittent wiper
2/5 Relay, seat belt reminder/key warning
2/6 Overload relay 15I-supply
2/14 Glow plug relay
2/15 Relay exhaust temperature switch

2/16 Intermittent tailgate wiper relay

2/22 A/C relay
2/23 Fuel pump relay
2/30 Overload relay X-supply

2/32 Fuel system main relay
2/35 Starter motor relay
2/43 Relay, heated rear seat
2/44 Relay, heated rear window/door mirrors
2/53 Relay, pulsed secondary air injection system (PAIR) pump
2/54 Relay 30-supply cargo compartment
2/56 Heated seat relay front left
2/57 Heated seat relay front right
2/74 Relay heating plugs coolant
2/76 Central locking/anti theft alarm (lock/alarm) control module
2/77 Relay alarm horn
3/1 Ignition switch

3/2 Light switch
3/3 Turn indicator/ DIM-DIP switch
3/4 Control cruise control
3/6 Switch, hazard flasher with flasher relay
3/8 Switch, heated rear window/door mirrors
3/9 Stop (brake) lamp switch
3/10 Back-up (reversing) lamps switch
3/12 Windshield wash/wipe switch
3/13 Tailgate wipe/-washer switch
3/20 Power window switch front passenger door
3/25 Switch power sunroof
3/35 Tailgate handle switch
3/37 Horn switches
3/38 Brake pedal switch
3/39 Clutch pedal switch
3/41 Power door mirrors switch
3/47 Handbrake switch
3/57 Climate control system
3/58 Switch rear foglamp
3/59 Beam height control
3/61 Trip computer control
3/62 Alarm switch in bonnet
3/63 Mode selector AW 50-42
3/65 Switch, heated rear seat
3/71 Gear position sensor
3/72 Kickdown switch (KD) throttle mechanism
3/76 Lock unit left rear
3/77 Lock unit right rear
3/78 Lock unit tailgate
3/84 Cargo compartment fans switch
3/85 Power window switch left rear door
3/86 Power window switch right rear door
3/89 Control unit left seat
3/91 Heated seat switch front left
3/92 Heated seat switch front right
3/93 Seat belt lock, left front seat
3/94 Seat belt lock, right front seat
3/95 TRACS switch
3/97 Power window switch driver's door
3/99 Switch front fog lamps
3/100 Lock unit driver's door
3/109 Trunk lid/fuel tank tiller cover switch
3/110 Lock unit passenger door
3/167 Upper contact breaker left backrest
3/168 Upper contact breaker right backrest
3/169 Lower contact breaker left backrest
3/170 Lower contact breaker right backrest

4/3 Control module, cruise control
4/4 Rheostat
4/9 SRS Supplemental Restraint System Crash Sensor
4/16 ABS control module
4/19 Remote control unit central locking/alarm
4/22 Electronic start inhibitor (Immobilizer)
4/28 Control module AW 50-42
4/29 Control module left front seat
4/30 ECC climate control module
4/31 Power unit blower fan
4/33 Control module power sunroof
4/37 Control module right front seat
4/44 Ignition discharge module (1DM) and ignition coil
4/46 Engine control module (ECM)
5/1 Combined instrument panel
6/1 Windshield wiper motor

6/2 Washer motor front
6/3 Right headlamp wiper motor
6/4 Left headlamp wiper motor
6/9 Power window motor driver's door
6/11 Power window motor passenger door front
6/13 Driver's side power door mirror
6/14 Passenger side power door mirror
6/15 Sunroof motor
6/24 Vacuum pump, cruise control
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/29 Engine coolant fan (FC)
6/30 Washer motor rear windshield
6/31 Fuel pump (FP)/Fuel injection pump
6/32 Tailgate wiper motor
6/33 Fuel level sensor
6/33L Fuel level sensor left
6/33R Fuel level sensor right
6/34 Power antenna
6/37 Central locking motor
6/38 Headlamp height adjustment motor left
6/39 Headlamp height adjustment motor right
6/48 Servo motor recirculation shutter
6/50 Backrest motor left seat
6/51 Motor, up/down front edge of left front seat
6/52 Motor, up/down rear edge of left front seat
6/53 Motor, backward-forwards left front seat
6/54 Pulsed secondary air injection system (PAIR) pump
6/59 Power window motor left rear door
6/61 Power window motor right rear door
6/69 Servo motor, floor, defroster and ventilation shutter
6/95 Servo motor temperature shutter left-hand side
6/96 Servo motor temperature shutter right-hand side
6/97 Left cargo compartment fan
6/98 Right cargo compartment fan

7/4 Brake fluid level sensor
7/5 Washer fluid level sensor
7/6 Oil pressure switch
7/8 A/C pressure sensor
7/11 Outside temperature sensor (ECC)
7/12 ECC sun sensor and LED indicator alarm/ immobilizer
7/15 Front oxygen sensor (HO2S)
7/16 Engine coolant temperature (ECT) sensor
7/17 Mass air flow (MAF) sensor/air volume sensor

7/21 camshaft position (CMP) sensor
7/22 RPM sensor
7/23 Knock sensor (KS) rear
7/24 Knock sensor (KS) front
7/25 Engine speed (RPM) sensor
7/31 ABS sensor, front left
7/32 ABS sensor, front right
7/33 Vehicle speed sensor (VSS)
7/34 Catalytic converter thermocouple
7/39 Antenna ring/ignition lighting
7/43 Thermostat left seat
7/44 Thermostat right seat
7/47 PTC resistor air preheating
7/51 Accelerator pedal (AP) position sensor
7/53 A/C pressure switch (Pressostat)
7/54 Throttle position (TP) sensor
7/56 ABS sensor left rear
7/57 ABS sensor right rear
7/64 Cabin temperature sensor
7/66 Thermostat rear seat left-hand side
7/67 Thermostat rear seat right-hand side
7/69 Outside temperature sensor, combined instrument panel
7/71 Boost pressure sensor
7/73 Engine coolant level sensor
7/74 Oil temperature sensor AW 50-42
7/77 Temperature sensor, intake air
7/79 Accelerometer
7/81 Manifold absolute pressure (MAP) sensor
7/82 Rear oxygen sensor (HO2S)
7/84 Tank pressure sensor
7/85 EBD pressure switch
7/94 Needle lift sensor
7/95 Altitude sensor
7/96 Movement detector left
7/97 Movement detector right
7/100 Car tilt sensor
7/101 Glass breakage sensor
7/102 Microphone
7/105 Outside temperature sensor
7/122 Movement detector
7/135 Alarm lead left rear side window
7/136 Alarm lead right rear side window
8/3 A/C solenoid switch

8/5 Idle air control (IAC) valve
8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/28 Turbo control valve
8/30 Steering wheel module SRS
8/31 Passenger module SRS
8/33 Igniter seat belt tensioner left side
8/34 Igniter seat belt tensioner right side
8/36 Shift lock solenoid
8/37 Solenoids AW 50-42
8/38 Shift solenoid 1
8/40 Lock-up solenoid
8/41 Pressure solenoid
8/43 Solenoid valve PAIR system
8/44 EVAP Canister valve
8/48 Rear view mirror
8/49 Stop solenoid
8/50 Injection timing valve
9/1 Cigarette lighter/12V-outlet front


9/2 Heated rear window
9/3 Backrest heater pad left seat
9/4 Backrest heater pad right seat
9/5 Cushion heater pad left seat
9/6 Cushion heater pad right seat
9/8 Cushion heater pad rear seat left-hand side
9/9 Backrest heater pad rear seat left-hand side
9/10 Cushion heater pad rear seat right-hand side
9/11 Backrest heater pad rear seat right-hand side
9/25 Cigarette lighter/12V-outlet rear
9/26-28 Heating plugs coolant
9/31 Engine coolant heater
10/1 Left front lamp unit

10/2 Right front lamp unit
10/3 License plate lighting
10/5 Left front fog lamp
10/6 Right front fog lamp
10/9 Left front parking lamps and turn signal lamp
10/10 Right front parking lamps and turn signal lamp
10/11 Left front parking lamps
10/12 Right front parking lamps
10/13 Left front turn signal lamp
10/14 Right front turn signal lamp
10/15 Left side turn signal flasher
10/16 Right side turn signal lamp
10/17 Right tail lamp unit
10/18 Left tail lamp unit
10/19 High-level stop (brake) lamp
10/20 License plate lighting left
10/21 License plate lighting right
10/22 Passenger compartment courtesy lamp
10/24 Cargo area lighting
10/26 Reading lamp left rear
10/27 Reading lamp right rear
10/29 Glove box lighting
10/30 Door warning lamp left front
10/31 Door warning lamp right front
10/32 Door warning lamp left rear side
10/33 Door warning lamp right rear
10/40 Gear shift position indicator lighting
10/43 Right stop (brake) lamp
10/44 Right parking-/tail lamps
10/46 Right side rear fog lamp
10/47 Rear right turn signal lamp
10/48 Right back-up (reversing) lamp
10/50 Left stop (brake) lamp
10/51 Left rear parking/tail lamps
10/53 Left side rear fog lamp
10/54 Rear left turn signal lamp
10/55 Left back-up (reversing) lamp
10/64 Right high beam lamp
10/66 Right low beam lamp
10/68 Left high beam lamp
10/70 Left low beam lamp
10/72 Ashtray lighting
10/96 Instrument lighting
10/97 Courtesy lighting, footwell driver's side
10/102 Courtesy lighting, footwell passenger side
10/113 Indicator LED alarm/electronic immobilizer
10/114 Vanity mirror lighting, left side
10/115 Vanity mirror lighting, right side
11A/1-9 Main fuses


11B/1-5 Fuses11C/1-40 Fuses
15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/3 Loudspeaker right front door
16/4 Loudspeaker left front door
16/5 Loudspeaker right rear door
16/6 Loudspeaker left rear door
16/7 Loudspeaker dashboard right side
16/8 Loudspeaker dashboard left side
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/16 Antenna booster
16/17 Loudspeaker parcel shelf left side
16/18 Loudspeaker parcel shelf right side
16/19 Alarm horn
16/26 Dashboard center loudspeaker
16/27 Splitting filter left door
16/28 Splitting filter right door
16/29 Loudspeaker left door
16/30 Loudspeaker right door
16/35 Alarm siren
16/36 TV receiver
16/45 RTI control module
16/46 RTI Display
16/48 CD-player RTI
16/49 TMC/FM receiver RTI
16/57 Loudspeaker left-hand side D-pillar
16/58 Loudspeaker right-hand side D-pillar
16/68 Antenna
16/72 Dolby module
17/1 Service socket for turning over starter motor

17/13 Data link connector DLC
18/4 SRS contact reel steering wheel
20/2 Distributor
20/3-7 Spark plugs
20/18 Blower fan resistor
20/22-26 Glow plugs
23/0-702 Junction points
24/1 Connector Dashboard harness - firewall harness

24/2 Connector Firewall cable harness - Engine compartment harness
24/3 Connector Left door sill harness - Firewall cable harness
24/4 Connector Right door sill harness - Firewall cable harness
24/7A 11-pin connector Tunnel cable harness - Firewall cable harness
24/7B 10-pin connector Tunnel cable harness - Firewall cable harness
24/9 Connector Roof cable harness - Firewall cable harness
24/13 Connector Dashboard harness - Engine compartment harness

24/14 Connector Left door sill harness - Engine compartment harness
24/15 14-pin connector Engine compartment harness - engine harness
24/17 11-pin connector Left rear door cable harness - Left door sill harness
24/18 11-pin connector Right rear door cable harness - Right door sill harness
24/19 4-pin connector Right door sill harness - Rear wheel sensor
24/20 12-pin connector Power sun roof cable harness - Firewall cable harness
24/21 6-pin connector Left door sill harness - Left seat
24/22 6-pin connector Right door sill harness - Right seat
24/25 14-pin connector Tailgate cable harness - Left door sill harness
24/35 8-pin connector, accessories
24/46 2-pin connector Heated rear seat cable harness - Tunnel cable harness
24/50 24-pin connector Driver's door cable harness - Firewall cable harness
24/53 26-pin connector Engine harness - AW 50-42
24/54 3-pin connector Stop solenoid and injection timing valve
24/59 16-pin connector RTI harness - RTI display
24/60 24-pin connector Passenger door cable harness - Firewall cable harness
24/61 15-pin connector Firewall harness - RTI harness
24/63 14-pin connector Climate control cable harness - Firewall harness
24/64 3-pin connector knock sensor
24/67 6-pin connector Left door sill harness - Tailgate harness
24/70 Connector Left door sill harness - Fog lamp cable harness, Power output/adapter wiring tow hitch
24/74 Connector Engine compartment harness - Glow plugs
24/81 6-pin connector tow hook
24/86 2-pin connector Left sill harness - Cargo compartment fan switch harness
24/87 2-pin cool box connector
31/4 Engine ground point (ground terminal - battery-engine)

31/5 Heated rear windshield ground
31/7 Ground terminal driver's side A post
31/11 Ground terminal cargo compartment left-hand side
31/12 Ground terminal cargo compartment right-hand
31/15 Ground terminal passenger side A post
31/44 Engine compartment ground point (battery ground terminal - body)
31/47 Ground terminal left cross member
31/48 Ground terminal right cross member
31/50 Ground rail (power ground)
31/51 Ground rail (signal ground)
31/52 Ground terminal left spring strut turret
31/55 Ground point engine coolant fan (FC)
31/65 Ground point steering column
31/71 Ground terminal right front side member
34/13 Front fog lamps, connector bridge
C/BA 2-pin connector fuel pump (FP)

C/BB 2-pin connector fuel level sensor
C/BC 4-pin connector power antenna/antenna booster
C/BD 3-pin connector fuel tank pressure sensor
C/CJ 6-pin connector cruise control
C/CL 6-pin connector tailgate wash/wipe
C/CR 14-pin connector audio
C/CS 10-pin connector audio
C/EA 1-pin connector engine cooling fan (FC)
C/EC 1-pin connector solenoid switch A/C
C/EG 2-pin connector engine coolant temperature (ECT) sensor
C/EH 3-pin connector camshaft position (CMP) sensor
C/EJ 2-pin connector engine speed (RPM) sensor
C/EM 2-pin connector by tunnel
C/EP 4-pin connector heated oxygen sensor (HO2S) front
C/EQ 4-pin connector heated oxygen sensor (HO2S) rear
Wire Color Code Identification and Other Abbreviations

There are a number of abbreviations used. These are explained below.
Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
EU/OS = Markets outside the USA and Canada
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
WEU = Western Europe
Other:
ALTER = Alternative
AUTO = Automatic transmission
AWD = All wheel drive
C70 = 2-door
EARLY = Early version
EXC = Exclusive
GA = Anti-theft alarm
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
LHD = Left-hand drive
MAN = Manual transmission
OTHERS = Others
RH = Right-hand side
RHD = Right-hand drive
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =
Early version,S70 -CH 459999V70 -CH 395001

MOD2 =
Late version,S70 CH 460000-V70 CH 395002-


C70 all
Markets outside USA and Canada:
MOD1 = Model year 1997

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 37
Power Door Lock Control Module: Service and Repair
ZZI1. Removing Main Control Module
Remove:
Driver's side soundproofing panel Under side of Dashboard.Control module by pressing it to the left. Disconnect
ZZI2. Installing Main Control Module
In reverse order.
> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions >
Page 42

1/1 Battery

2/2 Fog lamp relay

Page 43

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 44

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 45

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 46


11A/1-9 Main fuses

Page 47

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 48



Page 49

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 50

C70 all

> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions
Power Seat Control Module: Diagram Information and Instructions

> Page 55

1/1 Battery

2/2 Fog lamp relay

> Page 56

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 57

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 58

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 59


11A/1-9 Main fuses

> Page 60

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 61



> Page 62

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 63

C70 all

> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > With Heated Seat
Power Seat Control Module: Service and RepairWith Heated Seat
Control module
Preparations
Set the seat height adjustment to its uppermost position.
Remove:
- the battery negative lead

- two screws
- the four connectors.
Install:
In reverse order.
Programming memory functions
The new control module must be programmed with the positions for memory functions 1, 2 and 3. Otherwise diagno
> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > With Heated Seat > Page 66
Power Seat Control Module: Service and RepairWithout Heated Seat
Control module, replace
Preparations
CAUTION: Install the transport safety device for the SIPS Airbag.
Removing
Make a note of radio code if anti-theft coded radio is installed.
Remove:
- Battery negative lead.

- Seat from car.
- The two screws from the bracket.
- Connector from the control module.
Reinstalling
Check that the new control module has P/N 9174904 (for the left seat) or 9174905 (for the right seat).Reinstall in rev
SIPS airbag, removing the safety device
Remove the transport safety device from the sensor module and return it to its storage place on the inside of the cont
Programming the memory functions
The new control module must be programmed with the positions for memory functions 1, 2 and 3. Otherwise diagno
> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater C
> Radio - Interference/Noise On AM Band
3390025Technical Service Bulletin #
Radio - Interference/Noise On AM Band
V70/XC70 2001- S80 1999-
Section
3
Group
39
No.0025
Year
01
Month
07
Reference:This service bulletin replaces the previous service bulletin SB 390025 from February 2001, which should be
Purpose:Additional source of electrical interference, V70 rear seat ground, is added.
AM Radio diagnostics, interference
Background
This Service Bulletin explains how to fault trace sources electrical interference with the AM radio. Electrical interferen
Before deciding to fault trace for AM interference, refer to Service Bulletin 39-0018: AM Radio Reception Diagnosing
Electrical interference causes static noise by inducing a signal that is picked up by the vehicle wiring and transported th
> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Seat Heater Control Module: > 3390025 > Jul > 01 > Radio - Interference/Noise On AM Band > Page 75

Select necessary parts according to diagnostics
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented cus
AM Radio Diagnostics, Interference
1
Information and explanation
Radio noise at 11-6 MPH on AM
S80 Chassis - 049149
See SB 39-0010
General Static/crackling noise (helicopter noise) S80 Chassis - 116810
UEM processor sound being heard in the audio system. UEM has a long ground wire which in some cases can act as an
Static noise - Volvo navigation system (VNS)
V70 Chassis no. 000257-
If a seek lest gives the same number of clearly audible AM stations but a "static" sound is heard while using the Volvo
Intermittent pulsing, buzzing sound with seat heater
on
S80 Chassis no 029668-147860
V70 Chassis no 000257-026213 Torslanda

V70 Chassis no -028000 Gent
V70XC Chassis no -000907
A pulsing, buzzing noise may be heard from the radio on AM frequency if seat heater is activated. As a service solution
AM static due to insufficient rear seat ground
Install the ground lead see step 11-17.
Ticking radio interference sounds of approximately one second interval might appear on the AM band due to insufficie

the back seat. This radio interference could be reduced if the framework of the seat back is given an improved groundin
Replacing the interior light housing (Chassis no. see step 1, "Information and explanation")
Interior light housing, replacing
Replacing the interior light housing, see VADIS
Repair and Installation
Function group 35
Courtesy lighting and the upper electronic module.
Install the:
- ground wire (1) from the service kit to the new interior light housing
- new interior light housing in the car
Note
Make sure that the ground wire does not get pinched between the clip and the ceiling (see arrows)
Install grounded shield on VNS connector and wiring (Chassis no., see step 1, "Information and explanation")
Grounded shield, installing
Remove the:
- rear left panel cover and the cargo compartment left panel, see VADIS
Repair and Installation Function group 85

Cargo compartment side panel cover and the side panel in the cargo compartment
- connector (1)
- screw (2).
Assemble the shield.
5
Install the shield on the connector.

Install the:
- connector (3) to the VNS unit
- ground wire (1) with screw (2). Adjust the shield
- front left panel.
Note!
Ensure that the shield is pushed up against the VNS unit when installed to minimize interference.
Install adapter cable on front seats (Chassis no, see step 1, "Information and explanation")
7
Adapter cable, installing
Preparations
Move the seat to the rear-most position.
Raise the front of the seal to the upper-most position
Remove the key from the ignition switch.
Disconnecting the connector (power adjustable seats)


Disconnect the seat heater wiring plug (1) from its socket.
Installing the adapter wiring (power adjustable seats)
Plug the:
- adapter wire into the socket at the bracket (2)
- seat heater wiring plug into the adapter socket (1).
10

Secure the wiring and resistor with tie straps 11). Check that wiring and connectors are not in contact with any other co
Install the rear seat ground lead (Chassis no, see step 1, "Information and explanation")
11
Removing the battery negative terminal
Disconnect the battery negative terminal, see VADIS:
Repair and installation
Function group 31
Replacing the battery.
12
Removing the left-hand side cushion

Fold the backrest cushion for the rear seat forward. Grip the side cushion as close to the upper mounting as possible.

Pull the cushion until it releases. Lift the cushion up out of the lower mounting.
13
Removing the left-hand side backrest cushion
Fold the backrest cushion up.
Disconnect the connector for the seat belt tensioner by the outer mounting for the backrest.
Detach the half moon clip and ring holding the seat belt buckle in place.
Remove the screw holding the backrest cushion. Detach the backrest cushion. Position the backrest cushion in the door
14
Exposing the back panel
Remove the:
- five half moon clips from underneath the cushion
- guide for the inner mounting for the cushion. Undo the tie strap at the inner edge of the backrest upholstery.
Push the upholstery and padding to one side to access the clip holding the wire for the seat belt tensioner.
Disconnect the wire from the clip.
15
Installing the ground lead in the back panel


Drill a 5 mm hole in the plate between the clamp for the backrest mounting and the clip for the wire for the seat belt ten
Position the hole approximately 15 mm (0.6 ) from the clip.
Remove any burs.
Install the:
- ground lead using screw p/n 958244. Route the ground lead along the existing wire through the backrest upholstery
- cable for the seat belt tensioner in the clip.
16
Installing the backrest cushion
Push the padding and upholstery back into position. Pull the tie strap closed at the inner edge of the backrest upholstery
Install the:
- guide for the inner mounting for the cushion
- inner half moon clip and ring for the strap for the seat belt
- remaining half moon clips

- backrest (1). Tighten to 48 Nm (35 lbf.ft).
Connect the seat belt tensioner connector.
Install the strap for the seat belt buckle.

17
Connecting the ground terminal
Fold up the insulation panel under the rear seat.
Remove the rear ground terminal 31/47.
Install the ground lead together with the removed wiring using a new screw from the kit. Tighten the screw.
Tighten to 10 Nm (7 lbf.ft).
Fold the:
- insulation back into place
- rear seat back into position.
Install the battery negative terminal, see VADIS:
Repair and installation Function group 31 Replacing the battery.
Discard the excess material from the kit.

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
3390025 > Jul > 01 > Radio - Interference/Noise On AM Band
Radio - Interference/Noise On AM Band
V70/XC70 2001- S80 1999-
Section
3
Group
39
No.0025
Year
01
Month
07
Reference:This service bulletin replaces the previous service bulletin SB 390025 from February 2001, which should be
Purpose:Additional source of electrical interference, V70 rear seat ground, is added.
AM Radio diagnostics, interference
Background
This Service Bulletin explains how to fault trace sources electrical interference with the AM radio. Electrical interferen
Before deciding to fault trace for AM interference, refer to Service Bulletin 39-0018: AM Radio Reception Diagnosing
Electrical interference causes static noise by inducing a signal that is picked up by the vehicle wiring and transported th
> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Seat Heater Control Module: > 3390025 > Jul > 01 > Radio - Interference/Noise On AM Band > Page 89

Select necessary parts according to diagnostics
AM Radio Diagnostics, Interference
1
Information and explanation
Radio noise at 11-6 MPH on AM
S80 Chassis - 049149
See SB 39-0010
General Static/crackling noise (helicopter noise) S80 Chassis - 116810
UEM processor sound being heard in the audio system. UEM has a long ground wire which in some cases can act as an
Static noise - Volvo navigation system (VNS)
V70 Chassis no. 000257-
If a seek lest gives the same number of clearly audible AM stations but a "static" sound is heard while using the Volvo
Intermittent pulsing, buzzing sound with seat heater
on
S80 Chassis no 029668-147860
V70 Chassis no 000257-026213 Torslanda

V70 Chassis no -028000 Gent
V70XC Chassis no -000907
A pulsing, buzzing noise may be heard from the radio on AM frequency if seat heater is activated. As a service solution
AM static due to insufficient rear seat ground
Install the ground lead see step 11-17.
Ticking radio interference sounds of approximately one second interval might appear on the AM band due to insufficie

the back seat. This radio interference could be reduced if the framework of the seat back is given an improved groundin
Replacing the interior light housing (Chassis no. see step 1, "Information and explanation")
Interior light housing, replacing
Replacing the interior light housing, see VADIS
Repair and Installation
Function group 35
Courtesy lighting and the upper electronic module.
Install the:
- ground wire (1) from the service kit to the new interior light housing
- new interior light housing in the car
Note
Make sure that the ground wire does not get pinched between the clip and the ceiling (see arrows)
Install grounded shield on VNS connector and wiring (Chassis no., see step 1, "Information and explanation")
Grounded shield, installing
Remove the:
- rear left panel cover and the cargo compartment left panel, see VADIS
Repair and Installation Function group 85

Cargo compartment side panel cover and the side panel in the cargo compartment
- connector (1)
- screw (2).
Assemble the shield.
5
Install the shield on the connector.

Install the:
- connector (3) to the VNS unit
- ground wire (1) with screw (2). Adjust the shield
- front left panel.
Note!
Ensure that the shield is pushed up against the VNS unit when installed to minimize interference.
Install adapter cable on front seats (Chassis no, see step 1, "Information and explanation")
7
Adapter cable, installing
Preparations
Move the seat to the rear-most position.
Raise the front of the seal to the upper-most position
Remove the key from the ignition switch.
Disconnecting the connector (power adjustable seats)


Disconnect the seat heater wiring plug (1) from its socket.
Installing the adapter wiring (power adjustable seats)
Plug the:
- adapter wire into the socket at the bracket (2)
- seat heater wiring plug into the adapter socket (1).
10

Secure the wiring and resistor with tie straps 11). Check that wiring and connectors are not in contact with any other co
Install the rear seat ground lead (Chassis no, see step 1, "Information and explanation")
11
Removing the battery negative terminal
Disconnect the battery negative terminal, see VADIS:
Repair and installation
Function group 31
Replacing the battery.
12
Removing the left-hand side cushion

Fold the backrest cushion for the rear seat forward. Grip the side cushion as close to the upper mounting as possible.

Pull the cushion until it releases. Lift the cushion up out of the lower mounting.
13
Removing the left-hand side backrest cushion
Fold the backrest cushion up.
Disconnect the connector for the seat belt tensioner by the outer mounting for the backrest.
Detach the half moon clip and ring holding the seat belt buckle in place.
Remove the screw holding the backrest cushion. Detach the backrest cushion. Position the backrest cushion in the door
14
Exposing the back panel
Remove the:
- five half moon clips from underneath the cushion
- guide for the inner mounting for the cushion. Undo the tie strap at the inner edge of the backrest upholstery.
Push the upholstery and padding to one side to access the clip holding the wire for the seat belt tensioner.
Disconnect the wire from the clip.
15
Installing the ground lead in the back panel


Drill a 5 mm hole in the plate between the clamp for the backrest mounting and the clip for the wire for the seat belt ten
Position the hole approximately 15 mm (0.6 ) from the clip.
Remove any burs.
Install the:
- ground lead using screw p/n 958244. Route the ground lead along the existing wire through the backrest upholstery
- cable for the seat belt tensioner in the clip.
16
Installing the backrest cushion
Push the padding and upholstery back into position. Pull the tie strap closed at the inner edge of the backrest upholstery
Install the:
- guide for the inner mounting for the cushion
- inner half moon clip and ring for the strap for the seat belt
- remaining half moon clips

- backrest (1). Tighten to 48 Nm (35 lbf.ft).
Connect the seat belt tensioner connector.
Install the strap for the seat belt buckle.

17
Connecting the ground terminal
Fold up the insulation panel under the rear seat.
Remove the rear ground terminal 31/47.
Install the ground lead together with the removed wiring using a new screw from the kit. Tighten the screw.
Tighten to 10 Nm (7 lbf.ft).
Fold the:
- insulation back into place
- rear seat back into position.
Install the battery negative terminal, see VADIS:
Repair and installation Function group 31 Replacing the battery.
Discard the excess material from the kit.

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations
Seat Heater Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations > Page 101

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications
ABS Main Relay: Specifications

SPECIFICATIONS
Resistance between terminals 3-12 ............................................................................................................................
Resistance between terminals 10-13 ..........................................................................................................................
> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 109
ABS Main Relay: Description and Operation
The combination relay is by the control module. It has two relay circuits, both controlled by the control module. The co
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Electrical Specifications
Electronic Brake Control Module: Electrical Specifications

SPECIFICATIONS
Power supply ....................................................................................................................................................................
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Electrical Specifications > Page
Electronic Brake Control Module: Mechanical Specifications

TIGHTENING SPECIFICATIONS
Mounting bolts .................................................................................................................................................................
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructio
Electronic Brake Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 117

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 126
Electronic Brake Control Module: Service Precautions

CAUTION: 80 C The control module must not be heated to above . Remove control module when stoving for exampl
NOTE: Always switch off the ignition before connecting or disconnecting a connector or the test box to a control mod
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, Replacem
Electronic Brake Control Module: Service and RepairControl Module, Replacement [MMMM]
MMMM. Control module, replacement
[MMMM1]
Preparations
- Ignition off.- Remove air filter casing and hose to air heater.
[MMMM2]
Removing control module
Clean around the connections.
Remove:
- The connection to the control module by first pressing in the catch on the back of the cover (toward wheel housing)
[MMMM3]
Checking the control module

Check that the control module is of the correct type, depending on whether the car is fitted with TRACS or not.Chec
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Control
Module, Replacement [MMMM] > Page 129

[MMMM4]
Installing control module
Center the control module relative to the hydraulic unit valves before pushing them into place.
1.8 Nm (1.3 ft lb)- Install control module and tighten bolts to .
Connect:
- Pump motor and control module connectors.- Air filter casing and hose to air heater.
[MMMM5]
Function check
- Read out any DTCs which are posted in the control module and replace them.- Switch off Volvo ST.
Check that ABS warning light stops flashing.
- Test drive the car.
Check that no new DTCs are posted.
Warning!
The ABS and EBD systems are not available while Volvo Diagnostics is activated. Take great care when t
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, Replacem
Electronic Brake Control Module: Service and RepairRepair/Replacement Of Control Module Connector [NNN
NNNN. Repair/replacement of control module connector
NNNNA. Repair/replacement of control module connector
[NNNNA1]
Repair/replacement of connector as per general instructions.
It is important that the leads are connected correctly after repair/replacement of the connection Check therefore the le
Carry out as follows
NNNNB. Table for connection from the connector to the control module- Ignition off- Connect adapter 951 135


> Relays and Modules > Relays and Modules - Brakes and Traction Control > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram Information and Instructions
Voltage Protection Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 163

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions
Cruise Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
183

1/1 Battery

2/2 Fog lamp relay

184

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
185

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

186

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

187


11A/1-9 Main fuses

188

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

189



190

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

191

C70 all

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192
Cruise Control Module: Connector Views
1B
Power supply Control module power supply.
3B
Ground Control module ground connection
4B
Diagnostics Binary signals that can be both input and output
6B
Stop (Brake) light
Battery power when brake pedal is depressed. When brake pedal is up the connection should be grounded via the
7B
Vacuum pump
Activated when system is being controlled and speed is to be increased. Non-continuous ground with the frequen
8B
Speed signal
Signal originates at the speedometer in the form of a sine wave. Transformed in the speedometer to a square wav
9B
Regulator
Activated constantly when the system is active and the speed is to be increased or held constant. When speed is to
3E
Park/Neutral position switch
Body ground through starter when gear selector is in the N or P position in a car equipped with automatic transm
4E
SET+ Battery power when switch is in the SET+ position.
6E
RESUME Battery power when selector switch is in RESUME position.
7E
Power supply to vacuum pump and regulator
A relay in the control module feeds battery power to the vacuum pump and regulator. The relay is operated when
8E
SET- Battery power when switch is in the SET- position.
9E
Brake and clutch valve Battery power when selector switch is set to ON or RESUME and brake and clutch peda
> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 193
Cruise Control Module: Service and Repair
Replacing control module
Removing
- Ignition off.
- Remove central electrical unit cover in engine compartment.
- Remove cruise control control module.
Installing
Reinstall in reverse order.Check function.

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Relay > Component Information > Locations
Cruise Control Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Relay > Component Information > Locations > Page 197

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations
Condenser Fan Motor Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 205

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > A/C - Service Manual Update
Control Module HVAC: Technical Service BulletinsA/C - Service Manual Update
S70/V70/C701998-
Section:8
Group:87
No.:0013
Year:99
Month:09
Reference: This Service Bulletin supplements Service Manual: Climate control, Section 8(87), S70/V70/C70, 1997-, T
Supplement to service manual 8(87)
Background:
This service bulletin is a supplement to existing information. As a running introduction in production during August 19
The new control module replaces the earlier version and can be installed in both older and newer cars.
- The sun sensor sensitivity cannot be programmed on the older control modules shown.
Customer reported symptoms

The Table shown of Symptoms supplements that found in the Service Manual, WW. Fault symptom WWB table.
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > A/C - Service Manual Update >
Page 213

Checking the sun sensor programming
Fault-tracing information
Condition
- No diagnostic trouble codes (DTCs) stored.
- The fault is permanent.
Possible source
- The sun sensor sensitivity in the ECC control module is programmed too high or too low.
Fault symptom(s)
- The passenger compartment temperature does not correspond to the set value.
- The passenger compartment temperature is not reduced when sun intensity is high.
- Airflow may vary.
Programming ECC solar sensor
Check the programming of the ECC sun sensor sensitivity
Note!
The intensity of the sun affects the temperature in the passenger compartment. To maintain an even temperature in
The higher the value, the more the control module compensates for the intensity of the sun. However if compensatio
The lower the value, the less the control module compensates for the intensity of the sun. However, low compensat
- Ignition on.
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > A/C - Service Manual Update >
Page 214

- Use the Programming function to read off and program the ECC control module.
Read off the sun sensor programming. Make a note of the value. Program as required. Programmable compensation is:
Then continue with:
^ Operation done
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions
Control Module HVAC: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 217

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 226
Control Module HVAC: Description and Operation
Communication and Programming With ECC Control Module
The air conditioning system's control module is connected to the diagnostic test point, and its diagnostics conform to
Error Indication
20 seconds
20 seconds
If a fault develops on the air conditioning system the orange-colored light-emitting diodes for the A/C and recirculati
Self-Adjustment
Viadamper
If the the diagnostic testa point,
motors on by means
new control of the
module Volvo
have not System Tester.
been self-adjusted, or if programming has changed the green
- 30 km/hr (19 mph) 15 secondsDriving the car above for at least and charging the generator (D+ signal high).
NOTE: It the green A/C diode is not flashing self-adjustment can only be carried out using the Volvo System Tester
During self-adjustment the green light-emitting diode for the A/C flashes.If self-adjustment fails an error code is stor
Normal function of the fan.
-TheThe
control module
readings automatically
from checks
the sensor and the signals
control following
are components following
within acceptable self-adjustment:-
limits.
Reading Error Codes; Erasing Error Codes

The Volvo System Tester is used to read error codes, counters, rolling values and to erase error codes, via diagnostic
The control module can be programmed for different chassis and equipment, allowing one and the same control module
Programming is carried out via the diagnostic test point using the Volvo System Tester.
The control module can be programmed with the following parameters:

- If the car is left or right-hand drive.
- Type of engine, petrol or diesel.
- If the air conditioning system's air intake has a dust filter.
- Adjustment for the temperature inside the car in relation to the temperature controls.
- Adjustment for the blower motor speed in relation to the position of the fan controls.
NOTE
: A new control module must always be programmed for left or right-hand drive before it will work. Damper motors
If a used control module is fitted programming for left or right-hand drive must be checked to ensure that it correspond
New control modules are set up for petrol engines with no dust filter. Re-program these parameters if they do not corre
Before the control module is programmed the two green indicating diodes will flash. If the A/C is off and recirculation
Control Module HVAC: Testing and Inspection
Connector Pin Out:
Contactor A
Contactor C
Control Module HVAC: Adjustments
KKA1 General on programming
The ECC control module can be programmed with certain information. The purpose of the programming is to adjust th
KKA2Then continue with:
KKA2 Programming driver position (LHD or RHD)

NOTE!
In order for a new ECC control module to operate the control module must be programmed for driver position (LHD o
After programming in the driver position the green LED in the AC button will flash and continue to do so until the auto
- Ignition on.
- left-hand drive right-hand driveUse the Programming function to read out and program the ECC control modu

If the control module was not previously programmed no data can be read off.
Read off the driver position. Make a note of the reading. If the programming is not correct, program in the correct versi
Yes:
KKA3No: Any further programming to do? Go to Operation done
KKA3 Programming the engine type
NOTE!
This programming sequence allows the ECC control module to adapt the control module and the climate control syste
- Ignition on.
-
Use the Programming function to read off and program the ECC control module. Programmable data is: gasoline
Read off the engine type. Make a note of the reading. If the programming is not correct, program in the correct version.
Yes:
KKA4 Programming passenger compartment ventilation filter

NOTE!
If the car has a passenger compartment ventilation filter the control module must be programmed with this informatio
- Remove the cover panel over the blower fan air intake to determine if the car has a passenger compartment ventil
- Ignition on.
- with without
Use the Programming function to read off and program the ECC control module. Programmable data is: or pass
Read off if a passenger compartment ventilation filter is programmed. Make a note of the reading. If the programming
Yes:
KKA5 Programming the passenger compartment temperature

NOTE!
2 C (3.6 F)
The relation between the temperature in the passenger compartment and the temperature setting on the selector knob c
- Ignition on.
-
between 2 C ( 3.6) in 0.5 C (0.9 F) steps Use the Programming function to read off and program the ECC contr
Read off the passenger compartment temperature programming. Make a note of the reading. Program as necessary.
Yes:
KKA6 Programming the blower fan speed

NOTE!
8 liters/second (17.8 cubic.ft/min)
The blower fan's speed control (air flow) when the blower fan speed selector switch is in AUTO position can be repro
- Ignition on.
-
between 8 l/s ( 17.8cubic.ft/min) in 4 l/s (8.9 cubic.ft/min) steps. Use the Programming function to read oft an
Read off blower fan speed programming. Make a note of the reading. Program as necessary.
Then operation is done.

Control Module HVAC: Service and Repair
ECC control module replacement
TTTA1 Preparations
NOTE!
Before replacing a control module the programmed data must be read off first. The information will then be download
TTTA2 Removing the ECC control module

- Ignition off.
- Remove radio if installed.
- Insert hand through radio compartment opening and remove the ECC control module by pressing it out from beh
- Disconnect both of the ECC control module connectors.
TTTA3 Check
- Check that control module connectors are OK.
TTTA4 Installing the ECC control module

- In reverse order.
TTTA5 Supplementary operations

- Program in the information that was read off the old control module.
- After programming it is necessary to carry out self adjustment of the system motors.
- (DTC)Check no diagnostic trouble code was stored during repairs.
> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations
System Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 238

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations
Fuses
> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Page 246

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations
Fog/Driving Lamp Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 254

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations
Headlamp Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 261

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 269

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations
Relay Box: Locations
Fuses
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 276

Panel Locations

Relays

Panel Locations

Other Relays
Relay Box: Application and ID
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Loca
Engine Control Module: Component Locations
The ECM is located in the control module box, next to the Transmission Control Module (TCM).
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Loca
291
Engine Control Module: Ground Locations
Control Module Ground Point
The control module ground leads are connected to a common ground terminal (31/71) in the engine compartment
The power ground and signal ground are connected to the same terminal.
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diag
Instructions
Engine Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 294

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Engine Control Module: Connector Views
A1-A9

A10-A23

A24-A35

A36-A43

B1-B8

B9-B24

B25-B38

B39-B43
Connector A
Connector B
Engine Control Module: Description and Operation

SYSTEM OVERVIEW
The Motronic 4.4 is an Electronic Fuel / Ignition Engine Management System which controls:
FC
EVAP
PAIR^ Fuel Injection^ Ignition^ Engine Idle Speed^ Engine Cooling Fan ()^ Evaporative Emission () System^ A
ECM
The Engine Control Module () incorporates microprocessor which receives signals from the various sensors in the ca
The Engine Control Module incorporates adaptive functions, which enable it to adjust its computations continuously
Efficient engine management maintains low exhaust emissions. Since CO content and idling speed do not require ad
Substitute values can be adopted for:
ECT
TP
HO2S
MAF- Engine Coolant Temperature () Sensor- Throttle Position () Sensor- Heated Oxygen Sensors ()- Mass Air
DTCs
ST DLCFaults are recorded in the Engine Control Module memory in the form of Diagnostic Trouble Codes (). Info
The Engine Control Module is housed in a ventilated box in the engine compartment.
OBD SIGNALS
INPUT
TWC
The Engine Control Module also incorporates an On-Board Diagnostic () function. Signals from sensors, and the ope
Information > Diagrams > Page 312

The Engine Control Module receives signals describing running conditions from the following components:
RPM
CMP
MAF
ECT
TP
HO2S
HO2S
KS
TCM
TCM
MIL TCM
Pressostat
PAIR
^ Engine speed and crankshaft position, from the Engine Speed () Sensor at the flywheel (7/25)^ Working cycle
CONTROL FUNCTIONS
The Engine Control Module controls the following components and functions on the basis of these input signa
^ Main relay (2/32)^ Fuel pump, by activating the Fuel Pump Relay (2/23)^ Fuel injection, by operating the Inj

IDM
IAC
IAC
FC
CP
MIL
HO2S
PAIR PAIR^ Ignition, by transmitting signals to the Ignition Discharge Module () integrated with the Ignition C
OTHER OUTPUT SIGNALS
The Engine Control Module also transmits signals to the following components:
TCM
TCM
TCM
RPM
ECT
^ Acknowledgment of torque limiting through timing retardation, to the Automatic Transmission Control Modul
Engine Control Module: Service and Repair
Points To Observe When Replacing Engine Control Module

- (ECM) (DTCs)
When changing an engine control module from one car to another, remember to note any diagnostic trouble code
-
The engine control module must not be removed from the car until the main relay has interrupted the supply. Thi
- Always check the control module and connector on the control module box for bent or damaged pins or sockets.
Removing Locking Strip

-
As part of the anti-theft system on cars with an immobilizer the control module box in the engine compartment is
- Mark up the center of the screw and drill a suitable hole for a screw puller. Insert screw puller and remove the scr
- Remove the locking strip across the engine control module box cover.
- Clean the engine control module box cover carefully so that no dirt or swarf falls into the box when it is opened.

Removing The Engine Control Module
- (IAC)
Check that supply from main relay has been interrupted. Easiest method is to place fingertips on idle air control
- Open engine control module box cover and remove Motronic 4.4 engine control module (module nearest engine)
Installing New Engine Control Module

- Inspect connector pins and sockets for damage.
- Install new engine control module.
- Switch on ignition.
- Read off any diagnostic trouble codes.
- Erase diagnostic trouble codes and reset adaptive functions.
Installing Locking Strip
-
As part of the anti-theft system on cars equipped with an engine immobilizer, the engine control module box in th
CAUTION: Before reinstalling locking strip, make sure that the car has been repaired and no faults persist.
- Locate the slit underneath the engine control module box with your fingers and hook the locking strip into it.

- Fold over the locking strip and tighten the security screw (P/N 1334099-7) so that its head breaks off.
Erasing Diagnostic Trouble Codes And Resetting Adaptive Functions

-
It is important both that diagnostic trouble codes are erased and adaptive functions are reset when the engine cont
Erase diagnostic
^ Diagnostic troubletrouble codes.
codes are erased and adaption reset separately.^
^ Reset adaptive functions.
NOTE:
If using the engine control module from another car, diagnostic trouble codes (if any) must be erased and adapti
Engine Control Module: Tools and Equipment
Volvo ECU Release Key
AST tool# V9995722
Volvo ECU Release Key. Applicable to: V70 XC (01-) / XC70, C70 Coupe, V70 (-00), V70 XC (-00), S80, XC90, V7
- Made in Germany
- Call AST for Pricing
Contact AST for pricing.
Assenmacher Specialty Tools1-800-525-2943

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Inform
Main Relay (Computer/Fuel System): Specifications

MAIN RELAY
Resistance of coil (between terminals 85 and 86)
At 20C (68F) .........................................................................................................................................................

Main Relay (Computer/Fuel System): Locations
Fuses
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) >
Component Information > Specifications > Page 322

Panel Locations

Relays

Panel Locations

Other Relays
Main Relay (Computer/Fuel System): Description and Operation

MAIN RELAY
ECM
FPThe Engine Control Module () activates the main relay (2/32) when the ignition is switched on. At the same time
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Specific
Air Injection Pump Relay: Specifications

PULSED SECONDARY AIR INJECTION PUMP RELAY
Resistance ...................................................................................................................................................................
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Specific
Air Injection Pump Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component
Information > Specifications > Page 332

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specificati
Fuel Pump Relay: Specifications

FUEL PUMP RELAY
Single Stage Electronic Relay
Activation frequency ..................................................................................................................................................

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specificati
Fuel Pump Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams >
Instructions
Fuel Pump Relay: Diagram Information and Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams >
Fuel Pump Relay: Description and Operation
FUEL PUMP CONTROL
one second
The ECM activates the main relay (2/32) when the ignition is switched ON. The fuel pump relay (2/23) is activated s
As the engine is turned by the starter motor, the RPM sensor (7/25) and CMP sensor (7/21) deliver engine speed and
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Inform

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

Fuses
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) >

Panel Locations

Relays

Panel Locations

Other Relays

MAIN RELAY
ECM
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions
Air Bag Control Module: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 372

1/1 Battery

2/2 Fog lamp relay

Page 373

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 374

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 375

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 376


11A/1-9 Main fuses

Page 377

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 378



Page 379

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 380

C70 all

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 381
Air Bag Control Module: Connector Views
SRS Signal Specification
General
All values given below are between the respective terminal in column 1 and terminal 6 (power ground) unless otherw
U= DC voltage in volts (V)
U low = Voltage approximately 0 VU bat = Battery voltage (V)

Terminal 1 - 24
Page 382

Terminal 25 - 49
Page 383

Terminal 50
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 384
Air Bag Control Module: Description and Operation

The Sensor Module Function
The sensor module has twin electronic deceleration sensor elements connected to one microprocessor which calculat
If both results show that parameters have been exceeded, a violent frontal collision is indicated, and the sensor modu
Airbag modules and pyrotechnical seat belt tensioners are activated simultaneously by the sensor module.
The entire SRS system is continuously monitored by the microprocessor in the sensor module. Should a system fault
Air Bag Control Module: Service and Repair
CDC. Replacement Of The SRS Control Unit
Disassembly
CDC1. Preparation
Make a note of any radio code.Ignition off.Disconnect the battery negative lead.
CDC2. Removal of SRS control unit
WARNING! Make sure the battery is disconnected before removing or installing the control unit.
1 screw on the console and hold the console back with the connectors1 cover on the control unit3 screws, Torx 30
CDC3. Removal of connector from the SRS control unit
Remove:
Body and Frame, Interior Trim-Console Panels and covers. See Screws and connectors.
Remove:
Push the button (1) in and move the lock mounting (2) forwardsPull the connector in the direction of arrow (3).

CAUTION!
Avoid touching the contacts on the SRS control unit. There is a risk of an electrostatic discharge which can caus
Assembly
CDC4. Installation of connector to SRS control unit
WARNING! Make sure the battery is disconnected before removing or installing the control unit.
Install:
Push the connector into the control unit in the direction of arrow (1)Secure the connector on the control unit by m
CDC5. Installation of SRS control unit
10 Nm (7.5 ft-lb)Install 3 screws, Torx 30. Torque setting = .
CAUTION!
The screws are self-tapping screws, therefore make sure the screw threads are correctly aligned before the screw
NOTE: Use the removed screws. If replacing screws with new screws, use a type approved for grounding.
CAUTION! It is important to install the control unit securely in the body to ensure that it will work correctly.
The electrical grounding path is through one fixing screw to the grounding strip. It is essential, therefore, that the
Final Work

CDC6. Final check
WARNING! Make sure that nobody is inside the car when connecting the battery.
After installing all the parts, do the following:

Turn the ignition key to position IIConnect the battery negative lead.
NOTE:
3 seconds Check that the SRS warning lamp is not broken by turning the ignition key to position II. The SRS wa
(VADIS) (VST)Check that the SRS warning lamp in the combination instrument does not remain on. If the lamp
> Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Locations
Seat Belt Warning Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Locations > Page 391

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations
Starter Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 399

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions
Starter Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page
405

1/1 Battery

2/2 Fog lamp relay

406

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
407

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

408

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

409


11A/1-9 Main fuses

410

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

411



412

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

413

C70 all

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
LOCATION
The transmission control module (TCM) is located in the control module box in the engine compartment, compar
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 419
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 420
Control Module: Service Precautions
CONNECTING DISCONNECTING CONTROL MODULES

TEMPERATURE
The control module must not be heated to above 30 C. Remove control module when staving for example.
ARC WELDING
REPLACING
Disconnect connector from control modules when arc welding.Remove control module before carrying out any a
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Part and S
Control Module: Application and IDPart and Serial Number
PART AND SERIAL NUMBER

The transmission control module (TCM) part number and serial numbers are stamped on a plate on the unit.
1 Volvo P/N
2 Identification code
3 Part design
4 Serial number
5 Number according to car specification, type code
6 Location. Compartment no. 3 in the control module box

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Part and S
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Page 424
Control Module: Service and Repair
1. Notes and cautions
CAUTION:
- (TCM)
(DTCs)When transferring the Transmission Control Module between different cars be sure to make a note of an
- Turn off the ignition before removing the TCM from the car.
NOTE:
-
Always check the TCM and control module box connector have the required pins and sockets and that these have
- Damaged or loose pins or sockets can cause a malfunction.
2. Removing the TCM

- Ignition OFF
- Open control module box
- Remove the TCM (slot 3 nearest the right fender).
3. Inserting control module TCM
- Check that none of the pins or sockets on the connector are damaged.
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and
ID > Page 425

- Install new TCM.
- Ignition ON.
- Read off any DTCs set and then clear them.
4. Adaptation of the throttle position TP signal

- The TP signal must be adapted whenever a new control module is installed.
- Proceed as follows:
Block all four wheelsStart engine.
NOTE: Apply parking brake and press down hard on the brake pedal with left foot during the entire proc
(AP)
Set gearshift selector to position DFully depress the Accelerator Pedal so the kickdown switch closes.Kee
> Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations
Heated Glass Element Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 430

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions
Power Window Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions >
Page 438

1/1 Battery

2/2 Fog lamp relay

Page 439

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 440

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 441

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 442


11A/1-9 Main fuses

Page 443

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 444



Page 445

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 446

C70 all

> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Wiper Relay: Locations
Fuses
> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 451

Panel Locations

Relays

Panel Locations

Other Relays
> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions
Wiper Relay: Diagram Information and Instructions

> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions >
Page 457

1/1 Battery

2/2 Fog lamp relay

Page 458

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 459

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 460

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 461


11A/1-9 Main fuses

Page 462

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 463



Page 464

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 465

C70 all

> Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
ZZ J. Replacing Hood Catch With Switch
Remove hood catch

Install hood catch
> Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Shock Sensor, Antitheft > Component Information > Service and Repair > Replacing Glass Breakag
Shock Sensor: Service and RepairReplacing Glass Breakage Control Module
ZZF1. Removing Glass Breakage Control Module
Remove:
glove compartment panel and SRS passenger airbag module. glass breakage control module from mounting by pu
Disconnect connectors.
ZZF2. Installing glass breakage control module

In reverse order.
Shock Sensor: Service and RepairReplacing Glass Breakage Sensor
ZZG1. Removing Glass Breakage Sensor
Remove:
glove compartment panel and SRS passenger airbag module. Disconnect connector from glass breakage control m
cut out a piece to remove the glass breakage sensor(2).glass breakage sensor (3).
ZZG2. Installing Glass Breakage Sensor
Install:
glass breakage sensor.Connect connector to glass breakage sensor.loudspeaker grille.glove compartment panel an
Shock Sensor: Service and RepairReplacing Resistive Wire In the Rear Windows (5-Door)
ZZH1. Removing resistive wire

Remove rear side window.
ZZH2. Installing resistive wire

Install rear side window.
Shock Sensor: Service and RepairReplacing Movement Sensor
ZZO1. Removing Movement Sensor
Remove driver's side soundproofing panel Underneath Dashboard.
Fold down carpeting and remove carpet bracket.Remove rear seat air duct.
Disconnect pre-routed 5-pin connector (1).
ZZO2. Installing Movement Sensor

In reverse order.
Program control module according to Programming a new VGLA control module in See: Accessories and Optional Eq
> Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Tow Sensor, Antitheft > Component Information > Service and Repair
Tow Sensor: Service and Repair
ZZN1. Removing Tilt Sensor (5-door)
Fold up floor hatch.Remove cover over spare wheel well.
Disconnect tilt sensor connector.Remove tilt sensor from bracket.
ZZN2. Installing Tilt Sensor (5-door)

In reverse order.
> Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Description and Operation
Ultrasonic Sensor: Description and Operation
Identifying Alarm Components
Ultrasonic sensors can be identified by two small microphones at the top of each B-post.
> Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Description and Operation > Page 484
Ultrasonic Sensor: Service and Repair
ZZR1. Removing Ultrasonic Sensor
Remove cover with sensor from B-post.Disconnect switch.
ZZR2. Installing Ultrasonic Sensor

In reverse order.
> Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Switch > Component Information > Diagrams > Diagram Information and Instructions
Fuel Door Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
490

1/1 Battery

2/2 Fog lamp relay

491

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
492

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

493

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

494


11A/1-9 Main fuses

495

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

496



497

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

498

C70 all

> Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Switch > Component Information > Diagrams > Page 499
Fuel Door Switch: Service and Repair
ED2 Replacing Fuel Tank Filler Cover/Trunk Lid Switch in Door Panel (Driver's Door Only):
- Ignition off.
- Remove door panel. See: Body and Frame/Doors, Hood and Trunk/Doors
- Remove switch from panel.
- Disconnect switch connector.
- Replace switch.
- Test switch function.
Assemble in reverse order.

> Sensors and Switches > Sensors and Switches - Body and Frame > Heated Mirror Switch > Component Information > Service and Repair
Heated Mirror Switch: Service and Repair
EB1 Removing Dash Board/Tunnel Compartment Switches:
- Ignition off.
-
Carefully insert a screwdriver or weatherstrip tool between the panel and the top of the rocker switch. Carefully p
CAUTION: Put something between the screwdriver and the surrounding panel so as not to damage it.
- Disconnect connector.
EB2 Installing
- Connect connector. Check that the rocker switch works before installing it in the panel.
- Reinstall rocker switch, press into place in panel.
> Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
ZZ J. Replacing Hood Catch With Switch
Remove hood catch

Install hood catch
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Switch: Diagram Information and Instructions

> Page 511

1/1 Battery

2/2 Fog lamp relay

> Page 512

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 513

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 514

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 515


11A/1-9 Main fuses

> Page 516

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 517



> Page 518

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 519

C70 all

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair
Power Mirror Switch: Service and Repair
ED2 Replacing Mirror Switch in Drivers Door Panel:
- Ignition off.
-
Remove door panel. See: Body and Frame/Doors, Hood and Trunk/DoorsRemove switch from panel.Disconnect
- Replace switch.

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Front Seat - Height Adjuster Knob
Power Seat Switch: Technical Service BulletinsFront Seat - Height Adjuster Knob
Section8
Group85
No.0007
Year99
Month10
S70/V70/V70XC/C701998-1999
Reference: This Service Bulletin replaces Service Bulletin 85-0007 dated August 1999, which should be discarded.
TitleFront seat, height adjuster knob
Background
This Service Bulletin describes how to install the new style height adjuster knob handles for the front seats.
Model Factory Chassis No.
S70 2 -609263
V70 2 -609946
C70 Coupe J -013183
C70 Convertible J -013183
V70 XC 2 -609946
Material
Description Quantity Part No.
Control knob front left 1 9475548
Control knob rear left 1 9475550
Control knob front right 1 9475549
Control knob rear right 1 9475551

Screw M4*6 4 980893
Front seat, height adjuster knob
Removing control knob (front and rear)
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Front Seat - Height
Adjuster Knob > Page 527

Carefully bend out the lock tab on the inside of the knob.
Pull the knob upwards. (See illustration)
Marking and drilling holes
Warning!
When drilling holes, use eye protection.
Mark up where the hole is to be drilled.
+ +A =23.4 0.3 mm (59/64" 0.010") from the upper edge.
+ +B =9.0 0.2 mm (29/64" 0.008") from the side edge.
Position counterhold behind the height adjustment lever so that lever and the plastic cover are not damaged during cent
Carefully center punch before drilling.

Drill holes, 3.5 mm (9/64").
Marking and drilling holes
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Front Seat - Height
Adjuster Knob > Page 528

Warning!
When drilling holes, use eye protection.
Mark up where the hole is to be drilled.
+ +A = 21.7 0.3 mm (55/64 0.010") from the upper edge.
+ +B = 9.1 0.2 mm (29/64" 0.008") from the side edge.
Position counterhold between the height adjustment lever and its cover. A 5 mm (1/4") flat steel bar or equivalent is sug
Position the counterhold in such way that the cover is not damaged during or after drilling.
Carefully center punch before drilling.
Drill holes, 3.5 mm (9/64").
Installing control knob (front and rear)
Install new adjuster knob.
Install 2 new screws (part number 980893).
Tighten to 2.5 Nm (1.8 ft.lb).
Operation No. Labor description Time allowance
85224-2 Replacing seat control knob 0.1hr

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Diagram Information and Instructions
Power Seat Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
531

1/1 Battery

2/2 Fog lamp relay

532

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
533

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

534

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

535


11A/1-9 Main fuses

536

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

537



538

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

539

C70 all

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 540
Power Seat Switch: Service and Repair
Replacing "Backrest Switch":
Preparations:
Make a note of radio code if anti-theft coded radio is installed.
Remove:
- battery negative lead (disconnect).

- seat from the car. See "Replacing Seat Assembly."
- backrest upholstery. See "Backrest Upholstery, Replacement".
- protective pad.
Removing:
NOTE: Check positioning of the switch before removing.
- Cut off cable ties.

- Disconnect the switch from the folding mechanism.
- Replace switch.
- Install in reverse order.
Replacing "Rake Switch":
Removing:
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 541

- Carry out preparations as outlined under backrest switch above (AD B1).
- Fold the backrest forward.
NOTE: Check positioning of the switch before removing.
- Cut off cable ties.

- Detach switch from the seat.
- Replace switch.
- Install in reverse order.
> Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Diagram Information and Instructions
Seat Heater Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 546

1/1 Battery

2/2 Fog lamp relay

Page 547

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 548

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 549

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 550


11A/1-9 Main fuses

Page 551

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 552



Page 553

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 554

C70 all

> Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 555
Seat Heater Switch: Service and Repair
Removing Dash Board/Tunnel Compartment Switches:
- Ignition off.
-
Installing
> Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and Instructions
Sunroof / Moonroof Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 569
Sunroof / Moonroof Switch: Service and Repair
- Ignition off.
-
EB2 Installing
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications
Brake Fluid Level Sensor/Switch: Specifications

Mounting Hardware .........................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instruct
Brake Fluid Level Sensor/Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 576

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 585
Brake Fluid Level Sensor/Switch: Description and Operation
Brake fluid reservoir and level sensor
The brake fluid reservoir is divided into three chambers, two of which are for the brake circuits. One is for the prima
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 586
Brake Fluid Level Sensor/Switch: Service and Repair
DDM1 Replacing Brake Fluid Level Switch:
- Disconnect level switch

- Unscrew cover.
The level switch is in the cover.
- Reinstall in reverse order.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions
Braking Sensor/Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Page 600
Braking Sensor/Switch: Service and Repair
Replacing EBD pressure switch
Preparations
Clean around EBD pressure sensor connection to master cylinder.Put rags under the EBD pressure sensor to protect p
Removing EBD pressure sensor
Disconnect
Ignition off.Jackconnector
front endfrom
of carEBD
up.-pressure sensor.
Protective
Remove: - cap from bleed nipple by LH front wheel.
- Connect hose to drain bottle.
- Open bleed nipple, depress brake pedal and hold it down or lock it in that position.
- Close bleed nipple.
- Remove EBD pressure sensor and plug connector so that no dirt enters the braking system.
Check EBD pressure sensor

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Page 601

TheO-ring
EBD pressure sensor comes with different seals between it and the master cylinder:-
- Captive washer
-
Check
Conical that there is no dirt in the EBD pressure sensor connector.
seal^
Installing new EBD pressure sensor

- 15 Nm (10.3 ft. lbs.)Install EBD pressure sensor.Tighten to .
-
Connect connector to EBD pressure sensor.Release brake pedal.Top up with new brake fluid in the reservoir if re
Finishing
- Connect connector to brake fluid level sensor.
-
Check that there are no leaks.Clean up any brake fluid spillage with lukewarm water and car-wash shampoo.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructio
Parking Brake Warning Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 615
Parking Brake Warning Switch: Service and Repair
Remove center console.
side piece under parking brake lever.

Remove:-
- cover in center console locker.
- screws at front of center console.
Disconnect
Disconnect connectors
parking at the front of the center console.
brake connector:-
- Lift up carefully.
Removeparking
Removing screw holding switch.
brake switch:-
- Disconnect and replace switch.
- Assemble in reverse order.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation
Traction Control Switch: Description and Operation
TRACS switch
The TRACS switch (5) switches TRACS on and off (cars with TRACS only). Once the ignition is switched on, TRA
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation > Page 619
Traction Control Switch: Service and Repair
- Ignition off.
-
EB2 Installing
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS Wheel Sensor - Installa
Wheel Speed Sensor: Technical Service BulletinsABS Wheel Sensor - Installation Tool
No.109
Car Market:U.S. & Canada
Date:FEBRUARY, 1998
Title:NEW TOOL TO INSTALL ABS SENSOR WHEEL
Newer hub kits (such as 271795) do not include ABS pulse or sensor wheels. A new socket has been developed for inst
U.S. retailers will be billed by Volvo Cars of North America, Inc., and Canadian retailers will be billed by Volvo Cana
TOOL PRICE: UNTIL 2-28-98 AFTER 2-28-98

9995694-8 U.S. $43.65 $50.85
(EG-139-98-06)
9995694-8 CANADA $61.11 $71.19

(EG-339-98-06)
9995694-8 SOCKETUsed to install ABS sensor wheel on the hub.

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 624
Wheel Speed Sensor: Specifications
Mounting Bolts 8 ft.lb

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions
Wheel Speed Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 636
Wheel Speed Sensor: Description and Operation
Wheel sensors and pulse wheel
On the front wheels, the pulse wheel is pressed onto the outer driveshaft and the wheel sensor is located in the spindl
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [KKKK]
Wheel Speed Sensor: Service and RepairFront Wheel Sensor [KKKK]
KKKK. Front wheel sensor, replacement
KKKA. Front wheel sensor, replacement
Special tool(s): 115 8147
[KKKKA1]
Preparations
- Ignition off.
- Remove wheel.
[KKKKA2]
Removing sensor
NOTE: Clean sensor and connector carefully before removing them.
- Remove sensor mounting bolt and pull sensor out.

- Remove connector.
[KKKKA3]
Installing sensor
- Clean sensor seat free of dust and rust so sensor ends up in right position relative to pulse wheel.
- Brush any dirt off of pulse wheel. Use a soft brush.
[KKKKA4]
- 10 Nm (7.5 ft lb)Install sensor and tighten bolt to .

- Install connector.
[KKKKA5]
Installing wheel
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [
KKKK] > Page 639

- Check that brake disc and rim contact surfaces are clean
- Grease hub center guide for rim with anti-rust agent 1161038-3.
- Install wheel.
- 110 Nm (80 ft.lb)Install bolts hand tight. Then tighten them in star pattern to . If tightening with nut runner, use t
NOTE: Tightening bolts in star pattern to specific torque settings is important to prevent stresses in the brake disc.
[KKKKA6]
Operational checks
- Read off any DTCs posted in control module and erase them.
- Quit DTM by switching off ignition.
- Test-drive car and check that ABS warning indicator goes out.
- Read off DTCs and check that DTC 1-1-1 appears.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [KKKK] > Page
Wheel Speed Sensor: Service and RepairRear Wheel Sensor, With Integrated Wiring [LLLL]
LLLL. Rear wheel sensor, with integrated wiring, replacement
LLLLA. Rear wheel sensor, with integrated cabling, replacement
[LLLLA1]
Preparations
- Ignition off.- Remove wheel.
4-door cars:
- Fold RH rear seat forwards.- Remove luggage compartment mat.- Remove fuel pump and level sensor covers.
5-door cars:
- Fold up front floor panel and bend mat back.- Remove fuel pump and level sensor covers.
[LLLLA2]
Removing wheel sensor connector
KKKK] > Page 641

- Undo connector 24/19 to wheel sensors and remove leads from opening.- Pull wheel sensor leads through from und
[LLLLA3]
Removing wheel sensors
Note! Clean around sensor carefully before removing it.
- Remove sensor mounting bolt and extract :sensor.- Remove wheel sensor leads.- Remove sensor.
[LLLLA4]
Installing wheel sensors

10 Nm (8 ft lb)- Clean sensor seat free of dirt and rust so sensor ends up in right position relative to pulse wheel.- Br
[LLLLA5]
Installing wheel sensor connector
KKKK] > Page 642

- Run a lead down through hole for level sensor and fuel pump to rear axle.- Attach new connector to lead.
Note! Protect connector from dirt and moisture.
- Pull connector up alongside fuel hoses to the other connector.- Connect connector to wheel sensors. Install leads to
[LLLLA6]
Finishing
- Replace covers on fuel pump and level sensor. Check that seals are intact.- Lay mats back.
[LLLLA7]
Operational checks
KKKK] > Page 643

- Read off any DTCs posted in control module and erase them.- Quit DTM by switching off ignition.- Test drive car,
Wheel Speed Sensor: Service and RepairReplacing Front Wheel Sensor Wiring
Replacing front wheel sensor wiring
The wiring to the front wheel sensor is integrated into the engine compartment wiring. In the past, damage to the whe
Note: The earlier repair kit, P/N 9442120-3, should no longer be used
Replacing wheel sensor cable harness

Raise the car and remove the wheel on the side on which the wiring is to be replaced.
Disconnect cable harness from:
- Wheel sensor
- Brackets on spring strut and in wheel arch.
- Clip on brake pipe
-
Clip in engine compartmentPull up the cable harness in the engine compartment.
The new cable harness should be routed in the same way as the old to avoid damage caused by rubbing.
approximately 20 cmCut off the old cable harness from the cable duct and discard.
KKKK] > Page 645

The routing and attachment of the cable harness varies with model year and variant. The new cable harness is too lon
Strip cable harnesses
Strip the new cable harness and strip the cut cable harnesses in the car. Use cable stripping tool 951 2641-3.
Strip insulation
Strip 25 mm of the outer insulation on the existing cable harness, and 65 mm on the new cable harness.Open the cab
65 and 25 mmBend the cable several times at the score. Pull off the insulation. Check that the stripped sections are
KKKK] > Page 646

Thread the larger piece of heat-shrink tubing onto the new cable harness.
30 mm long. Cut off the two smaller pieces of heat-shrink tubing to Thread them onto the 65 mm long, stripped cab
Strip cable pairs
Strip insulation on the 4 cable ends 13 mm with pliers 951 2620.
Twist cable ends

There may be a thin plastic film residue on the white (tinned) conductor units. Untwist the stripped cable ends a little
Splice the same colored cable ends
KKKK] > Page 647

Position a crimping sleeve in the crimping tool 951 2649, in crimping slot "A" (This is easier on a workbench). Sque
Install crimping sleeve
Place both cable ends (same color) in the crimping sleeve in the crimping tool. Insert cables in crimping sleeve so tha
Note: Insert cables in the crimping tool on the side without text!
Press crimping sleeve tight.Check by hand that crimping sleeve is secure.
Splice the cable pairs

KKKK] > Page 648

When the cable ends are together solder the tops of the conductor units outside the crimping sleeve. This work may o
Install a section of heat-shrink tubing onto the cable splice
Heat the heat-shrink tubing

Foldheat-shrink
The both cable splices
tubing is
asintended
illustrated
to(arrow).
provide Carefully
good electrical
pull the
insulation.Hold
heat-shrink tubing
a putty
over
knife
thebehind
soldered
thecable
heat-shrink
splices.tub
KKKK] > Page 649

Pull the heat-shrink tubing over the cable splices.
Checking ABS system
Ignition
After repairsoff.
are complete it is important to check the ABS system.-
- Connect adapter 951 1354 to control module connector on wiring side (see illustration)
- Connect breakout box. 981 3190 to adapter.
- Control module disconnected.
110 NmHeat with a hot air gun to seal the heat-shrink tubing at both ends. The new, spliced cable harness should be
KKKK] > Page 650

- Take readings described in the table
Wheel Speed Sensor: Service and RepairReplacing Pulse Wheel
Replacing pulse wheel
Special tools:
999 5242
Remove:
- Drive shaft. See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaf
- The pulse wheel by splitting with a screwdriver (A) and tapping off (B).
Clean:
- Clean mating surface for the pulse wheel on the drive shaft using a wire brush.
Install/reconnect:
KKKK] > Page 652

- Apply metal adhesive to the drive shaft mating surface for the pulse wheel.
- New pulse wheel. Carefully tap it into place with tool, 999 5242.
> Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Service and Repair
Coolant Level Sensor: Service and Repair
Replacement Procedure:
- Lift up expansion tank and tip to access its underside.

- Disconnect level switch.
- Pull out and replace engine coolant level switch.
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Inform
Coolant Temperature Sensor/Switch (For Computer): SpecificationsTemperature/Resistance

Temperature/Resistance
Resistance
7300 ohms at 32 deg F

Coolant Temperature Sensor/Switch (For Computer): Locations

ENGINE COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature Sensor is mounted in the thermostat housing.

Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) >
Component Information > Diagrams > Diagram Information and Instructions > Page 664

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Coolant Temperature Sensor/Switch (For Computer): Description and Operation

ECT ECM
The Engine Coolant Temperature () Sensor supplies the Engine Control Module () with a signal describing the tempe
FC
OBD^ Injection period^ Idling speed^ Engine Cooling Fan ()^ Ignition timing^ On-Board Diagnostic () functi
NTC
5 VThe sensor incorporates a temperature-sensitive resistance with a Negative Temperature Coefficient (). The senso
0 V 5 VThe voltage across the sensor is a function of the engine temperature and, therefore, of sensor resistance. Vol
The engine control module (ECM) uses substitute values if the signal from the engine coolant temperature (ECT) sen
The engine coolant temperature (ECT) sensor is mounted in the thermostat housing.
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
JA14 Replacing Engine Coolant Temperature (ECT) Sensor:
- Drain off coolant

- Remove thermostat housing (two TORX 40 screws). Disconnect connector.
- Disconnect terminal pins from connector (see image) in order to thread the wiring through a ring wrench.
- Remove temperature sensor and replace.
- Test sensor.
CAUTION: Do not forget to top up coolant. Then run engine to normal operating temperature and check coolant lev
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Inform
Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions
Brake Switch (Cruise Control): Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 702
Brake Switch (Cruise Control): Description and Operation
Vacuum Valves (pedal valves)
Older Valve The older type of valve is adjusted by turning the threaded piston sleeve in or out to achieve the des
New Valve
A spring-loaded piston activates a microswitch and a vacuum valve. The valve is self-adjusting, using small plast
Identical vacuum valves are located on the pedal assemblies. During adjustment, the pedal is depressed to allow t
When the pedal is depressed, when braking or releasing the clutch, the spring pushes the piston back, breaking th
Stop (brake) Light Switch
The stop light switch is an extra safety device, in case the brake pedal is depressed and the vacuum valve does no
The stop light switch is normally open, but closes when the brake pedal is depressed. The control module is then
Since the control module is grounded through the stop lights, they must be functioning in order for the system to
The stop light switch is located on the pedal assembly at the brake pedal. Newer model years from 1995- have a n
Brake Switch (Cruise Control): Adjustments
Stop (brake) light switch early type
Adjustment
- Pedal jack removed and brake pedal released.

- Undo locknut if not already loose.
- Connect battery negative lead if disconnected.
- Unscrew stop (brake) light switch (from brake pedal) until stop (brake) light lights.
- Screw switch in gently (towards brake pedal) until stop (brake) light goes out again.
- Tighten locknut. Ensure that switch position does not change.
- Check that wiring is not twisted.
- Install soundproofing.
Brake Switch (Cruise Control): Service and Repair
Replacing stop (brake) light switch early type
Note! There are two types of stop (brake) light switch. An early type that requires manual adjustment, and a late
Preparations
- Check that ignition is switched off.

- Disconnect battery ground lead.
- Remove soundproofing.
Removing
- Undo stop (brake) light switch locknut.

- Unscrew stop (brake) light switch.
Installing
- Depress brake pedal 12 mm. Lock the pedal in position with a pedal jack.
- Screw in new stop (brake) light switch.
- Connect the connector.
- Continue with adjustment according to Stop (brake) light switch early type.
Replacing stop (brake) light switch later type
Preparations
- Check that the ignition is switched off.

Removing

- Depress brake pedal and lock it in the depressed position with a pedal jack.
- Press stop (brake) light switch housing forward towards the pedal mounting bracket to release the white locking s
- Pull the white locking sleeve towards the tip of the stop (brake) light switch as far as it will go.
- Push in stop (brake) light switch catches and remove switch.
Check
thatthe
Check thenew
white locking
stop sleeve
(brake) light isswitch
pulledtoout towards the tip of the stop (brake) light switch as far as it will go.
ensure:-
- that the catches are not in contact with the white locking sleeve.
Installing
Note! Brake pedal must be depressed.


- Install stop (brake) light switch. Check location of switch in bracket.
- Press stop (brake) light switch into place. There is a distinct click when the catches engage with the bracket.
- Remove pedal jack.
- Carefully pull up brake pedal to its highest position. The stop (brake) light switch will then adjust itself automatic
- Shake (do not pull) the stop (brake) light switch lightly and check that it is secure.
- Check that the stop (brake) lights is working.
- In cars with automatic transmission and shiftlock, check that shiftlock is working.
- Reinstall soundproofing.
> Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Diagram Information and Instructions
Clutch Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Page 720
Clutch Switch: Description and Operation
Vacuum Valves (pedal valves)
Older Valve The older type of valve is adjusted by turning the threaded piston sleeve in or out to achieve the des
New Valve
A spring-loaded piston activates a microswitch and a vacuum valve. The valve is self-adjusting, using small plast
Identical vacuum valves are located on the pedal assemblies. During adjustment, the pedal is depressed to allow t
When the pedal is depressed, when braking or releasing the clutch, the spring pushes the piston back, breaking th
Clutch Switch: Adjustments
RE. Brake And Clutch Valve, Adjustment
RE1. Adjustment Of Clutch Valve
Ignition off.Disconnect connectors.Disconnect hose couplings so that vacuum servo releases. Valves should be cl
Old Valve Type:
0.5 - 1.0 mm
Play in piston should be .Disconnect vacuum hoses and connector from valve.Test operation and inspect for leaks
New Valve Type:
Press pedal so that it does not make contact with the valve.Pull piston out as far as possible and release pedal slow
Clutch Switch: Service and Repair
RE. Brake And Clutch Valve, Replacement
RE1. Adjustment Of Clutch Valve
Ignition off.Disconnect connectors.Disconnect hose couplings so that vacuum servo releases. Valves should be cl
Old Valve Type:
0.5 - 1.0 mm
Play in piston should be .Disconnect vacuum hoses and connector from valve.Test operation and inspect for leaks
New Valve Type:
Press pedal so that it does not make contact with the valve.Pull piston out as far as possible and release pedal slow
> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions
Cruise Control Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 727

1/1 Battery

2/2 Fog lamp relay

Page 728

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 729

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 730

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 731


11A/1-9 Main fuses

Page 732

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 733



Page 734

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 735

C70 all

> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 736
Cruise Control Switch: Description and Operation
Cruise Control Switch
The cruise control selector switch is on the turn indicator lever. In order to set the desired speed, the selector swit
Adjust the speed of the car to the desired value, press the SET switch and the mise control will be activated. The
A temporary acceleration, such as when overtaking another car, does not affect the function of the cruise control.
To change the speed setting, use the SET switch. Pressing the + or - switch corresponds to about 1 mph of accele
ON Turns on the cruise control.

OFF Turns off the cruise control.
RESUME
Activates
SET Resumes cruise controlspeed.
last programmed and sets programmed speed.
SET- -1 mph Reduces programmed speed,
To return to the last speed setting from the pressing
cruise once
control corresponds
system, to selector
move the . switch to the RESUME settin
SET+ +1 mphIncreases programmed speed, pressing once corresponds to .
> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 737
Cruise Control Switch: Service and Repair
Selector Switch, Replacement
Replacing selector switch
Removing
- Ignition off.
- Remove four mounting screws holding steering column covers.
- Remove both steering column covers.
- Carefully remove switch connector from its holder.
- Remove switch mounting screws and remove switch.
- Disconnect selector switch connector.
Installing
Reinstall in reverse order.Check function
> Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications
Oil Pressure Sender: SpecificationsElectrical Switching

Electrical Switching
Contacts (Closes/grounds Below:)5.8-8.6 psi

> Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 742
Oil Pressure Sender: Locations

Location of components
1. Control module box2. Engine coolant-level-sensor3. Outside temperature sensor4. Engine coolant temperature (EC
Oil Pressure Sender: Description and Operation
40-60 kPa 5.8-8.6 psiThe oil pressure switch is located on the front of the cylinder block and consists of a switch wh
Oil Pressure Sender: Service and Repair
DDO1 Replacing:
The oil pressure switch is located on the bottom edge of the engine between the dip stick and starter motor.
Remove
Carry splash
out work withguard under
the car engine.
raised.-
- Disconnect pressure switch.
- Screw out and replace pressure switch.
> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions
Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 759
Ambient Temperature Sensor / Switch HVAC: Service and Repair
TTTE1 Removing outside temperature sensor (ECC)

- Ignition off.
- Remove glove compartment
- Remove soundproofing panels
- Detach outer temperature sensor by turning it counter-clockwise and then pulling it out.
- Disconnect the sensor connector.
TTTE2 Installing outside temperature sensor (ECC)

- In reverse order.
TTTE3 Finishing
- Check that temperature sensor is operating by reading oft the outer temperature.
- (DTC)Check no diagnostic trouble code was stored during fault-tracing.
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C - Service Manual Update
Cabin Temperature Sensor / Switch: Technical Service BulletinsA/C - Service Manual Update
S70/V70/C701998-
Section:8
Group:87
No.:0013
Year:99
Month:09
Reference: This Service Bulletin supplements Service Manual: Climate control, Section 8(87), S70/V70/C70, 1997-, T
Supplement to service manual 8(87)
Background:
This service bulletin is a supplement to existing information. As a running introduction in production during August 19
The new control module replaces the earlier version and can be installed in both older and newer cars.
- The sun sensor sensitivity cannot be programmed on the older control modules shown.
Customer reported symptoms

The Table shown of Symptoms supplements that found in the Service Manual, WW. Fault symptom WWB table.
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C - Service
Manual Update > Page 764

Checking the sun sensor programming
Fault-tracing information
Condition
- No diagnostic trouble codes (DTCs) stored.
- The fault is permanent.
Possible source
- The sun sensor sensitivity in the ECC control module is programmed too high or too low.
Fault symptom(s)
- The passenger compartment temperature does not correspond to the set value.
- The passenger compartment temperature is not reduced when sun intensity is high.
- Airflow may vary.
Programming ECC solar sensor
Check the programming of the ECC sun sensor sensitivity
Note!
The intensity of the sun affects the temperature in the passenger compartment. To maintain an even temperature in
The higher the value, the more the control module compensates for the intensity of the sun. However if compensatio
The lower the value, the less the control module compensates for the intensity of the sun. However, low compensat
- Ignition on.
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C - Service
Manual Update > Page 765

- Use the Programming function to read off and program the ECC control module.
Read off the sun sensor programming. Make a note of the value. Program as required. Programmable compensation is:
Then continue with:
^ Operation done
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 766
Cabin Temperature Sensor / Switch: Specifications
Min. Resistance Max. Resistance
197.7 K ohms at -40 deg F 216.7 K ohms at -40 deg F
42.3 K ohms at 14 deg F 44.9 K ohms at 14 deg F
9.7 K ohms at 77 deg F 10. K ohms at 77 deg F

> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions
Cabin Temperature Sensor / Switch: Diagram Information and Instructions

> Page 769

1/1 Battery

2/2 Fog lamp relay

> Page 770

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 771

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 772

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 773


11A/1-9 Main fuses

> Page 774

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 775



> Page 776

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 777

C70 all

> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 778
Cabin Temperature Sensor / Switch: Service and Repair
TTTC1 Removing passenger compartment temperature sensor (ECC)

- Ignition off.
- Remove radio if installed.
- Insert hand through radio compartment opening and detach the ECC control module by pressing it out from behin
-
Insert hand through control module opening and detach the switch next to the passenger compartment temperatur
TTTC2
-
Insert hand through control module opening and the passenger compartment temperature sensor by pressing toge
NOTE! Note how the temperature sensor was positioned before removing it.
- Disconnect passenger compartment temperature sensor's connector.

> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 779

TTTC3 Installing passenger compartment temperature sensor (ECC)
- Reconnect passenger compartment temperature sensor connector.
-
Insert hand through control module opening and install passenger compartment temperature sensor. Take care to
NOTE!
This work is made easier by looking in the opening for the switch next to the passenger compartment temperatu
- Install switch next to passenger compartment temperature sensor.
- Install ECC control module.
- Reinstall radio, if any.
TTTC4 Finishing
- Check the fault has been corrected by reading out the passenger compartment temperature.
- (DTC)Check no diagnostic trouble code was stored during fault-tracing.
> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions
Solar Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 784

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 793
Solar Sensor: Service and Repair
TTTD1 Removing solar sensor (ECC)
- Ignition off.
- Remove solar sensor by inserting a weatherstrip tool at sensor side and prying it carefully up.
- Lift up sensor and disconnect connector.
TTTD2 Installing solar sensor (ECC)

- In reverse order.
TTTD3 Finishing
- Check that fault has been corrected by reading off solar intensity. Apply light to the solar sensor so that the value
> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit - Installation
Fuel Gauge Sender: Technical Service BulletinsFuel Sending Unit - Installation
Section2
Group23
No0046
Year00
Month01
850/S70/V70/C70 Coupe'1994-
Reference: This Service Bulletin replaces the previous Service Bulletin 23-0046 from October 1999, which should be d
Fuel sending unit, replacement
Background
This service bulletin describes how to install the new style fuel sending unit. Only the new style sending unit is availab
The new type of sending unit can be installed on S70/V70/C70 vehicles and on the 800 series vehicles from chassis No
850-4 drs Turbo 1, 3 131664-

850-5 dr Turbo 2 037635-
850-4 drs w/o Turbo 1,3 043709-
850-5 drs w/o Turbo 2 048625-
Material Quantity Part No.
Gauge 1 9463238
Sending unit 1 See parts information system
Gasket 1 See parts information system
Replacement of fuel sending unit
Fuel sending unit, replacement Special tools: 999 5486
Preparations Station wagon

> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit -
Installation > Page 799

Raise the front hatch.
Remove the four screws for the hatch.
Pull hatch backward.
Pull away carpeting and fold down rear seat back rest
Sedan
Fold forward right side backrest.
Remove:
-
Trunk carpet, and pull away right side wheel housing panel (On some vehicles the panel is made of hard material an
- Wire and connector attachments. The attachment is secured with two clips over the access cover for the sending uni
- Remove the two access covers for the sending unit and fuel pump.
-
Protective cap covering sending unit retaining nut (if applicable). In some cases it may be necessary to loosen fuel t
Caution!
The fuel tank MUST be supported before the screws for the tank straps are loosened.
Mark up

Before removing old sending unit, place gauge as per illustration.
Place a piece of masking tape on the floor board, under the aim tab.
Make two lines on the tape, using the two slits on the tab as template.
Harness
Separate the connector for the sending unit.
Move the harness from the sender over to the right side of the vehicle.
Attach a string or similar to the connector as per illustration.
Carefully pull over the harness with the connector to the access hole of the sending unit.
Note!
Place the string so that the harness of the new sending unit can be pulled back over again.
4
Remove fuel sending unit

Caution!
Place the retaining nut back on the threaded neck if the new sending unit is not installed immediately. The threaded
Remove the retaining nut with special tool 999 5486.
Carefully pull up the sending unit half way, letting the fuel inside the tube drain out.
Caution!
Ensure so that no fuel spill occurs while lifting the sending unit out of the vehicle.
Remove the sending unit with the gasket.
Install new fuel sending unit
Note!
The mark (arrow) on the sending unit must be pointing within the marks on the tape.
Install new gasket on sending unit.
Lubricate the top surface of the sending unit to avoid twisting white tightening the retaining nut. Use petroleum jelly or
Carefully insert the new sending unit into the tank.
Alignment of the sending unit

Align the sending unit as per illustration.
Install the retaining nut and torque to 30 Nm (22 ft. lbs). Check installation of sending unit with gauge as per illustratio
Route harness
Attach the string to the connector of the sending unit. Carefully pull the harness over to the access hole for the fuel pum

Ensure that the harness is moved back to the left side of vehicle.
Install sending unit connector and mount connectors to the bracket.
Installing removed parts
Install:
- Protective cap over sending unit If applicable.
- Torque screws for fuel tank straps 25Nm (20 ft.lbs) if applicable.
- Cover plates for access holes.
- Harness bracket and connectors.
- Panels and carpeting over spare wheel.
Ensure proper operation of fuel gauge.

38618-2 Fuel sending unit replacement according to SB 23-00460.5 hr
> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit - Installation > Page 80
Fuel Gauge Sender: Technical Service BulletinsFuel Sending Unit - Replacment
Section2
Group23
No.0046
Year99
Month10
850/S70/V70/C70 Coupe1994-
Background
The new type of sending unit can be installed on S70N70/C70 vehicles and on the 800 series vehicles from chassis No.

850 -4 drs Turbo 1,3 131664-
850 -5 drs Turbo 2 037635-
850 -4 drs w/o Turbo 1,3 043709-
850 -5 drs w/o Turbo 2 048625-

Gauge 1 9463238
Fuel sending unit, replacment
Special tools: 999 5486
1
Preparations
Station wagon

Pull away carpeting and fold down rear seat back rest.
Sedan
Remove:
Trunk carpet, and pull away right side wheel housing panel (On some vehicles the panel is made of hard material and m
- Wire and connector attachments. The attachment is secured with two clips over the access cover for the sending unit.
- Protective cap covering sending unit retaining nut (if applicable). In some cases it may be necessary to loosen fuel tan
clamp for filler neck, and reposition tank to remove protective cap.
Caution!
2
Mark up

3
Harness
Note!
4
Caution!
Caution!

5
Note!
Lubricate the top surface of the sending unit to avoid twisting while tightening the retaining nut. Use petroleum jelly or
6

Install the retaining nut and torque to 30 Nm (22 ft. lbs).

Check installation of sending unit with gauge as per illustration.
7
Route harness
Attach the string to the connector of the sending unit.
Carefully pull the harness over to the access hole for the fuel pump.
8
Install:- Protective cap over sending unit If applicable.- Torque screws for fuel tank straps 25 Nm (20 ft.lbs) if applicab

23903-2 Fuel sending unit replacment according 0.5 hr
to SB 23-0046
> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 809
Fuel Gauge Sender: SpecificationsVolume/Resistance (AWD Vehicles)

Volume/Resistance (AWD Vehicles)
Fuel Level Sensor Empty Fuel Tank (0 US Gallons) 322.5 - 332.5 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 5 -15 ohms
Fuel Pump (FP) Unit Sensor Resistance Empty Fuel Tank (0 US Gallons) 157.5 - 162.5 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 2.5 -7.5 ohms
Ejector Sensor Resistance Empty Fuel Tank (0 US Gallons) 165 - 170 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 2.5 - 7.5 ohms
Fuel Gauge Sender: Adjustments
Fuel Level Sensor Not Centered:
JA6 Preparations:
If the level sensor nut is not centered in the hole in the panel, the fuel tank should be slackened off and centered.
JA7 Adjusting Fuel Tank:
- Raise the car.

- Slacken off fuel tank straps and press the tank forward by hand as far as it will go.
- Lower the car.
JA8 Further Adjustment:

-
If the fuel tank needs further adjustment use the shaft of a hammer as a lever between the nut and panel. Take car
- Remove the nut and level sensor. See: Service and Repair
JA9 Tightening Fuel Tank:

- When work on the level sensor is finished tighten the fuel tank straps.
- Raise the car.
- Press the fuel tank forwards so that the level sensor nut is centered in the hole in the panel.
- Tighten the fuel tank.
- Lower the car.
- Reinstall. See: Service and Repair
Fuel Gauge Sender: Service and Repair
NOTE
: There are certain differences when replacing the fuel level sensor in 4-door and 5-door models. Start the procedure fo
DDL1 Removing Hatches and Panels:
- Fold down right rear seat backrest.

- Remove hatches and panels and cargo compartment carpet.
- Remove right wheel arch panel. In variants with a soft panel lift up the corner of the panel.
DDL2 Disconnecting Connector:
- Disconnect fuel level sensor and separate wiring.
DDL3 Removing Covers:

- (FP)Remove covers over fuel level sensor and fuel pump .

- Remove the rear hatch and both side panels.
- Fold up the front hatch, unscrew the two screws on each side, pull the hatch backward and lift up.
- Fold back cargo compartment carpet to the left.
- Disconnect fuel level sensor connector, SB, and separate wiring.

- Remove plastic cover over fuel level sensor cover. Put to one side.
- Remove covers over fuel level sensor and fuel pump (FP).
DDL7 Removing Fuel Level Sensor:

Wrench 999 5486
- Pull fuel level sensor cable out through the hole by the fuel level sensor.
- Remove the plastic fuel level sensor collar. Use tool 999 5486-9.
- Lift up the fuel level sensor.
- Remove gasket.
CAUTION: Reinstall the collar, otherwise the pipe sleeve may swell making the collar hard to reinstall.
DDL8 Installing Fuel Level Sensor:
- Use a new rubber gasket.

- Lubricate the inside and top of the rubber gasket with petroleum jelly.
- Install gasket on fuel tank sleeve.
- Install fuel level sensor with electrical connections along the car.
- 30 Nm (22.1 ft.lb)Tighten nut to .
- Turn fuel level sensor cables to the left and thread them through the hole by the fuel pump (FP).
- Put all cables together in the protective tube. Wind insulating tape around the protective tube.
- Connect fuel level sensor.
- Reinstall covers, hatches and cargo compartment carpet in reverse order. Check that no cables are trapped.
> Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 819

1/1 Battery

2/2 Fog lamp relay

Page 820

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 821

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 822

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 823


11A/1-9 Main fuses

Page 824

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 825



Page 826

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 827

C70 all

> Sensors and Switches > Sensors and Switches - Instrument Panel > Lamp Out Sensor > Component Information > Locations
Lamp Out Sensor: Locations
The bulb failure warning sensor for rear lighting in four door cars is located in the cargo compartment, next to the lef
The bulb failure warning sensor for the rear lighting in a five door cars is located under the left side panel in the carg
> Sensors and Switches > Sensors and Switches - Instrument Panel > Lamp Out Sensor > Component Information > Locations > Page 831
Lamp Out Sensor: Service and Repair
GF1 Removing:
- Ignition off.
- Remove left-hand side panel
- Fold up rear floor hatch.
- Remove bulb failure warning sensor, press it out from the center compartment.
GF2 Installing:
- Connect connector.
- Test bulb failure warning sensor function.
- Install bulb failure warning sensor, press it in from the wheel well. Ensure that the clips engage properly Fold dow
- Reinstall left-hand side cushion.
> Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Specifications
Outside Temperature Display Sensor: SpecificationsTemp./Resistance

Temp./Resistance
Resistance At Temperature

> Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Specifications > Page 835
Outside Temperature Display Sensor: Service and Repair
DDQ1 Replacing:
TheDisconnect
temperaturethe
is sensor from its under
located mounting.
the front bumper. It has a gray connector.-
- Disconnect and replace temperature sensor.
1161417-9Lubricate connector with grease P/N .

> Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 849

Remove:-
Disconnect
brake connector:-
Removeparking
brake switch:-
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation
Brake Light Switch: Description and Operation
Brake light switch
The brake light switch sends a signal to the control module telling it that braking has started, so that the control modu
The brake light switch is powered from the battery. When contact is made, the brake light switch comes on and the c
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 854
Brake Light Switch: Service and Repair
Replacing stop (brake) light switch later type
Preparations
- Check that the ignition is switched off.
Removing
- Depress brake pedal and lock it in the depressed position with a pedal jack.
- Press stop (brake) light switch housing forward towards the pedal mounting bracket to release the white locking s
- Pull the white locking sleeve towards the tip of the stop (brake) light switch as far as it will go.
- Push in stop (brake) light switch catches and remove switch.

Check
thatthe
Check thenew
white locking
stop sleeve
(brake) light isswitch
pulledtoout towards
ensure: - the tip of the stop (brake) light switch as far as it will go.
- that the catches are not in contact with the white locking sleeve.
Installing
Note: Brake pedal must be depressed.

- Install stop (brake) light switch. Check location of switch in bracket.
- Press stop (brake) light switch into place. There is a distinct click when the catches engage with the bracket.

- Remove pedal jack.
- Carefully pull up brake pedal to its highest position. The stop (brake) light switch will then adjust itself automatic
- Shake (do not pull) the stop (brake) light switch lightly and check that it is secure.
- Check that the stop (brake) lights is working.
- In cars with automatic transmission and shift lock, check that shift-lock is working.
- Reinstall soundproofing
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair
Fog/Driving Lamp Switch: Service and Repair
- Ignition off.
-
EB2 Installing
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair
Hazard Warning Switch: Service and Repair
EB1 Removing:
NOTE: The hazard warning signal flasher switch is located under the radio and is replaced in the same way as the o
- Ignition off.
-
EB2 Installing
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Recalls for Headlamp Switch: > NHTSA
04V504000: Headlamp Switch Replacement
Headlamp Switch: RecallsRecall 04V504000: Headlamp Switch Replacement
Make / Models : Model/Build Years: Volvo / C70 1998-2000 Volvo / S70 1998-2000 Vo
COMPONENT: Exterior Lighting: Headlights: Switch
Potential Number Of Units Affected : 97000
SUMMARY: On certain passenger and sport utility vehicles, over an extended period of time, the headlight switch ma
CONSEQUENCE: The head lights may not operate properly which could result in intermittent or no headlight functio
REMEDY: Dealers will replace the headlight switch. The manufacturer has not yet provided an owner notification sch
NOTES: Volvo Recall NO. 142. Customers can also contact The National Highway Traffic Safety Administration's A
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Recalls for Headlamp Switch: > NHTSA
99V235000: Headlamp Switch Malfunction
Headlamp Switch: RecallsRecall 99V235000: Headlamp Switch Malfunction
Vehicle Description: Passenger vehicles. Operation of the headlight switch, over an extended period of time, can result
Dealers will replace the headlight switch.
Owner notification began September 15, 1999. Owners who take their vehicles to an authorized dealer on an agreed up
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head
Oct > 04 > Recall 04V504000: Headlamp Switch Replacement
Headlamp Switch: All Technical Service BulletinsRecall 04V504000: Headlamp Switch Replacement
Make / Models : Model/Build Years: Volvo / C70 1998-2000 Volvo / S70 1998-2000 Vo
COMPONENT: Exterior Lighting: Headlights: Switch
Potential Number Of Units Affected : 97000
SUMMARY: On certain passenger and sport utility vehicles, over an extended period of time, the headlight switch ma
CONSEQUENCE: The head lights may not operate properly which could result in intermittent or no headlight functio
REMEDY: Dealers will replace the headlight switch. The manufacturer has not yet provided an owner notification sch
NOTES: Volvo Recall NO. 142. Customers can also contact The National Highway Traffic Safety Administration's A
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head
Aug > 99 > Recall 99V235000: Headlamp Switch Malfunction
Headlamp Switch: All Technical Service BulletinsRecall 99V235000: Headlamp Switch Malfunction
Vehicle Description: Passenger vehicles. Operation of the headlight switch, over an extended period of time, can result
Dealers will replace the headlight switch.
Owner notification began September 15, 1999. Owners who take their vehicles to an authorized dealer on an agreed up
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Replacing Head Light Switch
Headlamp Switch: Service and RepairReplacing Head Light Switch
Replacing Head Light Switch
Note! See Adapting the light switch to different markets. See: Adapting Headlight Switch to Different Markets
Removal
Remove the switch nearest the light switch according to Replacing dashboard and tunnel compartment switches. See
Position a finger behind the light switch. Press the light switch out.
Release the connector.
Installation
In reverse order.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Replacing Head Light Switch > Page 886
Headlamp Switch: Service and RepairReplacing Dashboard and Tunnel Compartment Switch
Replacing Dashboard and Tunnel Compartment Switches
Removing
Ignition off.
Carefully insert a screwdriver or weatherstrip tool between the panel and the top of the rocker switch. Carefully pry o
Note! Put something between the screwdriver and the surrounding panel so as not to damage it.
Disconnect connector.
Note! The hazard warning signal flasher switch is located under the radio and is replaced in the same way as the othe
Installing
Connect connector. Check that the rocker switch works before installing it in the panel. Reinstall rocker switch, press
Test switch function.

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Replacing Head Light Switch > Page 887
Headlamp Switch: Service and RepairAdapting Headlight Switch to Different Markets
Adapting the Light Switch to Different Markets
- The light switch can be adapted to different markets using the selector.
Position A: Low beam not on when the ignition is switched on
- Press in and turn the selector on the light switch to the required position.
Position B: Low beam on when the ignition is switched on
- Press in and turn the selector on the light switch to the required position.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Lamp Out Sensor > Component Information > Locations
Lamp Out Sensor: Locations
The bulb failure warning sensor for rear lighting in four door cars is located in the cargo compartment, next to the lef
The bulb failure warning sensor for the rear lighting in a five door cars is located under the left side panel in the carg
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Lamp Out Sensor > Component Information > Locations > Page 891
Lamp Out Sensor: Service and Repair
GF1 Removing:
- Ignition off.
- Remove left-hand side panel
- Fold up rear floor hatch.
- Remove bulb failure warning sensor, press it out from the center compartment.
GF2 Installing:
- Connect connector.
- Test bulb failure warning sensor function.
- Install bulb failure warning sensor, press it in from the wheel well. Ensure that the clips engage properly Fold dow
- Reinstall left-hand side cushion.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair
Turn Signal Switch: Service and Repair
EA1 Removing:
- Position the steering wheel straight ahead.

- Ignition off.
steering wheel cover screws.

Remove:-
- steering wheel covers. Push the upper one to one side.
- switch screws.
- Disconnect connector. Replace switch.
EA2 Installing:
CAUTION
: The turn signal switch should be in the neutral position when it is installed. The pin that controls automatic cancel
wiper and/or turn signal indicator switch. Ensure that the ground lead is positioned under the lower mounting scre
Install:-
- steering wheel covers and screws.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > T
> 2332 > May > 98 > Campaign - MAF Connector Loose
Campaign - MAF Connector Loose
GROUP:23
NO:32
ISSUING DEPARTMENT:Warranty
CAR MARKET:U.S. and Canada
DATE:May, 1998
TITLE:
Service Campaign83C (8382754)VOLVO S70/V70/C70Series

REFERENCE BULLETINS:
Service Bulletin 23-0010, Parts Bulletin23-830
MAF WIRING HARNESS
Reposition and secure
BULLETIN REFERENCE
A. SERVICE CAMPAIGN 83C DESCRIPTION
B. VEHICLES INVOLVED
C. RETAILER VEHICLE CAMPAIGN LIST
D. PARTS INFORMATION
E. OWNER NOTIFICATION
F. STOCK VEHICLES
G. RETAILER RESPONSIBILITY
H. CAMPAIGN REIMBURSEMENT PROCEDURES

I. RETAILER ALLOWANCE
A. Service Campaign 83C Description
Volvo Cars of North America, Inc. and Volvo Canada Ltd. have announced a service campaign affecting 1998 Volvo S
There is the possibility normal engine vibration may effect the electrical connection in the cable connector at the mass
All owners of these affected vehicles will by notified by mail the week of June 1, 1998.
B. Vehicles Involved
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component
Information > Technical Service Bulletins > Recalls: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 905

Assy plant 1 Assy plant 2
874 409466-489615 874 408556-489482

875/876 342001 - 434252
Assy plant 3 Assy plant J
874 422325-484420 872 000339-000691

875 356958-428582
Engine variant code: 52, 53, 56
Note:
The chassis numbers above give only an indication of chassis number range affected.
Prior to the release of this Service Campaign, this repair was performed on vehicles within the affected vehicle chassis
NOTE:
RETAILERS MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THIS CAMPAIGN.
Vehicle eligibility should be confirmed:
1) Refer to DCS Vehicle Inquiry
2) Refer to the Vehicle Campaign Listing
C. Retailer Vehicle Campaign List
"A Retailer Vehicle Campaign List" will be sent separately identifying the specific vehicles eligible for this campaign.
A separate listing office vehicles listed in this service campaign is included in this Service Manager Bulletin.
D. Parts Return
Please refer to Parts Bulletin Group: 23 No: 83C Dated May, 1998 There are no parts to return.
E. Owner Notification
During the week of June 1, 1998 an announcement letter will be sent directly to Volvo owners.
F. Stock Vehicles
All vehicles in retailers stock and qualifying for this campaign must be inspected/repaired prior to a customer taking po
G. Retailer Responsibility
Retailers are to perform this campaign on eligible vehicles regardless of mileage/kilometers or vehicle age. The campai
In the event that the original announcement letter is lost or misplaced, the owner is not to be refused this important cam

Specialist will follow up to ensure that this campaign is proceeding smoothly.
H. Campaign Reimbursement Procedures
All claims should be submitted using the short form application. A repair code has been established. The repair code fo
I. Retailer Allowance
Service Campaign 83C

Technical Service Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 912

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Technical Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Air Flow Meter/Sensor: All Technical Service BulletinsMass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Reference: TP 2306202, Section 2(23, 26) Engine management system Motronic 4.4; 850 (B5254T) 1997-
Vehicles involved: Engines with Turbo (engine codes 52, 53, 56)
Service Campaign 83C: Mass Air Flow (MAF) sensor connector
Background:
The MAF wiring harness should be attached and routed according to the information to minimize an open circuit and/o
Model:
M/Y 98 (as indicated by (W) in the VIN)
Volvo S70/V70/C7O Turbo versions.
Material:
Part Part number Quantity
tie strap 948211-8 1
Mass Air Flow (MAF) sensor connector
Change fusebox location

Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring
Harness > Page 918

Slacken off the two nuts holding the fusebox bracket a few turns.
Press the fusebox backward and towards the left side of the car.
Tighten nuts to 25 Nm (18.4 ft. lbs).
Disconnect connector
- Disconnect connector
- Disconnect/connect connector 3 times to remove oxide layer on the mating surface.
- Check that no terminals have been backed out of the connector and they are undamaged.
Lubricate the connector

Check terminals if they are greased.
Add grease only if it is missing.
Use low temperature grease. 0.5 gram/car. Make sure that no dint is introduced with the grease.
Secure the cable harness to the mass air flow (MAF) sensor
Position cable with an 18 mm (23/32") diameter loop (B), so that it is not putting stress on the connector (check with ca
Harness > Page 919

Hold the cable in the position it is to be fixed and check that the cable is not stretched.
If the cable is stretched, position cable on the other side of the turbocharger control valve (TCV) hoses which are under
Install tie strap (A) (P/N 948211-8) as illustrated.
Check
- Check that the clearance between MAF connector and fuse is 3.2 mm (1/8") or more.
- Check that the fresh air intake is properly secured on the turbo charger (TC). If necessary tighten clamp.
Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring
Harness > Page 925


Harness > Page 926

Check
Air Flow Meter/Sensor: Specifications

MASS AIR FLOW SENSOR
Resistance between connectors 1 and 4;

Approx ..................................................................................................................................................................
Air Flow Meter/Sensor: Locations

Mass Air Flow Sensor
The Mass Air Flow Sensor is located between the Air Cleaner cover and the fresh air intake.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > D
Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > D
Air Flow Meter/Sensor: Description and Operation

MAF ECMThe Mass Air Flow () Sensor supplies the Engine Control Module () with a signal describing the intake a
This information is used to calculate:
Injection period
^ Ignition timing^ If the engine coolant fan needs to run-on.
The mass air flow (MAF) sensor consists of a plastic housing containing a connector, electronic circuitry and an alum
0 V 5 VThe mass air flow (MAF) sensor is supplied with battery voltage and has separate power and signal ground p
170C
Since working temperature is relatively high (), and the flow and temperature sensitive resistors are mounted on the s
The engine control module (ECM) will adopt substitute values if the mass air flow (MAF) sensor signal is missing o
ACLThe mass air flow (MAF) sensor is located between the Air Cleaner () cover and the fresh air intake.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information
BA. Atmospheric Pressure Sensor

and Instructions
Barometric Pressure Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Barometric Pressure Sensor: Description and Operation

ATMOSPHERIC PRESSURE SENSOR
ECM
The Atmospheric Pressure Sensor supplies the Engine Control Module () with a signal describing air pressure. It
Atmospheric pressure sensor acts on the control of:
- Boost pressure at high altitude

- Injection time when starting at high altitude.
At heights above 2,400 meters the following are disabled:
- Leak diagnostic
- PAIRPulsed Secondary Air Injection System () diagnostic
- MAFMass Air Flow () Sensor, faulty signal.
The atmospheric pressure sensor contains a piezoelectric crystal in the shape of a diaphragm. One side of this dia
The voltage across the sensor is a function of air pressure and, therefore, of sensor resistance.
0 Volts VoltsVoltage can vary between and .
5 VoltsThe sensor is supplied with a stabilized voltage of from the engine control module (ECM).
If the signal from the atmospheric pressure sensor is faulty or missing the engine control module (ECM) adopts a
The atmospheric pressure sensor is located by the right hood catch.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information >
Camshaft Position Sensor: Locations

CAMSHAFT POSITION SENSOR
Rear of cylinder head, exhaust side cam.

and Instructions
Camshaft Position Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Camshaft Position Sensor: Description and Operation

CMP ECM
RPM
KSThe purpose of the Camshaft Position () Sensor is to supply the Engine Control Module () with information about
The Camshaft Position Sensor consists of the following components:
^ Trigger rotor (1)^ Hall detector (2)^ Cover (3)
12 V
0V
12 VThe trigger rotor rotates at the same speed as the camshaft (4). The engine control module (ECM) supplies the H
Since the camshafts rotate at half the crankshaft speed, the output signal alternates between high and low every secon
The engine control module (ECM) uses the camshaft position (CMP) sensor signal to determine the cylinder in whic
The engine control module (ECM) delivers ignition in cylinders 1 and 3 when the signal is low (0 V) and in cylinder
If the signal from the camshaft position (CMP) sensor to the engine control module (ECM) disappears, the engine ca
The camshaft position (CMP) sensor is located at the rear of the engine, on the exhaust side.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) >
Specifications

Resistance

Specifications > Page 975


> Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (
For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 978

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Page 987

ECT ECM
FC
NTC
> Page 988
- Drain off coolant

- Test sensor.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Spe
Engine Speed Sensor: Specifications

ENGINE SPEED SENSOR
Resisance of coil .........................................................................................................................................................

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Spe
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Dia
Instructions
Engine Speed Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Engine Speed Sensor: Description and Operation

ENGINE SPEED SENSOR
RPM
0.1 V 55 V
ECM
The periphery of the flywheel/carrier plate is provided with a series of holes. As it passes, each hole induces a voltag
At 90 TDC for cylinder 1 there is a longer hole. When this longer gap passes the engine speed (RPM) sensor, voltage
The engine will stop if the signals from the sensor to the engine control module (ECM) cease.
The Engine Speed Sensor consists of the following components:
^ Housing (1)^ Permanent magnet (2)^ Coil (3)

Engine Speed Sensor: Service and Repair
1. Remove:
- Battery
- (ACL)Air Cleaner housing complete with intake pipe.
- Battery shelf Detach:
- ACL bracket.
2. Separation of transmission connector halves

- Remember rubber gasket.
- Detach connector from transmission.
- Remove cable clamps around cable harness and rubber grommet.
- Remove sockets from connector casing.
- Insert screwdriver between casing and socket and press catch in.
Press sockets from casing.
3. Remove socket for rpm sensor cables.
- 2-pin, pins 16 and 17.

4. Removal of sensor
- Clean thoroughly around sensor
- Remove sensor
- Install new sensor
- Rub some Vaseline on sensor O-ring.
- 5.5 Nm.Tighten to:
5. Reconnect connector halves.

- Ensure that rubber seal is in position.
- Install cable clamps round cable harness and rubber seal.
- Reinstall connector on transmission.
- Plug in connector from car Remember rubber seal.
6. Reinstall:
- ACL bracket.
- Battery shelf
- ACL housing with intake pipe and connections
- Battery
7. Checking DTCs
- Using a suitable scan tool, check that DTCs have been cleared.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagra
Instructions
Fuel Level Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information
Fuel Tank Pressure Sensor: Specifications

FUEL TANK PRESSURE SENSOR
Sensor Voltage at Tank Pressure:
1.5 Volts at -2.5 kPa (7.5 in vac)2.5 Volts at 0 pressure4.5 Volts at 2.5 kPa (3.6 psi)
(Only used on certain models)

Fuel Tank Pressure Sensor: Locations

FUEL PUMP AND FUEL TANK PRESSURE SENSOR:
In the fuel tank.

and Instructions
Fuel Tank Pressure Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Fuel Tank Pressure Sensor: Service and Repair

Preparations
5-door models:
- Remove all floor hatches and fold back carpet.
- (FP)Remove cover over fuel pump unit.
4-door models:
- Fold forward rear right back seat.
- Remove luggage compartment carpet.
- Fold back corner of wheel housing panel at shock absorber mounting.
- Remove cover over fuel pump unit.
Disconnecting Connectors
- Disconnect all connectors on the bracket.
- Remove rubber bracket around wiring.
- Remove fuel filler pipe ground lead from nut on fuel tank level sensor cover.
- Ensure that all cables routed through the fuel pump unit hole are free to follow the fuel tank when it is lowered.
Component Information > Diagrams > Page 1036

Removing Fuel Filler Pipe
- Remove circlip securing rubber seal.
- Release rubber seal from bodywork.
Removing Fuel Tank

- Position mobile jack with fixture 999 5972 under fuel tank, check that the lifting platform is flat so as not to dam
- Undo tank retaining straps and lower tank slightly.

Removing Front Bracket
- Remove the entire mounting from the bracket by pulling it towards the right of the car.
- Disconnect the hose between the EVAP canister shut-off valve and air cleaner (ACL) from the clamp on the fuel
Hint: Note position of hose in the clamp in case it opens. The hoses must be reinstalled in their original position
Installing New Fuel Tank Pressure Sensor

- Remove the screw
- Remove clamp
Note! The clamp will be reused.
- Disconnect hose.
- Remove cable harness.
- Install the new pressure sensor, route cabling as before.
SqueezeClamp:
Removing clamp with
- a pipe wrench. Hold in place.
- Pry apart with a small screwdriver.
Press inClamp:
Installing the clamp
- with a pipe wrench until it locks.

Installing Fuel Tank
- Raise the tank so that front holder can be installed to the bracket by pressing it until it locks into place.
- Ensure that cabling routed through the fuel pump unit hole will not be trapped when the fuel tank is installed.
- Raise the fuel tank and fix it to the bodywork.
- Install EVAP canister shut-off valve hose in the clamp on the fuel tank.
Installing Fuel Filler Pipe Rubber Cover

- Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
- Check that circlip (1) is in position.
- Lubricate rubber cover sealing surfaces (2) with petroleum jelly.
- Install rubber cover (ensure that it is correctly positioned in relation to bodywork).
- Install circlip (4) and drain pipe (3).
- Connect all connectors.
Warning! Install fuel filler hose ground cable on level sensor cover.
- Install rubber bracket around wiring.
- Install panels, covers and carpets.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Informa
BC. Outside Temperature Sensor

Intake Air Temperature Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Intake Air Temperature Sensor: Description and Operation

OUTSIDE TEMPERATURE SENSOR
ECMThe outside temperature sensor supplies the Engine Control Module () with a signal describing the outside
-7C (19.4F)This signal is used to disable certain diagnostic functions when the temperature is under .
The following diagnostic functions are disabled:
- Leak diagnostic
- PAIRPulsed Secondary Air Injection () System diagnostic
- Misfire diagnostic
- Boost pressure control diagnostic
NTC
5 Volts
0 Volts 5 VoltsThe sensor incorporates a temperature-sensitive resistance with a Negative Temperature Coefficie
If the signal from the outside temperature sensor is faulty or missing the engine control module (ECM) adopts su
The outside temperature sensor is located under the bumper on the left-hand side.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specificat
Knock Sensor: Specifications

KNOCK SENSOR
Tightening torque .......................................................................................................................................................

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specificat
Knock Sensor: Locations

KNOCK SENSORS
BB. Knock Sensor (KS)
The Knock Sensors are mounted on the cylinder block.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams
Instructions
Knock Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Knock Sensor: Description and Operation
KNOCK SENSORS
KSThe function of the two Knock Sensors () is to supply the ECM with the signals required to determine if the engin
CMPThe ECM uses the KS and Camshaft Position () Sensor signals to identify the cylinder in which knock is presen
The engine management system incorporates two KS, each of which consists of the following components:
^ Housing (1)
^ Sleeve (2)
^ Piezoelectric crystal (3)
^ Contact strips (4)
^ Damping weight (5)
^ Washer (6)
^ Nut (7)
Engine knock produces vibrations which are transmitted through the block. The piezoelectric crystal (3) reacts to the
The front KS detects knock in cylinders 1, 2 and 3, while the rear KS serves cylinders 4 and 5.
The sensors are mounted on the cylinder block.
Knock Sensor: Service and Repair

REPLACING KNOCK SENSOR
Special Tools: 999 5533 (5), 999 5474
Preparations
Battery- negative lead.

Remove:
- Throttle pulley cover.
- Throttle cable.
- Spark plug cover.
- Crankcase ventilation from the cylinder head.
Removing Fuel Rail With Injectors
Fuel rail
Remove: - cover
- Injector connectors
- Fuel line clips (2) and fuel rail mounting screws (2)
- Install the five holders 999 5533 on injectors.
- Remove the clip to the vacuum pipe from the pressure regulator.
- Put a tie strap around delivery line and injector 1 holder to prevent them twisting and leaking fuel.
- Carefully lift up injectors and fuel rail and place on a protective cover on top of engine.
NOTE! Handle injectors carefully to avoid damage to nozzles and needles.

Removing hoses and Connectors
Front charge
Remove: - air pipe.
- ACLAir Cleaner () inlet hose.
- CPCanister Purge () Valve hose at Intake manifold.
- Pipe from pressure regulator and place on top of engine.

- Air duct to control module box.
- PAIRVacuum hose to Pulsed Secondary Air Injection System () Solenoid Valve.
- TCHose to Turbocharger () Control Valve from intake manifold.
- Hose to crankcase ventilation from front edge of intake manifold.
- IAC TPIdle Air Control () Valve and Throttle Position () Sensor connectors.
- Brake system servo hose.
- Injector cable harness clip.
Removing Intake Manifold
Upper -intake manifold screws (3).

Remove:
- Dipstick from intake manifold.
- Lower intake manifold screws.
- Intake manifold support bracket screw.
- Intake manifold by lifting it approx. 20 mm, to release intake manifold from engine.
Removing Knock Sensors
The large
Remove: - hose on the flame trap.
- KSKnock Sensor () connector.
- KSKnock Sensors ().
Installing Knock Sensors

Knock
Install: - sensors (KS) and tighten.
20 Nm (14.76 ft.lb)Tightening torques .
NOTE! 3 o'clock position half-past five position Front knock sensor (KS) must be tightened in the and rear kn
- Knock sensor (KS) connector.

- Flame trap hose.

Installing Intake Manifold
New -gasket with four lower manifold screws.

Install:
- Intake manifold.
Note! Ensure that crankcase ventilation hose is not trapped between cylinder head and intake manifold when tigh
- Three upper intake manifold screws.
20 Nm (14.76 ft.Ib)Tighten all screws to .
- Support bracket.
- Dipstick.
Installing Fuel Rail
Pipe -from pressure regulator.

Install:
- Fuel rail and two fuel line clamps, press clip holding the pipe from the pressure regulator into place.
- New screws and tighten.

- Remove injector holders.
- Injector connectors. Check that each connector is fitted with a rubber seal.
- Fuel rail cover.

Reinstalling Hoses and Connectors
Idle air
Install: - control (IAC) valve and throttle position (TP) sensor connectors.
- Turbocharger (TC) control valve hose to intake mani fold.
- Canister purge (CP) valve hose.
- Vacuum hose to pulsed secondary air injection system (PAIR) solenoid valve.
- Hose for crankcase ventilation to intake manifold.
- Front charge air pipe.
Installing
Air cleaner
Install: - (ACL) inlet hose.
- Throttle cable.
- Batery negative lead.
- Crankcase ventilation to cylinder head, use new clamp.
- Spark plug cover.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technica
routing of wiring
Oxygen Sensor: Technical Service BulletinsO2 sensors - New routing of wiring
Bulletin:2250010
Group:25
Date:02/01/2000
New routing of wiring for 02 sensors
Models:850, S70/V70/C701997-1998
Reference: This Service Bulletin laces the previous Service Bulletin 2-25-0010 from June 1999, which should be disca
Vehicles involved: B52X4X
Background:
To prevent contamination from reaching the probe's reference air, new routing has been developed for sensor wiring.
If one oxygen sensor is replaced, the new adapter wiring must be installed for both sensors.
Replacing the front heated oxygen sensor (HO2S)
Materials
Replacing the rear heated oxygen sensor (HO2S) B52X4S MY 97-98, B5234T MY 97
Materials
Replacing the rear heated oxygen sensor (HO2S) B5254T MY 97-98, B5234T MY 98
Materials
MOUNTING HEATED 02 SENSOR

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > O2 sensors - New routing of wiring > Page 1079

Heated 02 sensor, mounting
Preparation
Turbocharged engines
Remove:
- Fresh air intake hose between air cleaner (ACL) housing and turbocharger (TC).
Naturally aspirated engines
Remove:
- the preheating hose.
Removing/installing heated 02 sensor
Remove the front heated O2sensor. Use tool no. 9995543

Install a new heated 02 sensor.
Note! AWD. Replace front 02 sensor from the engine compartment.
Installing adapter wiring
Note! The illustrations only illustrate one of the adapter wiring systems, but the same method applies to both front and

When replacing the heated O2sensor adapter wiring (A), which is included in the kit, should be installed between the e
Form the adapter wiring (A) into a loop. Install a tie strap as illustrated.
Note! Ensure that the ends (B) of the adapter wiring protective sheath point downwards so that moisture does not gathe
This illustration displays a late version of the heated 02 sensor cable bracket. (Early type bracket is shown in the next s
On AWD cars the cable for the front heated 02 sensor should be routed over the fresh air intake hose.
Note! Ensure that the ends of the adapter wiring protective sheath point downwards so that moisture does not gather in
This illustration displays an early version of the heated 02 sensor cable bracket.
Installing fresh air intake hose:

Install fresh air intake hose.
Install preheating hose.
Erase diagnostic trouble code (DTC).
Test drive and check that no new diagnostic trouble codes (DTCs) have been stored.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifica
Oxygen Sensor: Electrical Specifications

OXYGEN SENSOR HEATER ELEMENT
Resistance;
Cold Sensor - approx. 20C (68F) ..........................................................................................................................
NOTE:
Front Sensor: Black Connector.Rear Sensor: Gray Connector.

Page 1084
Oxygen Sensor: Mechanical Specifications

OXYGEN SENSOR
Tightening Torque ......................................................................................................................................................
NOTE: Thread sealing compound P/N 1161408-8 should be applied to the sensor's threaded section.
Oxygen Sensor: Locations
HEATED OXYGEN SENSORS (HO2S) FRONT AND REAR:
Bank 1, Sensor 1 (Heated Oxygen Sensor, Front) is located before the catalytic converter.
Bank 1, Sensor 2 (Heated Oxygen Sensor, Rear) is located after the catalytic converter.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagram
Instructions
Oxygen Sensor: Diagram Information and Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Oxygen Sensor: Application and ID
Oxygen Sensor and Catalyst Configuration Example
V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts

L4 Engine W/1 Exhaust Banks & 2 Catalysts

Oxygen Sensor: Description and Operation

HEATED OXYGEN SENSORS
Front Oxygen Sensor
HO2S ECMThe Front Heated Oxygen Sensor () is used to supply the Engine Control Module () with information ab
TWC
The heated oxygen sensor (HO2S) is mounted upstream of the Three-Way Catalytic Converter (). The heated oxygen
To measure the oxygen content, the heated oxygen sensor (HO2S) requires a supply of ambient air as a reference. Th
The engine control module (ECM) will adopt substitute values if the front heated oxygen sensor (HO2S) signal is mi
Rear Oxygen Sensor
This is to:
- Make heated oxygen sensor (HO2S) control more accurate
- Check if the front heated oxygen sensor (HO2S) has aged
- Check that the three-way catalytic converter (TWC) is working.
The rear heated oxygen sensor (HO2S) differs from the front unit in that it reacts somewhat more slowly and that the
Function
285C
350 - 850C The heated oxygen sensor (HO2S) only operates above certain temperature , approx. . Normal operating
12 V
The heated oxygen sensor (HO2S) is heated electrically. One terminal is supplied with by the main relay, while a se
Cars in certain markets are also equipped with a rear heated oxygen sensor (HO2S) installed downstream of the three
30When the heated oxygen sensor (HO2S) is cold, the value of the PTC resistance is low and the current in the circu
The heated oxygen sensor (HO2S) can be damaged if it is exposed to condensed moisture from the engine while the
350C
Heating of the heated oxygen sensor (HO2S) starts immediately the engine is started. When sensor temperature reach

Both heated oxygen sensor (HO2S) terminals are connected to the engine control module (ECM).
0.9 VWhen the engine is running rich, the oxygen content of the exhaust gases is low or zero. The heated oxygen sen
0 VWhen the engine is running lean, there is an excess of oxygen in the exhaust gases. The output voltage from the h
The change from high to low signal level occurs at the ideal (stoichiometric) air/fuel ratio of 14.7 kg air/1 kg fuel.
The engine control module (ECM) continuously uses the heated oxygen sensor (HO2S) signal to control fuel injectio
Oxygen Sensor: Testing and Inspection

HEATED OXYGEN SENSOR DIAGNOSTICS
HO2S
DTC
Two Heated Oxygen Sensors () are used in the Motronic 4.3 and 4.4. The heated oxygen sensors (HO2S) are checked
ECM
TWC
The Engine Control Module () receives exhaust content data from the front heated oxygen sensor (HO2S) Using this
These changes are monitored by checking:
^ Front heated oxygen sensor (HO2S) mean signal voltage rear heated oxygen sensor (HO2S) control front heate
period.
^ To determine front heated oxygen sensor (HO2S) mean voltage the engine control module (ECM) uses the rea
The mean rear sensor signal voltage should be approx. 0.6 V when twin heated oxygen sensor (HO2S) control is acti
When the engine is running the adjustment carried out by the rear heated oxygen sensor (HO2S) should be positive a
signal. This signal provides information about the exhaust gas oxygen content downstream of the catalytic con

Twin heated oxygen sensor (HO2S) control starts and remains active when:
^ The front heated oxygen sensor (HO2S) has started control^ The rear heated oxygen sensor (HO2S) has reach
Twin heated oxygen sensor (HO2S) control is suspended during fuel shut-off, if the engine control module (ECM) de
^ EVAP system (diagnostic trouble code (DTC) EFI-315)^ Three-way catalytic converter (TWC) (diagnostic tro
A defective sensor may also have the correct mean signal voltage. For this reason the front sensor period is also mon
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information >
Throttle Position Sensor: Specifications

THROTTLE POSITION SENSOR
Resistance between terminals 1 and 3;
Idle position ..........................................................................................................................................................

Throttle Position Sensor: Locations
Throttle Position Potentiometer
Mounted on the throttle valve shaft, side of throttle body.

Instructions
Throttle Position Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Throttle Position Sensor: Description and Operation

TP ECM
The Throttle Position () Sensor supplies the Engine Control Module () with a signal describing the angle of the thrott
The throttle position (TP) sensor consists of the following components:
^ Hub and wiper contacts (1)^ Contact track (2)^ Rheostat (3)
5 V 0.5 V CTP 4.3 V WOTThe hub and wiper contacts are rotated by the throttle spindle, varying the sensor output
The engine control module (ECM) will adopt substitute values if the throttle position (TP) sensor signal is missing or
TBThe throttle position (TP) sensor is mounted on the Throttle Body ().
Throttle Position Sensor: Adjustments

not adjustableThrottle Position Sensor is .
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Compon
Transmission Position Switch/Sensor: Adjustments
SPECIAL TOOLS
- Gauge tool No. 999 5475, or equivalent
PROCEDURE
1. Preparations
- Make sure gear shift is set to position N.
- Remove:
BatteryBattery shelfAir intake manifold
Inspection And Adjustment
2. Adjustment
- Remove:
- Transmission
Install gauge tool cable
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
- Check that shaft is set to position N.
- The indentation on the tool should align with the marking on the gear position sensor.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor,
A/T > Component Information > Adjustments > Page 1123

3. Adjustment
- Remove:
Dipstick pipe bracket.Gear position sensor screws

- Rotate the gear position sensor so that the mark on the switch aligns with the indentation on the tool.
- 25 NmTighten sensor screws to:
4. Reinstall bracket for dipstick pipe.
- Make sure that the O-ring on the pipe is in place.
- 25 Nm.Tighten to: .
- Install:
16 Nm.
Rod arm on control shaft, then tighten to: Transmission cable on rod arm with washer and lock clips.Appl

5. Install:
- Air intake manifold
- Battery shelf
- Battery
- Reconnect battery leads.
6. Checking DTCs
- Using a suitable scan tool, check that DTC's have been cleared.
- Test position of gear position sensor with suitable scan tool.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Compon
1125
Transmission Position Switch/Sensor: Service and Repair
REMOVING OF GEAR POSITION SENSOR

1. Preparations
- Remove:
(ACL)
Battery Entire Air Cleaner Air intake manifold Battery shelfACL bracket.
2. Removal
- Remove:
Transmission cable from rod armRod armNut, lock washer and rubber seal from position sensor.
- Loosen dipstick pipe bracket.
- Remove the two screws from the gear position sensor.
- Carefully lift the sensor from control shaft.

DISASSEMBLING AND REASSEMBLING OF CONNECTOR
3. Disassembling
- Separate the connector on transmission.
- Disassemble connector. Remember rubber gasket.
- Disconnect cable clamps and detach connector from transmission.
- Remove rubber seal from connector.
At the same time slide the sockets out of the casing.
4. Detach socket for gear position sensor (8-pin) from other sockets.
- Remove gear position sensor.
5. Reassembling
- Reassemble position sensor socket with the other sockets.
- Reinstall sockets in casing and put rubber seal back in place.
- Reinstall cable clamps around cable harness and rubber seal.

- Reinstall upper connector section.
REINSTALLATION AND ADJUSTMENT OF GEAR POSITION SENSOR
6. Reinstallation
- Reinstall gear position sensor.
- Tighten sensor screws lightly.
- Reinstall rubber washer, lock washer and nut on control shaft connector.
- Tighten nut.
- Lock nut with lock washer.
7. Adjustment
- Adjust gear position sensor refer to Adjustments steps 2 and 3. See: Adjustments
8. Reinstallation, continue:
- Dipstick pipe bracket.
25 Nm.Make sure that the O-ring on the pipe is in place.Tighten to:

- Rod arm on control shaft.
16 Nm.Tighten to:

- Transmission cable on rod arm with washer and lock clips.
Apply grease part No. 1161241-3, or equivalent, sparingly to rod arm pin.
9. Reinstallation of engine compartment components

- Install:
Air filter bracketBattery shelfACL complete with inlet pipe.Battery

Reconnect battery leads.
10. Checking DTCs
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Sp
Vehicle Speed Sensor: Electrical Specifications

VEHICLE SPEED SENSOR
Resistance of sensor ...................................................................................................................................................

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Sp
> Page 1133
Vehicle Speed Sensor: Mechanical Specifications

Speed Sensor ..............................................................................................................................................................
NOTE: Use new O-ring.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Vehicle Speed Sensor: Service and Repair

1. Cars without turbocharged engines
- Preparation:
Ignition OFF
- Remove:
(ACL).Preheating hose between the manifold and the Air Cleaner
2. Cars with turbocharged engines

- Preparation:
Ignition OFF
- Remove:
(MAF)
(TC)Mass Air Flow sensor connectorHose between ACL and Turbocharger unit
(VSS)3. Separate the Vehicle Speed Sensor connector

- Remove:
- Nut to the cable conduit/bracket.
Unhook the parts.
- Clean thoroughly round sensor.
- Sensor screw and remove sensor.
4. Install new sensor with new O-ring.
- Oil the O-ring.
- Install sensor.
5.5 Nm.Tighten to:
- Install:
Bracket and cable conduit

5.5 Nm.Tighten to:
Connector.
- Install:
Preheating hose between the manifold and the ACL.

- Install:
Air pipe between TC and air cleaner ACL.
Make sure that all the connections are in place.
Mass air flow sensor connector
(DTCs)7. Checking Diagnostic Trouble Codes
- Check that DTCs have been erased.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vertical Acceleration Sensor > Component Informatio
Vertical Acceleration Sensor: Specifications

ACCELERATION SENSOR
Output voltage with car stationary .............................................................................................................................

Vertical Acceleration Sensor: Locations

ACCELEROMETER
The Accelerometer is mounted on the sub-frame.

Vertical Acceleration Sensor: Description and Operation

ACCELEROMETER
The Piezoelectric Accelerometer is used to detect unevenness in the road surface which is transferred to the engine v
5 V ECM 2.5 V
2.5 VThe accelerometer receives from the Engine Control Module (). Its output signal is approx. for a stationary ca
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > T
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Harness > Page 1167


Harness > Page 1168

Check
2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES


874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Harness > Page 1181


Harness > Page 1182

Check
1183


Approx ..................................................................................................................................................................
1184

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > D
Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > D

Injection period
170C
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information >

Idle position ..........................................................................................................................................................


Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


TP ECM

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Spec
Turbo Boost Sensor: Specifications
Boost pressure sensor
Measurement range 20.0 - 250 kPa.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations


> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Di

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information >
Diagrams > Diagram Information and Instructions > Page 1223

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Pa

CMP ECM
RPM
12 V
0V
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulleti
3301 > May > 98 > Campaign - Malfunctioning Ignition Switch
Campaign - Malfunctioning Ignition Switch
GROUP:33
NO:01
ISSUING DEPARTMENTWarranty
DATE:May, 1998
TITLE:
Service Campaign83D (8383805)VOLVO S70/V70Series

Service Bulletin 33-0002, Parts Bulletin33-83D
IGNITION STARTER SWITCHREPLACE
BULLETIN REFERENCE
A. SERVICE CAMPAIGN 83D DESCRIPTION
B. B. VEHICLES INVOLVED
F. STOCK VEHICLES
A. Service Campaign 83D Description
Volvo Cars of North America, Inc. and Volvo Canada Ltd have announced a service campaign affecting 1998 Volvo S
The ignition starter switch should be examined for proper operation. An insufficient electrical contact during cranking
All owners of these affected vehicles will be notified by mail the week of June 1, 1998
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical
Service Bulletins > Recalls for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 1241

Assy plant 1 VTM Assy plant 2 - VEC
874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

3. Retailer Vehicle Campaign List
"Retailer Vehicle Campaign List" will be sent separately identifying the specific vehicles eligible for (his campaign. Th
4. Parts Information
Please refer to Parts Bulletin Group: 33 No. 83D Dated May 1998
Model Part Number Part Description Qty
S70/V70 9447804-7 Ignition Starter Switch 1
All removed parts must be returned to the Technical Material Analysis (TMA) department, Rutherford, NJ, USA or No
5. Owner Notification
6. Stock Vehicles
7. Retailer Responsibility
8. Campaign Reimbursement Procedures
Retailer Allowance
Service Campaign 83D
Claim Repair Repair Labor Part Amount
Type Code Description Time Amount
8383805 02 Replace ignition 0.3 US $ 31.05

Starter Switch CA $ 42.62
Note:
All removed parts must be returned to the Technical Materials Analysis (TMA) Department, Rutherford, NJ, USA o
3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement
Ignition Switch: RecallsCampaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Reference: TP6001201, Section 6, 7 (60-64, 70-77) Front end, steering 850 1992-
Service campaign no: 83 D, Starter/ignition switch, replacement
Part required: Starter switch P/N 9447804 Quantity 1
Starter switch, replacement
Starter/ignition switch, replacement
Remove 1
Disconnect the negative battery cable.
Note!
The steering wheel does not have to be removed to replace the starter switch.
Service Bulletins > Recalls for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 1246

Release the lock for the tilt/telescope adjustment and pull the steering wheel toward the rear of the vehicle and lock the
Remove the steering column covers.
Removing electrical components 2
Carefully separate the connector from the starter switch.
Remove the two screws that holds the starter switch to the ignition lock.
Carefully remove the starter switch from the ignition lock.
Installing ignition switch 3

Reinstalling panelthe
Before installing and steering
starter wheel
switch; covers.
make 4 the starter switch is properly aligned with its c
sure that the center key hole in
Caution!
Route the wire harness for the starter switch so that no schafing and/or pinching can occur when reinstalling the ste
Reinstall column covers.Reconnect battery.Set radio code.

for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 1252

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement
Ignition Switch: All Technical Service BulletinsCampaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 1257


starter wheel
switch; covers.
Caution!

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Info
Ignition Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams
> Diagram Information and Instructions > Page 1261

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Info
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Star
Ignition Switch: Service and RepairStart Switch
Start switch
Removal
Note!
A new start switch and bracket has been introduced into production. Start switch kit 9452632 should be us
Preparations
Replacing steering column coverRemove the steering column covers according to
Note! Do not remove the upper cover from the apron molding.
Start switch
Installation
Replacing steering column coverInstall the connector on the start switchPosition the start switch on the steering wh
Remove the screws and bracketRelease the start switchDisconnect the connector.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Star
Ignition Switch: Service and RepairReplacing Steering Column Cover
Replacing steering column cover
Removal
Preparations
- Remove the ignition key.- Lower and pull the steering wheel out as far as possible.
Removing steering column cover
Installation
- Locate the lower cover. Check that the seals for the stalks are correctly positioned.- Position the upper cover. Press
- Undo the screws.- Pull the lower cover loose and remove it.- Fold up the upper cover.- Remove the mounting for th
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1277

KNOCK SENSORS

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Infor

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams >
Diagram Information and Instructions > Page 1280

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1289
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1290

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.
Page 1291


Remove:
The large

Knock

- Flame trap hose.
Page 1292


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.
Page 1293

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions
Impact Sensor: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
1299

1/1 Battery

2/2 Fog lamp relay

1300

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
1301

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

1302

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

1303


11A/1-9 Main fuses

1304

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

1305



1306

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

1307

C70 all

> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1308
Impact Sensor: Service and Repair
Side Impact Sensors
Removing the panel
Remove:
- the B-post panel
Removing the B-post sensor
Remove:
- the connector, press the catch and pull downwards.

- 2 screws.
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3301 > M
Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition
Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 1318

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3330002
Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition
Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 1323


starter wheel
switch; covers.
Caution!

> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignit
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 1329

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignit
Campaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 1334


starter wheel
switch; covers.
Caution!

> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 1335
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 1338

1/1 Battery

2/2 Fog lamp relay

Page 1339

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 1340

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 1341

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 1342


11A/1-9 Main fuses

Page 1343

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 1344



Page 1345

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 1346

C70 all

> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1347
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Start Switch
Start switch
Removal
Note!
Preparations
Start switch
Installation
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Start Switch > Page 1350
Removal
Preparations
Installation
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service and Repair
Downshift Switch: Service and Repair
1. Preparations
- Remove:
Throttle control cover (A)Locking clip (B) on cable tensionerUnhook cable from throttle control pulley (C
2. Remove sound insulation on driver side.

- For cars with SRS:
- Remove knee bolster.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service
and Repair > Page 1356

3. Removal
- (AP)Detach throttle cable from Accelerator Pedal
- Free the latch lugs that hold the kickdown switch in place by pushing a screwdriver into the opening in cowl-p
Push out switch with throttle cable.
- From the engine compartment side, make sure no remnants of the latch lugs remain between the insulation an
4. Reinstallation
- Installation of new throttle cable/kickdown switch
- Ensure that connector is correctly positioned upright.
- Make sure latch lugs engage cowl-panel.
5. Reattach throttle cable to AP
- Make sure rubber cushion is in place in the hole on AP.
- Use retainer in AP to fasten cable.
Make sure bead on the end of cable is anchored at the bottom of the retainer.
- Cars with SRS:
20 Nm. Replace knee bolster, tighten to: Reinstall sound insulation pad
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service
and Repair > Page 1357

6. Reinstall connector on kickdown switch
- Reinstall locking clip on cable tensioner
- Make sure cable is positioned correctly in the engine compartment.
- Firmly latch cable onto throttle control pulley
- 3.5 mm (0.14 inch)Insert a spacer between the throttle pulley idle stop and the bracket stop.
- Make sure locking clip is positioned firmly against bracket.
Adjust cable until it is under light tension.
7. Remove spacer Remove locking clip and replace cable tensioner in bracket with locking clip
- Reinstall cover
8. Checking DTCs
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and
Transmission Mode Switch: Description and Operation
ECON MODE (ECONOMY)
This shifting program is intended for "normal" driving and provides early upshifting combined with lock-up. In a
SPORT MODE (SPORT)
In Sport mode, the shifting points are designed to provide maximum performance. As long as acceleration is gent
The mode selector has a toggle switch for ECON and SPORT modes and a push-button for WINTER mode. The
WINTER MODE (WINTER)
Winter mode makes it possible to start driving in high gear to avoid wheelspin on slippery roads. This mode is al
D The car starts in 3rd gear. Automatic shifting between 3rd and 4th gears occurs earlier than in ECON mode
3 The car starts in 2nd gear. No up or downshifting occurs.
L The car starts in 1st gear. No up or downshifting occurs.
When Winter mode is selected, the warning light on the instrument panel lights.
If kickdown is activated in Winter mode, the transmission uses all gears for maximum performance.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and
Transmission Mode Switch: Service and Repair
- Ignition off.
-
EB2 Installing
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjus
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Adjustments > Page 1365

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjus

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications

Speed Sensor ..............................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications >
Transmission Speed Sensor: Service and Repair
1. Remove:
- Battery
- ACL bracket.

> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > S
Specifications
Transmission Temperature Sensor/Switch: Electrical Specifications

Oil Temperature Sensor
Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................
Transmission Temperature Sensor/Switch: Mechanical Specifications

Temperature Sensor ....................................................................................................................................................
Transmission Temperature Sensor/Switch: Application and ID

Volvo Number ..................................................................................................................................................................
Aisian Warner Number ....................................................................................................................................................

Transmission Temperature Sensor/Switch: Service and Repair

NOTE: Avoid skin contact with transmission fluid!
1. Preparation
- Remove:
(ACL)
BatteryAir Cleaner Housing complete with intake pipe.Battery shelf Detach:ACL bracket.
2. Separation of connector halves

- Remove cable clamps around wiring and rubber seal.
3. Remove:
- Remove socket for cables to oil temperature sensor.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component

2-pin, pins 12 and 13.
4. Remove:
- Detach cables' pins from socket.
- Push in locking device beneath socket and push out red lock lug slightly.
5. Removal of splashguard under engine

- Empty oil from transmission and reinstall oil plug with new seal.
40 Nm.Tighten to:
- Remove sensor.
- Collect oil in a container.
7. Installation of new sensor
- Install new sensor.

- 25 Nm.Tighten to:
8. Remove the cables pins from socket.

9. Installation:
- Lift up cables between oil cooler hose and control system cover.
- Reinstall splashguard under engine.
- Route the cables under gear position sensor.
- Take care not to damage the cables.
10. Reconnect cables to socket;

- Pin 12: blue/red cable
- Pin 13: blue/black cable
- Check pins are correctly positioned in socket.
- Make sure rubber seal is in place.

- Plug in connector from car. Remember rubber gasket.
12. Reinstall:
- ACL bracket.
- Battery shelf
- ACL with intake pipe and connections.
- Battery
-
Top up oil and test refer to Checking/Adjusting Oil Level. See: Transmission and Drivetrain/Automatic Trans
13. Checking DTCs
-
Check and erase DTCs. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/I
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Power Window Switches - Replac
Power Window Switch: Technical Service BulletinsPower Window Switches - Replacing
Section3
Group36
No.0011
Year99
Month06
S70/V70/V70 XC/C7O1998-
Replacing power window switch(s)
Background:
This service method describes how to replace the power switch (s) in the door panel without removing the door panel f
Cars involved:
ModelS70 V70 C70
Materials:
Description Quantity Part no.
Switch, drivers door 1 9148957

Switch, passenger door 1 9148951
Switch, rear doors 1 9148952
Replacing power window switch(s)
Hint: To aid in removal of switch.
If car has been parked in ambient temperatures less then 5C (46F) degrees for more then 4 hours, bring the car inside th
Removing switch, drivers door

> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Power Window
Switches - Replacing > Page 1391

Modify a 30 mm (1-1/4") wide spatula by rounding of the corners as per illustration. Sand all edge till smooth. The edg
Affix a 75 mm (3.0") piece of electrical tape covering the edge of the spatula (see illustration).
Carefully insert the spatula about 15 mm (9/16") down so that the tape gets pushed down together with the blade, and s
Note!
The spatula must be inserted as per illustration. Failing to do so may damage the base when replace the switch assem
Removing switch, passenger and rear doors
Affix a 75 mm (3.0") piece of electrical tape covering the edge of the spatula. (see illustration) Carefully insert the spat
Note!
The spatula must be inserted as per illustration. Failing to do so may damage the base when replace the switch assem
36478-2 Replacing power window switch(s) per unit 0.1 hr

> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions
Power Window Switch: Diagram Information and Instructions

> Page 1394

1/1 Battery

2/2 Fog lamp relay

> Page 1395

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 1396

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 1397

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 1398


11A/1-9 Main fuses

> Page 1399

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 1400



> Page 1401

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 1402

C70 all

> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1403
Power Window Switch: Service and Repair
ED2 Replacing Power Window Switch (All Four Doors):
- Ignition off.
- Remove door panel. See: Body and Frame/Doors, Hood and Trunk/Doors
- Push up the switch from the door panel.
- Disconnect control panel connectors.
- Replace switch.

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation
Washer Fluid Level Switch: Description and Operation
Removal
The windshield washer level switch closes when the fluid level is low.
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 1408
Washer Fluid Level Switch: Service and Repair
FE1 Removing:
Removal
- Remove washer reservoir filler pipe.

- Pull up level sensor. (Located at the end of the cable.)
FE2 Installing:
- Connect connector to level sensor.

- Install sensor, press carefully into place.
-
Reinstall washer reservoir filler pipe. Fill washer reservoir with water and check that the level sensor and filler pi
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Switch: Diagram Information and Instructions

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions
Wiper Switch: Diagram Information and Instructions

> Page 1426

1/1 Battery

2/2 Fog lamp relay

> Page 1427

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 1428

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 1429

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 1430


11A/1-9 Main fuses

> Page 1431

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 1432



> Page 1433

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 1434

C70 all

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1435
Wiper Switch: Service and Repair
EA1 Removing:
- Position the steering wheel straight ahead.

- Ignition off.
steering wheel cover screws.

Remove:-
- steering wheel covers. Push the upper one to one side.
- switch screws.
Disconnect connector and replace switch.
EA2 Installing:
CAUTION
: The turn signal switch should be in the neutral position when it is installed. The pin that controls automatic cancel
wiper and/or turn signal indicator switch. Ensure that the ground lead is positioned under the lower mounting scre
Install:-
- steering wheel covers and screws.
Test switch function.

> Maintenance > Alignment > System Information > Specifications
Alignment: Specifications
Alignment Specs
Front Axle
Caster 3.351.0
Max Deviation 1.0
Camber 01.0
Max Deviation 0.20.7
Toe-in 0.330.1
Max Deviation 0.1
Rear Axle
Camber (non-AWD) -10.5
Camber (AWD) -0.450.75
Toe-in (non-AWD) 0.10.2
Thrust angle 00.25
> Maintenance > Alignment > System Information > Specifications > Page 1440
Alignment: Description and Operation
Camber
Camber (C) refers to the wheel leaning in or outwards. The angle is considered positive if the wheel leans outwards a
Road holding is better with negative camber because the wheel stands upright when the body rolls.
Positive camber gives better feel for the road through the steering wheel. With an extreme wrong camber the tires we
Caster
The caster angle (B) is the angle between vertical line (A) and a line which goes through the center of the lower ball
Note! Caster angle cannot be adjusted.

King pin inclination
Originally king pin inclination (D) referred to king pin lean. Because the car does not have a king pin the inclination
TOE-IN
Toe-in
With toe-in the front part of the wheel points inwards. Toe-in can either be measured as an angle or as a difference b
Note!
Toe-in should always be adjusted in relation to the car's driving geometric axis (thrust line) which is derived from th
Toe-out

Toe-out or incorrect toe-in cause vibrations that increase tire wear. Tires slide sideways. Too much toe-in causes wea
Ackerman angles
The wheels follow different radii when cornering.In order to ensure that they turn at the same center, and to minimiz
> Maintenance > Alignment > System Information > Service and Repair > Alignment
Alignment: Service and RepairAlignment
Preliminary Checks
The wheel alignment must be correct to achieve satisfactory steering characteristics and to minimize tire wear. The alig
NOTE: All settings must be measured with the car unladen.
Since the following defects may affect the wheel alignment, they must be rectified, if necessary, before measuring and/
1. Different tire pressures.2. Differences in tire wear.3. Play in front wheel bearings.4. Play in ball joints or control a
Checking
NOTE:
Adjustment of the camber, if applicable, must always be carried out before adjusting the toe-in. Since the rear wheels
1. Jack up front end of car: Place hoist under control arms as close as possible to ball joints.2. Check for play in:
- steering gear or tie rod (track rod) ball joints.
- wheel bearings.
- spring strut upper mountings.
- control arm ball joints and bushings.
NOTE: If play is present in any of above, corrective action must first be taken.
3. Set up measuring equipment:
a. Set up and calibrate equipment as per equipment instructions.
> Maintenance > Alignment > System Information > Service and Repair > Alignment > Page 1445

b. Place turntables under front wheels. Use turntables which take up lateral movement.
NOTE: Car must be parked horizontally when front wheels are on turntables, to ensure that correct camber and
c. Bounce front end vigorously up and down a few times or turntables to ensure that suspension returns to normal
4. Checking camber.
0 1.0 1.0
a. Measure camber on each side. Correct value:. Value may differ by a maximum of between left and right whee
3.35 1.0 1.05. Checking caster: Measure caster on each side. Correct value: . Value may differ by a maximum of be
6. Checking toe-in:
a. Ensure that the instruments are adjusted relative to each other at the front and rear. This is extremely important
toe-in measured relative to the thrust axis of car. The thrust axis is defined as the line bisecting the angle betw
NOTE:
15' The angle between the longitudinal axis of symmetry and the thrust axis is known as the thrust angle. Thi
A. Axis of symmetry of wheels.B. Thrust axis.C. Thrust angle.
NOTE: The deviations in the adjoining figure are highly exaggerated for illustration purposes.

20' 6' (0.3 0.1)
b. Correct value: measured across both wheels.c. Measure toe-in at hub level, either as an angle or as the differen
3.6 1 mm (0.14 0.04 inch)at the rear and front respectively of the wheel. Example: Measurement at A should
Toe-In
Adjust toe-in by altering length of tie rods (track rods) after undoing locknuts. Increasing tie rod length increases angle
NOTE: 2 mm (0.08 inch) Length of tie rods must not differ by more than as measured between end of thread and loc

agent, P/N 1161432-8, after tightening nuts.
Camber
NOTES:
- 0 1The camber must be adjusted if the measured value exceeds a tolerance of .
- 1The difference between the left and right sides must not exceed .
1. Jack up car and remove wheel.2. Cars with sleeves in steering knuckle (stub axle carrier): Remove upper sleeve (o
0.5
1required) from steering knuckle (stub axle carrier). Removal of one sleeve will produce a change in camber of a
3. Cars without sleeves in steering knuckle (stub axle carrier): Replace bolts and nuts, and adjust as described below.
NOTE: Install new bolts and nuts.
a. Tighten bolts slightly without preventing movement of steering knuckle (stub axle carrier) outward or inward w
with a degree of resistance) Move steering knuckle outward or inward to extent permitted by play between bo
65 Nm (48 ft. lbs.) 90b. After adjustment, tighten both bolts toand through further .
4. Mount wheel.
110 Nm (81 ft. lbs.)a. Lubricate wheel locating pin on hub with anti-rust agent, P/N 1161030-0.b. First tighten w
NOTE: Also see specifications.

5. Recheck camber and toe-in.
Rear
Checking/Adjusting Rear Wheel Alignment

1. Lift up rear suspension.
Wheel
Check bearings.
for play in:-
- Support arm bushings.
- Control arm bushings.
2. Set up test equipment.
Set up and calibrate test equipment according to its instructions.The car should be on a flat surface with the whee
3. Checking camber angle.
-0.25 0.75
Nominal camber angle .If the camber angle is outside these parameters check control arms for damage.

4. Checking toe-in.
-
Check that the instruments are adjusted in relation to each other on the front and rear axles. This important so
- 0.1 0.2The correct toe-in is , over both wheels.
- maximum 0.25Permitted deviation from the axis of symmetry (angle of thrust) should be .
5. Unscrew the nut for the track rod inner screw slightly.
90 Nm (66.4 ft. lbs.)Adjust by turning the eccentric screws to increase or decrease toe-in.Tightening torques .
Alignment: Service and RepairAdjustments
General
General
For the car to have good steering properties and a minimum of tire wear the wheels must be correctly aligned. The w
Note! All measurements should be made with the car empty.
Corrections Before Wheel Alignment
The following may also affect the wheel angles. Before measuring and adjusting these faults should be rectified.1. D
Front Alignment
Checking And Adjusting The Wheel Alignment
Note! When checking and adjusting front wheel alignment the following applies:
- Any camber angle adjustment must always be made before adjusting the toe-in
-
Because the rear wheels have adjustable toe-in, the front wheels must always be adjusted in relation to the car's g
Note! All measurements must be made with the car empty. Check the tire pressure on all tires. See specification
Lift Up Front end

Lift under the control arms as close to the ball joints as possible.
the for
Check steering gear or tie rods
play in:-
- the wheel bearings
- the upper spring strut mountings
If there is play in any of the above components it must be corrected refer to the relevant repair information.
Set Up The Test Equipment

Set up and calibrate test equipment according to its instructions.
Position the turntables under the front wheels. Use turntables which take up lateral movement.
Note! The car must stand level when the front wheels are on the turntables. So that the correct values are obtained w
Bounce the front suspension heavily a few times when the car has been set onto the turntables. This must be done for
Checking Camber Angle

Check the camber angle on both sides.
0 1.0Correct value: .
1.0The camber angle may vary by a maximum of between the left and right wheels.

If the camber angle is outside these values, see Adjusting camber angle.
Adjusting Camber Angle
Note! 0 1 must not exceed 1. Adjust the camber angle if it lies outside the tolerance when checked. The variation b
Carry out the following when adjusting:
Raise cars and remove wheel
Cars with sleeves in the stub axles;
0.5 1.Remove the upper, if necessary both sleeves from the stub axle. This depends on how large the adjustment need
Cars without sleeves in the stub axles;
Replace screws and nuts and adjust as follows.
Note! Install new screws and nuts to stub axle
Tighten the screws slightly but not more than that necessary to allow the stub axle to be moved with some resistance
65 Nm (47.9 ft. lbs.) 90.Post adjustment, tighten both the screws to a angle-tighten
Install Wheels
Lubricate hub guide for rims with suitable rustproofing agent.
110 Nm (81.1 ft. lbs.)Install wheel studs lightly. Tighten crosswise to
Check camber angle and toe-in again.
Checking Caster Angle

3.35 1.0. 1.0 Check the caster angle on both sides. Correct value: The caster angle must not vary by more than betw
Checking Toe-In
Check that the instruments are adjusted in relation to each other on front and rear axles. This is important so that the
Note!
15 The difference between the wheel symmetry line and the thrust line is called the thrust angle. This angle may de
A. Wheel symmetry lineB. Thrust lineC. Thrust angle

Note! The differences in the adjacent diagram are exaggerated in order to illustrate the differences.

To set the rear wheel toe-in, see checking and adjusting the alignment of the rear wheels
Toe-In 20' 6'Correct value: measured over both wheels.
Measurements are taken at the height of the hub as an angular measurement or as the difference in mm between the f
Example.
3.6 1 mThe measurement at A must be greater than at a.
Adjusting toe-in
Adjustment is made with the tie rods after loosening the lock nuts. Longer rods give a greater angle and vice versa. S
Note! more than 2 mm.

The lengths of the tie rods must not vary between themselves by Measure between the lock nut and the edge of thre
Steering wheel position

Minor deviation, adjust at the same time as the toe-in adjustment a
For major steering wheel deviation, refer to Steering, Steering Column, Service and Repair.
> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
Fuel Rail Service Port

> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications
Air/Fuel Mixture: Specifications

Air / Fuel Mixture
[1]CO Content ..................................................................................................................................................................
[1] cannot be adjustedAir / Fuel Mixture and Idle Speed , only checked.
> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 1461
Air/Fuel Mixture: Testing and Inspection

Air / Fuel Mixture
cannot be adjustedCO Content (A/F Mixture) and Idle Speed , only checked.
- TWCCO Content is checked upstream of the Three-Way Catalytic Converter ().

- HO2SThe Heated Oxygen Sensor () must be connected during measurement.
- A/C must be switched OFF during measurement.
- Engine must be fully warmed up.
- Automatic transmission: Gear selector lever must be in PARK during measurement.
- EVAP-valve plugged.
CO Content .........................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 1462
Air/Fuel Mixture: Adjustments

CO content, idling speed
Notes:
CO content and idling speed cannot be adjusted, only checked.CO content is measured upstream of the three-way catal
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications
Idle Speed: Specifications
Idle Speed 850 +/- 50 rpm

Idle Speed and CO Content (Air/Fuel Ratio) cannot be
adjusted , only checked.
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1466
Idle Speed: Adjustments

Idle Speed Adjustment
cannot be adjustedIdle Speed and CO Content (Air/Fuel Ratio) , only checked.

> Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
Brake pipe master cylinder / ABS unit, replacing
Note! The method is almost the same for left and right-hand drive versions. On right-hand drive cars, the brake pipes
master cylinder and the ABS unit. They are clamped to the cowl in two places. All the illustrations in this sect
Preparation
- Disconnect the battery lead.
- Removing pipes
-
Collect the brake fluid. See Brake calipers front, replacing: Collect the brake fluid. See: Brakes and Traction Con
- Remove the plastic cap and the cable holder.
Switch off the ignition.
Remove:
- the plastic cap over the positive cable
- the positive cable nut at the wheel arch. Fold the cable to one side
- the screw on the clamp around the positive cable
- the nuts on the cable holder.

> Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair > Page 1470

Remove the air cleaner (ACL) housing
- Pull the air intake backwards (towards the engine) so that it disconnects from its mounting under the front cover p
- Disconnect the hose clamp for the air hose.
- Remove all the air hoses and connectors from the air cleaner (ACL).
- Remove the air cleaner (ACL) housing from its mountings. Pull it straight up.
Remove the integrated relay / fusebox
- Remove the integrated relay / fuse box bracket screw. Lift it up and put to one side. Tie it up using a cable.

Remove the brake pipes between the master cylinder and the ABS unit
- Clean the brake pipes terminals at the master cylinder and ABS unit.
- Place paper under the master cylinder to avoid brake fluid spillage.
- Remove the brake pipes from the master cylinder and ABS unit. Install sealing plugs.
- Remove the brake pipes.
Installing pipes

- Install the brake pipes
- 17 NmTighten the pipes to .
Install the integrated relay / fusebox
Install:
- 10 Nmthe bracket and the integrated relay / fusebox in the mounting screw in the bracket. Tighten to .
Install the cable holder and plastic cap

Install:
- 10 Nmthe cable holder. Tighten the nuts, Tighten to
- 25 Nmthe positive cable and integrated relay / fusebox nut. Tighten to
- the plastic cap at the positive cable.
Install the air cleaner (ACL)housing
- Connect all the air hoses and connectors to the air cleaner (ACL) housing.
- Tighten the hose clamp.
- Fold the air intake in under the front cover plate.
- Locate it in its mounting and press it into place.
- The positioning of the air intake can be seen through an oblong hole in the front cover plate.
Fill and bleed the brake system
- Remove the pedal jack.
- Fill and bleed the brake system. See: Fluids/Brake Fluid/Service and Repair
Checking for air in the brake system and for brake fluid leakage
200 Nm
40-mmCheck if there is still air in the system. Press down the brake pedal using a jack at a pressure equivalent to hea
If the pedal travel exceeds this limit, bleed again and re-check the pedal travel. Check that no leakage occurs from th
> Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair

Draining fuel injection system
Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers
throttle pulley cover

Remove:-
- cap from valve on fuel rail.
Connecting
Connect adapter 999 5484 to fuel draining unit 981 2270, 981 2273 and 981 2282.Connect adapter to fuel rail valve i
> Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1478

Draining fuel system
Remove cap from valve on fuel filter.Connect venting hose 999 5480 to valve upstream of fuel filter.System takes ap
Installing
Reinstall components in reverse order.
Caution! Remember to refit valve caps.

> Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks
> Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications
Ignition Cable: Specifications

IGNITION CABLE
Resistance:
Coil to Distributor ......................................................................................................................................................

> Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1492
Ignition Cable: Description and Operation

The Ignition Cable carries high voltage electricity from the ignition distributor to each individual spark plug.
Ignition Cable: Testing and Inspection

1. Inspect spark plug wires for signs of arcing or burning.
2. Check resistance of wires using an ohmmeter. Resistance should be:
4.5K ohms 20%

4.0K ohms 20%
3.3K ohms 20%
2.9K ohms 20% 2.3K ohms 20%Cylinder # 1 .......................................................................................................
3. If resistance is not within specifications, replace spark plug wire set.
Ignition Cable: Service and Repair

Remove and replace each Ignition Cable one at a time.
Remove the Ignition Cable from distributor cap tower and the spark plug it attaches to.
Re-attach the new cable in reverse order.
When re-installing, ensure that the Ignition Cable is routed properly and is secured in all wire clips.
> Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Specifications
Ignition Rotor: Specifications

IGNITION ROTOR
Resistance ...................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap
Spark Plug: SpecificationsGap

Spark Plugs
Engine
B 52XX T
Torque Kit Number Gap
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1503
Spark Plug: SpecificationsTorque

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1504
Spark Plug: Application and ID

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended
Compression Check: Technical Service BulletinsCompression Test - Amended

SECTION
2
GROUP
21
NO.842
DATESep. 1998
Amended procedure for compression test on older versions of the S70/V70
REFERENCE: TP 2101201, Section 2(20-22, 25-26) B5204, B5234, B5252, B5254 Engines; 850 1992-
TP 2102201, Section 2(21) Reconditioning, Engines B5202, B5204, B5234, B5254; 850 1992-
Background:
The amendments apply to the S70/V70 from the start of production, up to and including May 1997. see chassi No. belo
Service switch 17/1 can not be used for these models. It is not connected to the starter motor system. carry out the comp
Chassi No.:
S70 - 460000
V70 - 395002
Special tools: 999 9689, 115 8540
Compression test
High tension 1
Warning!
The ignition system works with high ignition tension and dangerous voltage in both low and high tension circuits.
High voltages are found throughout the ignition system, including the connectors etc.
Compression (normal value) 2
> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended > Page
1509

Note!
Applies when engine is warm, with wide open throttle (WOT) and when turning over the starter motor; 4.2-5.0 r/s (
Disconnect the engine speed (RPM) sensor. 3
Separate connector
Remove:
- ignition cables cover plate

- spark plugs.
Remove fuse 11B3 4
> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended > Page
1510

Disconnect fuel pump (FP) and ignition system by removing fuse 11B3.
Note!
Service switch 17/1 can not be used.
Preparations for measuring 5
Use a compression meter 999 9689-4 with extension sleeve 115 8540-3.
Measure compression with the engine at operating temperature and wide open throttle (WOT)
Press down accelerator pedal (AP) all the way.
Turn the ignition key to the starting position.
Measure compression in all cylinders.

Reinstall the spark plugs so the gasket is placed against the cylinder head. Torque tighten to 25 Nm (18.4 ft. lbs).
Installing
- components
- fuse 11B3.
> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Page 1511
Compression Check: Specifications

COMPRESSION SPECIFICATIONS
Normal value .................................................................................................................................................... 1.3 -
NOTE: Compression is measured with engine hot and throttle fully open while turning with starter motor at 250
Compression Check: Testing and Inspection
SPECIAL TOOLS
- Compression Tester No. 999 9689, or equivalent
- Starter Switch No. 115 8263, or equivalent
- Extension L155 No. 115 8540, or equivalent
NOTE:
For additional information on special tools and equipment used in this procedure, refer to Service and Repair. See: En
Distributor Ignition System (DI System)
The DI system
WARNING: - operates at high power and dangerous voltages in both low and high tension circuits.
- Dangerous voltages occur throughout the DI system, even in connectors etc.
NOTE: Measure compression with the engine hot and at wide open throttle
- 1.1-1.3 MPa (156-185 psi)Normal value B5234T and B5254T:

- 0.2 MPa (28.4 psi)Maximum deviation between cylinders:
NOTE:
This applies when the engine is warm and the throttle fully open and the engine being turned by the starter moto
1. Remove:
- timing pick-up connector
- HT lead cover
Remove
Lock throttlespark plugs and connect starter switch tool No. 115 8263, or equivalent.
open:-
Connect connector between alternator (+) and service output on control module.

2. Measure compression:
- Use compression tester tool No. 999 9689 with extension sleeve tool No. 115 8540, or equivalent.
- Measure compression in all cylinders.
- Reinstall spark plugs, screw in plugs until seal is in contact with cylinder head.
25 Nm (18 ft lb)Tighten to: .
- Reinstall components.
> Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Mechanical Camshaft Belt Tensioner - Adjusting
Timing Belt: Technical Service BulletinsMechanical Camshaft Belt Tensioner - Adjusting

Section
2
Group
21
No.0015
Year
99
Month
06
S70/V70/C701998-
Vehicles involved: B52X2/B52X4
Adjusting the mechanical camshaft belt tensioner
Background:
This Service Bulletin describes the adjustment of the mechanical camshaft belt tensioner.
Engine serial no.:
S70/V70/C70 1266128-
Adjusting the mechanical belt tensioner
Adjusting the camshaft belt tensioner and camshaft belt
1 Install timing belt.
2 Ensure that belt is tight between crankshaft and intake pulley, if not reinstall.
3 Tighten the center screw to 5 Nm (4 ft.lb).

4
Holding the center screw stationary, turn the eccentric (A) with a 6 mm allen wrench COUNTER-clockwise until
> Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Mechanical Camshaft Belt Tensioner - Adjusting > Page 1518

5
Turn the eccentric (A) back CLOCKWISE until the indicator (C) reaches the correct position based on the tempe
6 Hold the eccentric secure and tighten the center screw to 20 Nm (15 ft.lb).
Note!
When setting the final adjustment the needle (C) must enter the adjustment window (B) from the right. If the n
7 Press on the timing belt and verify that the indicator moves in response to the pressure.
8 Note!
If the bolts holding either cam wheel had been loosened, tighten them at this time to 20 Nm (15 ft.lb).
9 Press the camshaft belt and check that the belt tensioner needle moves freely.
Needle position at different temperatures
This adjustment is always carried out on a cold engine.
A suitable temperature is approximately 20C/68F.
At higher temperatures, for example with engine at operating temperature or at higher ambient temperature, the indicat
The illustration shows the needle position when adjusting the camshaft belt tensioner at different engine temperatures.
> Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 1519
Timing Belt: Specifications
Tension Pulley, Timing Belt ................................................................................................................................................

> Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 1520
> Maintenance > Timing Belt > Component Information > Service and Repair > Replacement, W/Mechanical Tensioner
Timing Belt: Service and RepairReplacement, W/Mechanical Tensioner
Important Note -Please Read-
Volvo changed the camshaft alignment (timing) marks during the 1998 model year. This vehicle will use one of the fo
With Straight Up Camshaft Alignment Marks
With Angled Camshaft Alignment Marks

> Maintenance > Timing Belt > Component Information > Service and Repair > Replacement, W/Mechanical Tensioner > Page 1523

REPLACING TIMING BELT/IDLER PULLEY/BELT TENSIONER
Special Tools: 999 5433
Note:
As the illustrations in the information are used for different model years and/or models, certain variations
Remove components
Caution! Remove the ignition key from the ignition switch before beginning work.
Note!
Crankshaft or camshaft must not be rotated under any circumstances more than is listed below. Failure to

upper timing belt cover.
Remove:-
- servo reservoir and expansion tank.
- Lift up and place on top of engine.
Note!
Take care not to spill servo oil from the bleed hole in the cap.Place paper wipe around the reservoir and th
- auxiliaries belt.
- front camshaft belt cover.
Position engine according to marking
Remove
Raise right front wheel.
the car.-
- Remove the nut for the cover in the fender liner.
- Install the upper camshaft belt cover.
- Turn crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
- Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The marking
- Remove upper camshaft belt cover.

Removing timing belt
Slacken
Slacken off belt
off belt tensioner center screw slightly.
tensioner-
- 6 mm (15/64")Hold the center screw still and turn the tensioner eccentric clockwise with a allen key to "10 o'clo
- Remove the camshaft belt from the belt tensioner, camshaft pulley and idler pulley and the water pump.
Remove vibration damper
Remove
Raise the car-vibration damper. Use counterhold 999 5433. Work the vibration damper loose.
- Remove camshaft belt
Checking the belt tensioner and idler pulleys
Replace
Check if necessary.
bearing wear:-
IdlerSpin the idler pulley and listen for noise.

pulley:-
- 24 Nm (18 lb ft)If replacing with a new idler pulley, tighten to
Tension pulley:

- When replacing, screw the tension pulley into place with the center screw.
- Screw in the center screw by hand.
- Ensure that the tensioner fork is centered over the cylinder block rib.
- Ensure that the allen hole on the eccentric is at "10 o'clock".
Installing camshaft belt
Install
Install the new camshaft belt over crankshaft pulley wheel.
belt as follows:-
- 180 Nm (133 lb ft)
25 Nm (18 lb ft) and angle tighten 30 degreesInstall vibration damper. Tighten the center nut to Use counterho
Tighten timing belt
Then install the new belt in the following order:1. idler pulley.2. intake camshaft pulley.3. exhaust camshaft pulley.4
This adjustment is always carried out on a cold engine.Suitable temperature is approximately 20C/68F.
At higher temperatures, for example with engine at operating temperature or at higher ambient temperature, the need

Tighten the timing belt as follows:
- Turn crankshaft clockwise carefully until the camshaft belt is tensioned.
- The belt must be tensioned between intake camshaft pulley, idler pulley and crankshaft.
-
Hold the belt tensioner center screw secure and turn the belt tensioner excenter counter clockwise until the tensio
- Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant tempera
- 20C (68F)At the needle must be centered in the window.
- See figure above.
- 20 Nm (15 lb ft)Secure the eccentric and tighten the center screw to
Check that the needle is in the correct positionIf this is not the case a new alignment must be carried out.
Check
Press the
Checking belt to see that the indicator on the tensioner moves easily.
markings:-
- Install the upper timing belt cover.
- Turn crankshaft 2 turns and check that the markings on the crankshaft and camshaft pulley correspond.
- Check that the indicator on the belt tensioner is within the marked area.

Reinstall components
12 Nm (8.8 lb ft)Front camshaft belt cover. Tighten to

Reinstall-
- 8 Nm (6 lb ft)Upper camshaft belt cover. Tighten to
- Auxiliaries belt.
-
Servo reservoir.Wipe clean.Check the level and top up as necessary.

- Expansion tank.
Note! Ensure that hoses are correctly positioned.
- Wipe clean and check engine compartment.

- Cover in fender liner.
- Front wheel.
Checking work
Note! Write the date and mileage on the decal and stick it on the camshaft belt cover.
Test drive engine.

- Wipe dry steering wheel and gear selector lever.
Replacing timing belt
Note:
This procedure uses depictions of a timing belt with a hydraulic tensioner. The procedure is the same for timing belts
Special Tools: 998 8500, 999 5456

Function test:-
Remove:
- spark plug cover
- two fuel line clamps
- lift expansion tank and place over engine to one side
- front timing cover
- auxiliaries belt

Position camshafts/crankshaft according to marking
- Remove right front wheel and slacken off fender liner slightly.
- Remove vibration damper heat shield.
- The camshaft pulleys should rotate until all the markings are aligned.
Check measure the belt tension
5 minutes
not
Wait3.5-4.6
after units For timing
aligning 21 mmbelt.Position
belts, the tension shouldinstrument
measuring be between . 8500 between the exhaust camshaft pulley and co
998
-
2.5-4.0 units
2.7-4.2 unitsFor the 23 mm belt the following applies:B5204/B5254/B5234: B5252:
NOTReplace tensioner damping unit if the recommended values are kept.

Hold tensioner damping unit upper screwSlacken off the lower screwTurn the tensioner damping unit so that the pull
lower screw
Remove:-
- tensioner damping unit
- upper timing cover
- timing belt
Greasing the bushing
Engines with automatic timing belt tensioners should have the lever bushing greased every time the belt is changed o
Tension pulley lever screw

Remove:-
- Tension pulley
- Sleeve behind screw
Grease the surfaces on the lever bushing, the screw and the sleeve with grease P/N. 11 61 246-2 (50g) or 11 61 247-0
Sleeve
Install:-
- Tension pulley lever screw
39 Nm 5 NmTorque tighten screw to

Check tensioner and idler pulleys:
Spin the pulleys and listen for noise in the bearings.Check that the tensioner pulley actuator arm has not seized in its
30 Nm (22 ft lb)
24 Nm (18 ft lb)Pulley, tighten to: Idler pulley, tighten to:
If a mechanical belt tensioner is being used, adjust according to "Adjusting the Mechanical Belt Tensioner" See: Eng
Lock tensioner damping unit
(2.0 mm)Check there there is no visible leakage.Compress tensioner with tools 939 5456. Position tensioner dampin
NOTE: If there is leakage or no resistance when pushed in or if it cannot be pushed in the tensioner damping unit
Install the new timing belt
25 Nm (18 ft lbs)
Install tensioner damping unit torque to .Place belt around the crankshaft and right idler pulley.Place belt over camsh
Installing camshaft pulley and timing beltCaution!
The timing belt must be installed correctly to obtain the correct timing. Before tightening the screws

Secure drive belt
Press hard or knock the belt twice in the direction of arrow (1) and twice in the direction of arrow (2) using a rubber

Secure camshaft pulleys
20 Nm
Tighten the camshaft screws (2 x 3) to Turn engine crankshaft two turnsPull lock pin out of tensioner damping unitP
Install
- the two fuel line clamps
- accessory belt
- spark plug cover
- expansion tank
- vibration damper protective panel
- fender liner, wheel
Test function
Test run engine.
Timing Belt: Service and RepairReplacement W/Hydraulic Tensioner
Special Tools: 998 8500, 999 5456
Remove:
- spark plug cover
- auxiliaries belt


5 minutes
not
Wait3.5-4.6
998
-
2.5-4.0 units
lower screw
Remove:-
- timing belt

Remove:-
- Tension pulley
Sleeve
Install:-
- Tension pulley
30 Nm (22 ft lb)
If a mechanical belt tensioner is being used, adjust according to "Adjusting the Mechanical Belt Tensioner" See: Eng


25 Nm (18 ft lbs)
Secure drive belt

20 Nm
Install
- accessory belt
- spark plug cover
- expansion tank
Test function
Test run engine.
> Maintenance > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner
Timing Component Alignment Marks: LocationsWith Mechanical Tensioner
Caution: Incorrect removal or installation of the timing belt can result in damage to internal engine components.
Timing Belt : Service and Repair : Replacing the Timing Belt/Idler Pulley/Belt Tensioner
For complete procedures refer to See: TimingBelt/Service and Repair

CAUTION! Do not rotate crankshaft or camshaft with timing belt removed. Pistons and/or valve damage can occur
Note: Volvo changed the camshaft alignment (timing) marks during the 1998 model year. This vehicle will use one o

> Maintenance > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner > Page 1543

Note:
Note:
Cylinder Head Assembly : Service and Repair : Cylinder Head Removal andInstallation Make sure that rear upp
> Maintenance > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner > Page 1544
Timing Component Alignment Marks: LocationsWith Hydraulic Tensioner

Note:
Note:
> Maintenance > Drive Belt > Component Information > Diagrams
Drive Belt: Diagrams

DRIVE BELT ROUTING
Early Belt Routing
New Belt Routing
The new auxiliary equipment belt has been introduced into production for the 850 with A/C from engine serial numb
The new belt is routed so that it contacts more of the generator (GEN) drive pulley.
Note: New belt P/N 9434341-5 can be used on early engines if the new routing is followed. No other components ne
> Maintenance > Drive Belt > Component Information > Diagrams > Page 1548
Drive Belt: Description and Operation
Accessory Drive Belt

(P/S)
The accessories (alternator, power steering pump, air conditioning A/C compressor) are driven by a multiple V-b
The tensioner consists of a spring and a friction element. The friction element provides the damping necessary to
> Maintenance > Drive Belt > Component Information > Service and Repair > Replacing the Auxiliaries Belt / Belt Tensioner
Drive Belt: Service and RepairReplacing the Auxiliaries Belt / Belt Tensioner
Auxiliaries belt/belt tensioner, replacing
Note!
As the illustrations in this service information are used for different model years and/or models, some vari
Removal
Removing the auxiliaries belt
Remove:
- the plastic cover on the blet tensioner using a small screwdriver. Use a wrench and turn clockwise as far as possib
- the belt.
Replacing the belt tensioner
Remove:
- both mounting screws from the auxiliaries belt bracket for the belt tensioner.
- 25 Nm (18.4 ft lb)the belt tensioner. Install the new belt tensioner. Tighten to
Installation
Installing the auxiliaries belt
Caution! Ensure that the belt is correctly seated in all the grooves on each pulley
> Maintenance > Drive Belt > Component Information > Service and Repair > Replacing the Auxiliaries Belt / Belt Tensioner > Page 1551

Use a wrench and turn the belt tensioner clockwise as far as possible.Install the belt as illustratedInstall the plastic co
Checking work
Start the engine.Check the rotation of the belt and the function of the belt tensioner.
> Maintenance > Drive Belt > Component Information > Service and Repair > Replacing the Auxiliaries Belt / Belt Tensioner > Page 1552
Drive Belt: Service and RepairNew Routing of Auxiliaries Belt
New routing of auxiliaries belt
A new auxiliaries belt is being introduced into production for cars with A/C. The new belt has a new routing so that i
Installing auxiliaries belt:
Put A/C compressor

the belt around the crankshaft and then around the auxiliary equipment in the following order:-
- (GEN)Generator
- idler pulley
- servo pump
Carry out a function test

> Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair
Preparation
- Removing pipes
-
Remove:

> Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair > Page 1557


Installing pipes

Install:

Install:
- Fill and bleed the brake system. See: Fluids/Brake Fluid/Service and Repair
200 Nm
> Maintenance > Filters > Cabin Air Filter > Component Information > Locations
Cabin Air Filter: Locations
The pollen filter is located under the cowl upper section on the passenger side of the engine compartment.
> Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Service Interval
Cabin Air Filter: Service and RepairService Interval

Cabin air filter:
Replace the cabin air filter with a new one every 15,000 miles (24,000 km). Volvo recommends replacing the filter mo
> Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Service Interval > Page 1566
Cabin Air Filter: Service and RepairInstallation of Pollen Filter Kit

INSTALLATION OF POLLEN FILTER KIT
Parts required for installation of pollen filter kit:

Pollen filter kit P/N 9134576-1
For cars with ECC and chassis nos. less than described below, additional parts are required: 854: 131217, 855: 03730
Bracket 6849320-4
Screw 979186-4
Washer 960138-6
Tie strip 948211-8
If a pollen filter kit has been previously installed in the vehicle, replace the filter element (P/N 1343232-3) after evap
Procedures:
- Remove nuts and wiper arms
- Remove clamps and drainage hoses
- Remove five (5) screws
- Remove upper section of bowl
For cars with Climate Control (ECC) M/Y 1993 and 1994 partly, chassis number lower than 854: 131217, 955: 0373
- Remove sensor from the mounting.

- Drill out the hole factory marked on the filter holder using a 3 mm (1/8") diameter drill.
- Screw the retaining bracket P/N 684932-4 into place with the screw P/N 979186-4 and washer P/N 960138-6.
1Note: The bracket, screw and washer is not included in the Pollen filter kit.
ALL CARS:
- Replace the existing air intake with the filter holder
For cars with Climate Control (ECC) M/Y 1993 and 1994 partly, chassis number lower than 854: 131217, 955: 0373
- Push the sensor into bracket
- Use a tie strip P/N 948211-8 to damp the cables to the bracket
All cars:

- Insert the filter.
- Replace the cowl upper section, drainage hoses and the wiper arms.
- Remove old decal, if any.
- Clean the area where the label is to be attached
- Unfold the transparent part and fill in the mileage and date on the decal
- Remove the protective plastic (2) and press the edge (1) over the decal.
- Remove the protective paper on the back side of the decal and place the decal there on the upper part of the cowl.
> Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1573

Installing

> Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair
Oil Filter: Service and Repair
Checking Engine Oil

- Park the car on a level surface.
Wipe dipstick before check.
- Oil level should be within the hatched area on dipstick.
1.0 or 1.5 liters (1 or 1.6 qt)The difference between MAX and MIN on the dipstick is about .
- Engine at normal operating temperature:
half a liter (0.5 qt)Wait at least three minutes after turning off the engine so that the oil can run back to th
- Cold engine:
It is best to check the oil when the engine is cold, before starting the car.If the level is at MIN, top up with
1 liters (1 qt)
1.5 liters (1.6 qts) of oil (red dip stick handle) of oil (fluorescent dip stick handle).
Oil Filter Replacement
1. Remove the oil filter

- Remove splashguard under engine.
- Use filter wrench tool No. 999 5458, or equivalent.
- Clean up oil spills with paper.
Avoid prolonged
WARNING: - skin contact with oil!
-
Prolonged and repeated skin contact with oil can remove the skin's natural oils. This can lead to irritati
-
Harmful compounds may be formed when the oil is used:Avoid skin contact, especially with used engin
> Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Page 1577

2. Install new oil filter:
- Apply oil to the gasket.
- Screw into place by hand until the gasket comes into contact with the mating surface.
Turn a further 1/2 - 3/4 turn.
- Version 2 has a fluorescent dip stick handle (version 1 is red).

> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Replacement Refrigerant Pipe/Hose or Expansion Valve
Hose/Line HVAC: Service and RepairReplacement Refrigerant Pipe/Hose or Expansion Valve
Special tools: 999 5385, 999 5472
TTTM1 Before starting work on refrigerant circuits
WARNING! FOLLOW THE SAFETY PRECAUTIONS FOR WORK ON NC SYSTEMS ACCORDING TO A
NOTE!
At the Receiver/Drier always install new O rings in pipes and quick-release connectors. Always plug pipes and coupli
NOTE! Read the section on oil in the system according to BG. See: Heating and Air Conditioning/Service and Repair
Replacing refrigerant pipe/hose; compressor - condenser
TTTM2 Removing refrigerant pipe/hose; compressor - condenser

- First read TTTM1.
- Drain system of refrigerant according to BD. (See above)
- Raise car.
- Remove air baffle.
- Detach pipe/hose from condenser.
- Detach pipe/hose from compressor.
TTTM3 Installation of refrigerant pipe/hose; compressor condenser
25 6 Nm (19 4 ft.lb)In reverse order.Tightening torque .
Replacing refrigerant pipe/hose; condenser - member

> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Replacement Refrigerant Pipe/Hose or Expansion Valve > Page 1583

TTTM4 Removing refrigerant pipe/hose; condenser - member
- First read TTTM1.
- Drain system of refrigerant according to BD. (See at top)
- Detach pipe/hose from connection on member.
- Raise car.
- Remove air baffle.
- Detach pipe/hose from condenser.
TTTM5 Installation of refrigerant pipe/hose; condenser - member
25 Nm (19 4 ft.lb)In reverse order.Tightening torque .
Removing refrigerant pipe/hose; member - evaporator
TTTM6
- First read TTTM1.
- Drain system of refrigerant according to BD.
- Remove fresh air intake and outlet hose to control module box.
TTTM7

Diesel engines:
- Remove fuel filter with bracket.
TTTM8
- Remove expansion tank.
TTTM9
- Detach pipe/hose to condenser from connection on member.
- Detach pipe from member.
- Detach pipe from evaporator with wrench 999 5385.
Replacing/cleaning expansion valve

TTTM10 Removing expansion valve
- First read TTTM1.
- Drain system of refrigerant according to BD.
- Mark pipe positions in relation to each other at flanged joint.
- Separate at flanged joint.
- Remove expansion valve.
TTTM11 Installing expansion valve
30 Nm (22 ft.lb)In reverse order.Tightening torque .
Installation of refrigerant pipe/hose; member - evaporator
TTTM12
In reverse order.
Replacement of refrigerant pipe; evaporator - receiver drier
TTTM13 Removing refrigerant pipe; evaporator - receiver drier

- First read TTTM1.
- Drain system of refrigerant according to BD
- Remove fresh air intake and outlet hose to control module box.
TTTM14

Diesel engines:
- Remove fuel filter with bracket.
TTTM15
- Remove expansion tank.
TTTM16
- Detach pipe from receiver drier with wrench 9995472.
- Detach pipe from evaporator with wrench 999 5385.
- Remove pressure switch (Pressostat) from pipe.
TTTM17 Installing refrigerant pipe; evaporator - receiver drier

In reverse order.
Replacing refrigerant pipe/hose; receiver drier - compressor

TTTM18
Replacing pipe/hose; receiver drier - compressor according to TTTN. Replacing Receiver/Drier or suction line See: Re
Hose/Line HVAC: Service and RepairReplacing Receiver/Drier or Suction Line
Special tools: 999 5474, 999 5472
TTTN1 Before starting work on the Receiver/Drier or suction line
WARNING! FOLLOW THE SAFETY PRECAUTIONS FOR WORK ON A/C SYSTEMS ACCORDING TO A
NOTE! Read the sections covering slow and quick leaks first, according to BG1. See: Heating and Air Conditioning/S
NOTE!
When replacing the Receiver/Drier always install new O rings in pipes and quick-release connectors. Always plug pip
Removing Receiver/Drier or suction line
TTTN2 Preparations
- TTTN1First read .
- Disconnect battery negative lead.
- Drain system of refrigerant according to BD and BF1. (See B above)
- Remove fresh air intake to control module box.
TTTN3
- (FC)Detach engine cooling fan relay and engine cooling fan (FC) motor cable from fan shroud.
- Detach fan shroud.
- Remove relay shelf and spacer washers.
- Disconnect the engine cooling fan (FC) connector.
- Disconnect the engine cooling fan (FC) motor connector.
TTTN4

-
For(CAC) disconnect
turbocharged hose from charge air cooler and bend out of the way
engines:-
- remove cover over throttle pulley.
- remove fan shroud
- cover radiator with protective panel 999 5474.
TTTN5
- Remove suction intake hose and intermediate section between fan shroud nozzle and filter.
TTTN6 Removing Receiver/Drier or suction line

- Detach quick-release connector to evaporator at the Receiver/Drier using a quick-release connector pulling tool 9
- Screw out screw to receiver/drier bracket.
TTTN7

- Raise car.
- Remove air baffle between spoiler and frame member.
- Detach pipe coupling to compressor (suction line).
- Remove Receiver/Drier, suction line and bracket, by lifting it when it is hooked in the side member.
- Remove Receiver/Drier and suction line from bracket.
remove
When suctionsuction
replacing line from Receiver/Drier.
line: -
NOTE! Note the position of the suction line relative to the receiver/drier.
Installing Receiver/Drier or suction line
TTTN8 If replacing Receiver/Drier:

- TTTN1First read .
- BGFill the new receiver/drier with new oil. See: Heating and Air Conditioning/Service and Repair
- 30 Nm (22 ft.lb)Transfer suction line from the old to the new receiver/drier. Tightening torque: .
NOTE! Note the position of the suction line relative to the Receiver/Drier.
TTTN9 When replacing suction line:

- TTTN1First read
- Fill new suction line with fresh oil. See also BG.
- 30 Nm (22 ft.lb)Install suction line on Receiver/Drier. Tightening torque: .
NOTE! Install suction line in same position as noted when it was removed.
TTTN10 Installing Receiver/Drier or suction line, common operations

- Install Receiver/Drier and suction line in bracket.
- Install Receiver/Drier and suction line with bracket in side member.
- Install the quick coupling to the evaporator at Receiver/Drier.
NOTE! Use new O-rings lubricated with compressor oil
- 25 6 Nm (19 4 ft.lb)Install pipe coupling to compressor. Tightening torque: .

-- Remove
Install airprotective
baffle. panel 999 5474
- Install fan shroud.
- Install relays and cable in fan shroud
-
Fordisconnect hose
turbocharged from charge air cooler (CAC) and bend out of the way
engines:-
- remove cover over throttle pulley.
- Install control module box fresh air intake.
- Install suction intake hose and intermediate section between fan shroud nozzle and filter.
- Reconnect battery negative lead.
- Fill system with refrigerant according to BD. (See above)
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Tightening Specifications
Gear Pressure Line W/O-Ring Seal .................................................................................................................................

> Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: SpecificationsFluid type

Fluid type
Fluid Type DOT 4 +

> Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1598
Brake Fluid: Testing and Inspection

REPLACEMENT GUIDELINES
Replacing brake fluid is recommended every 48000 km (30 000 miles), or every other year. In cars where the bra
BACKGROUND
The reason that brake fluid should be changed is that brake fluid is hygroscopic: that is, it absorbs water molecule
> Maintenance > Fluids > Brake Fluid > Component Information > Service and Repair > Brake Fluid, Replacement With Bleeding Unit [CCCC]
Brake Fluid: Service and RepairBrake Fluid, Replacement With Bleeding Unit [CCCC]
CCCC. Brake fluid, replacement with bleeding unit
Special tools: 115 8147, 999 2809
[CCCC1]
Replacement guidelines
48,000 km (30,000 miles)

Replacing brake fluid is recommended every , or every other year. In cars where the brakes are used and often (e.g. i
[CCCC2]
Background
The reason that brake fluid should be changed is that brake fluid is hygroscopic: that is, it absorbs water molecules fr
Note! Use only Volvo original brake fluid marked DOT 4+. Never re-use brake fluid.Always keep brake fluid in
[CCCC3]
Preparations
Ignition off
0.2 - 0.3 MPa (29-42.7 psi)- Jack car up and remove wheels.- Clean around brake fluid reservoir cap.- Remove fillin
[CCCC4]
Connecting bleeding unit
- connect bleeding unit to brake fluid reservoir.
Follow manufacturers' instructions for connecting and using bleeding unit.
[CCCC5]
Replacing brake fluid LH front

Remove:
- Protective cap from bleed nipple on front LH brake caliper.
> Maintenance > Fluids > Brake Fluid > Component Information > Service and Repair > Brake Fluid, Replacement With Bleeding Unit [CCCC] > Page 1601

Connect drain bottle hose. Open nipple approx. one turn.
2 - 3 dl (0.2 - 0.3 US qt)
- Push brake caliper piston to bottom of caliper using a bolt clamp. Leave bolt clamp in the pushed-in position.- Pres
[CCCC6]
Replacing brake fluid RH, front
[CCCC3 - CCCC5]- Repeat steps , on the front RH brake caliper. Then continue as per instructions below.
[CCCC7]
Removing brake pad LH rear
Remove:
- Brake pad from brake caliper as per KB , Service manual, TP 5001011.
[CCCC8]
Replacing brake fluid LH rear
- Remove protective cap from bleed nipple.- Connect drain bottle hose.- Open nipple approx. one turn.- Push brake c
[CCCC9]
Installing rear brake pad
- Install brake pad as per KB , Service manual, TP 5001011.- Depress brake pedal a few times.
[CCCC10]
Replacing brake fluid RH, rear
- Repeat steps CCCC6 - CCCC8, on RH rear brake caliper.

[CCCC11]
Removing bleeding unit
Remove:
- Bleeding unit connection from brake fluid reservoir.
[CCCC12]
Finishing work
- Depress brake pedal repeatedly until brake pistons return to normal position.- Check brake fluid level and install re
[CCCC13]
Installing wheels
Make sure that brake disc and rim contact surfaces are clean.
- Grease hub center rim guide with anti-rust agent 116 1038-3.
Install:
110 Nm (81.2 ft lb)- Wheel.- Nuts hand tight. Then tighten them in a star pattern to . It tightening with a nut wrench
Note! Tightening nuts in a star pattern to a specified torque is important to prevent stresses arising in the brake d
Brake Fluid: Service and RepairBrake Fluid, Replacement Without Bleeding Unit [DDDD]
DDDD. Brake fluid, replacement without bleeding unit
Special tools: 115 8147, 999 2809
[DDDD1]
48,000 km (30,000 miles)

[DDDD2]
Background
Note!
Use only Volvo original brake fluid marked DOT 4+. Never re-use brake fluid. Always keep brake fluid in
Note! Check continuously that there is enough brake fluid in the brake fluid reservoir when replacing brake fluid
[DDDD3]
Preparations
- Ignition off.- Jack car up and remove wheels.- Clean around brake fluid reservoir cap. Get a drain bottle and hose to
[DDDD4]
Replacing brake fluid, front
2 - 3 dl (0.2 - 0.3 US qt)
- Remove protective cap from bleed nipple.- Connect drain bottle hose. Open nipple approx. one turn.- Push brake ca
[DDDD5]

Replacing brake fluid RH front
[DDDD2 - DDDD4]- Repeat steps , on the front RH brake caliper.
[DDDD6]
- Remove brake pad brake caliper.
[DDDD7]
2 - 3 dl
Remove:
- Remove tools from brake caliper.
[DDDD8]
Install brake pad.
- Depress brake pedal a few times.
[DDDD9]
Repeat steps

[DDDD10]
Finishing work
Clean off any brake fluid spillage with lukewarm water and car-wash shampoo.
[DDDD11]
Installing wheels
110 Nm- Grease hub center rim guide with anti-rust agent 116 1038-3.- Re-fit wheel.- Tighten nuts hand tight. Then
> Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications

Use hydraulic fluid quality ...................................................................................................................................................
> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity Specification

Coolant volume ..........................................................................................................................................................
> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1613
Coolant: Fluid Type Specifications
Coolant Specifications
Genuine Volvo or equivalent type C coolant diluted 50/50 with pure water.
> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Differential Fluid - A/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Retailer Technical Journal 16773Transmission and AWD lubricantsDate 1-23-2009
Note!
If using a printed copy of this Retailer Technical Journal, first check for the latest online version.
NOTE!
THIS DOCUMENT SUPERSEDES RTJ 16773, DATED 1-16-2009. A new manual transmission fluid has been ad
> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1618

AFFECTED VEHICLES
> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1619
Differential Fluid - A/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
MODEL/YEAR: All Models
SUBJECT:
Transmission and AWD Lubricants

REFERENCE: Owners Manual and VIDA
> Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Differential Fluid - M/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1624

AFFECTED VEHICLES
> Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1625
Differential Fluid - M/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Differential Fluid - Transfer Case: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids >
Page 1630

AFFECTED VEHICLES
> Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1631
Differential Fluid - Transfer Case: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - A/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1636

AFFECTED VEHICLES
> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1637
Fluid - A/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications

CAPACITY AW50-42LE
Refill After Servicing ...........................................................................................................................................................

> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1640
Fluid - A/T: Fluid Type Specifications
Transmission Fluid
Type .................................................................................................................................................... DEXRON II-E, DE

> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1641
Fluid - A/T: Service and Repair
Replacing Transmission Fluid
Changing Oil
Note!
Use only automatic transmission fluid which fulfills both Dexron IIE and Ford Mercon standards. Avoid s
Conditions
The oil should be replaced only in the following instances:-

When the on-board diagnostic system (OBD system) has recoreded that the oil temperature is too high, diagnosti
- If the oil smells burnt and is discolored and no diagnostic trouble code (DTC) has been stored. For example due t
- On cars used in continuous taxi service and/or used to tow trailers extensively, should have the oil changes at 750
Warning! The oil may be very hot if the car has just been driven. Avoid skin contact.
Draining
- Remove the splash guard under engine (certain versions)

- Remove the oil plug. Drain the transmission oil.
Installing the oil pan plug
40 Nm. Install the oil pan plug with a new gasket.Torque Install splash guard (certain variants).
Preparing to flush the transmission
the battery
Remove-
- the battery shelf.
Remove the return hose on the control system cover.Install a plastic plug in the connection on the cover.Install a tran
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1642

Refilling
Apply the parking brake. Move the gear selector lever to position P. Add approximately 2 liters of oil.Start the engin
Further filling
7.6 0.25 litersFill with approximately 2 liters of oil.Apply the parking brake.Start the engine and let it idle.Move the
Erasing diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs)
After replacing the transmission, the adaptation and the "Transmission oil change" counter must be reset.
> Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - M/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1647

AFFECTED VEHICLES
> Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1648
Fluid - M/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
Oil Fill Specifications
Capacity ...............................................................................................................................................................................
> Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1651
Fluid - M/T: Fluid Type Specifications
Transmission Specifications
Volvo Synthetic Transmission Oil .......................................................................................................................................

> Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - Differential: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1656

AFFECTED VEHICLES
> Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1657
Fluid - Differential: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Type 1155 Bevel Gear
Differential Fluid
Capacity ...............................................................................................................................................................................
Type 1165 Final Drive
Differential Fluid
Capacity ...............................................................................................................................................................................
> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1660
Fluid - Differential: Fluid Type Specifications
Differential Fluid
Type .....................................................................................................................................................................................
Differential Fluid
Type .....................................................................................................................................................................................
> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - Transfer Case: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1665

AFFECTED VEHICLES
> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 1666
Fluid - Transfer Case: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications

Bevel Gear 1155 Volume .....................................................................................................................................................
> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1669
Fluid - Transfer Case: Fluid Type Specifications

Bevel Gear 1155
Grade ....................................................................................................................................................................................
> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1670
Fluid - Transfer Case: Service and Repair
Filling Bevel Gear Fluid
NOTE:
If bevel gear has been removed, position the bevel gear so that it is standing on the oil pan (as it is loctated in the car)
Remove level plug.
P/N 1161648Fill with oil () until the oil runs out of the level plug hole.
CAUTION!
0.2 LThen drain of oil
Install the level plug.
35 NmTighten level plug: ....................................................................................................................................................

> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Engine Version 1With filter .................................................................................................................................................

> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1675
Engine Oil: Fluid Type Specifications
Engine Oil
Grade .......................................................................................................................................................... API SJ, SJ/CF,

> Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications

Volume .................................................................................................................................................................................
> Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1680
Power Steering Fluid: Fluid Type Specifications

[1]Transmission oil grade ...................................................................................................................................................
[1]_________________________________: Volvo P/N 11 61 317-1

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications
Refrigerant: Capacity Specifications
Total Capacity Cold Market Vehicle 1.80 lb (US)
Warm Market Vehicle 1.65 lb (US)

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1685
Refrigerant: Fluid Type Specifications
Refrigerant Type R-134a

> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications
Refrigerant Oil: Capacity SpecificationsCapacity

Capacity
Total Capacity 200 mL

0.211 US Quarts.
> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1690
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil Volvo # 11 61 407-0, or equivalent

> Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA]
Brake Bleeding: Service and RepairBleeding Brakes With Bleeding Unit [AAAA]
AAAA. Bleeding brakes with bleeding unit
Note! Bleeding braking systems with ABS takes longer than bleeding conventional braking systems.
[AAAA1]
Guidelines for bleeding
When overhauling or replacing brake calipers, it is usually enough to bleed the brake pipe concerned as below. One c
Note!
[AAAA2]
Preparations
Ignition off.Jack car up.Clean filler cap on brake fluid reservoir and the surrounding area.
Remove:
- Filler Gap.
0.2-0.3 MPa (29-42.7 psi)Set bleeding unit to .
[AAAA3]

> Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA] > Page 1695

- Connect bleeding unit to brake fluid reservoir. Follow manufacturers' instructions for connecting and using bleedin
Note! Repeat this step between bleeding each brake caliper.
[AAAA4]
Bleeding LH front wheel
Remove:
- Protective cap from bleed nipple and connect hose from drain bottle.
Open bleed nipple and close it again once no further air bubbles can be seen in the escaping fluid. Tighten bleed nipp
Remove:
- Hose from bleed nipple and re-install protective cap.
[AAAA5]
Bleeding other wheels

Continue bleeding as per AAAA-AAAA5 in the following order:

- RH front wheel- LH rear wheel- RH rear wheel
Remove:
- Bleeding unit connector from brake fluid reservoir.
[AAAA6]
Check
200 N
40 mm (1.6 in)
40mm (1.6 in)
Check if there is any air left in the system by depressing the brake pedal as if braking sharply (a braking power equiv
Brake Bleeding: Service and RepairBleeding Brakes Without Bleeding Unit [BBBB]
BBBB. Bleeding brakes without bleeding unit
Note! Bleeding braking system with ABS takes longer than bleeding conventional braking systems.
[BBBB1]
When overhauling or replacing the brake caliper, mechanical bleeding in the usual way will normally be enough, but
Note! Use only genuine Volvo brake fluid marked DOT 4+ Never reuse brake fluid. Always keep brake fluid in
[BBBB2]
Preparations
Ignition off.
- Jack car up.
Clean brake fluid reservoir filler cap and area around it.
Remove:
- Remove filler cap.
Fill brake fluid reservoir completely.
[BBBB3]


Depress brake pedal a few times to remove any air bubbles in the master cylinder.
Note! This step must be carried out between bleeding each brake caliper concerned.
- Remove protective cap from bleed nipple and connect hose from collecting bottle.- Open bleed nipple.- Push brake
[BBBB4]
[AAAA3]Continue bleeding as per In the following order:
- RH front Wheel.- LH rear wheel.- RH rear wheel.
Check
200 N
31 40 mm (1.6 in)Check if there is any air left in the system by depressing the brake pedal sharply (a braking power
If pedal travel is longer than 40 mm (1.6 ins) bleed again and then re-check pedal travel.
Check that brake fluid level is not over the MAX mark.
> Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
WARNING: The manufacturer provides arming and disarming instructions as part of each applicable service p
Read and understand all applicable service procedures and safety precautions completely before beginning work
Failure to follow all SRS service precuations and procedures may result in damage to the vehicle, personal injur
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
Fuse: Locations
Fuses
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1706

Panel Locations

Relays

Panel Locations

Other Relays
Fuse: Application and ID
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
Fuse Block: Locations
Fuses
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1718

Panel Locations

Relays

Panel Locations

Other Relays
Fuse Block: Application and ID
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
Fuse Block: Service and Repair
Replacing Relay In the Main Fuse Box and Other Relays In the Engine Compartment:
DC1 Removing:
battery negative lead.

Remove:-
- relay. Position of relays as in image.
DC2 Installing:
- Install relay.
- Connect battery negative lead.
Test relay function.
Relay Position, Engine Compartment:
1) Main relay2) Pulsed secondary air injection system (PAIR) pump / Glow plug relay (Diesel)3) Starter relay4) Air
> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations
Fuses
> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1731

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
The service reminder indicator (SRI) is lit for two minutes each time the engine is started until it is reset after the next s
The service reminder indicator (SRI) is lit when one of the following factory set service intervals is reached:
VDO not USA/CAN
15,000 km/10,000 miles750 operating hours12 calendar months

VDO USA/CAN 15,000 km/10,000 miles
(cars without turbocharger (TC)
750 operating hours12 calendar months
VDO USA/CAN 7,5OO km/5,000 miles

(cars with turbocharger (TC))
500 operating hours12 calendar months
> Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Vehicles With Early Version VDO Instrument Pane
Maintenance Required Lamp/Indicator: Service and RepairVehicles With Early Version VDO Instrument Pane
MUST USE SRIAll Volvo's with VDO instrument panel the Volvo Scan Tool to reset the Service Reminder Indicator
The SRI is reset using the Volvo Scan Tool via the 16-pin DLC connector located in front of the transmission shifter or
The Diagnostic Socket previously used to reset the SRI has been eliminated beginning with the 1996 model year vehicl
EDITOR'S NOTE:
There has been some development regarding aftermarket SRI resetting tools.
Assenmacher Specialty Tools Inc. has developed a Scan Tool that will reset the SRI on Volvo's.
I have contacted Assenmacher Specialty Tools to confirm this but do not represent Assenmacher Specialty Tools I
(303)Specialty
Assenmacher 530-2424 Tools Inc.Phone
Fax (303) 530-4720
Maintenance Required Lamp/Indicator: Service and RepairVehicles With Late Version VDO Instrument Panel
Resetting the Service Reminder Indicator (SRI):
Ignition
To reset the off
service reminder indicator (SRI) carry out the procedure as following:-
- Press and hold in the trip odometer reset button
- Switch on ignition
- Continue pressing in the reset button for 10 seconds until Service Reminder Indicator starts flashing.
- Release reset button within 4 seconds
Maintenance Required Lamp/Indicator: Service and RepairVehicles With Yazaki Instrument Panel
The service reminder indicator (SRI) is lit for two minutes each time the engine is started until it is reset after the next s
Resetting the service reminder indicator (SRI):
- Remove rubber plug without scratching the glass.

- Press in button as far as it will go.
- Install plug.
The service reminder indicator (SRI) is lit when the following factory set service interval is reached:
Yazaki 15,000 km/10,000 miles

> Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
If the lamp comes on (or stays on after the vehicle has started), the engine diagnostic system has detected a possible f
NOTE:
If the fuel filler cap is not closed tightly or if the engine is running when the car is refueled, the Malfunction Indicato
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance
Tires: Customer InterestWheel - Imbalance

SECTION
6
GROUP
65
NO. 802
DATEAug. -97
Wheel imbalance855, V70 All-wheel drive (AWD) 1997-
REFERENCE: TP 6502201, SECTION 6, 7 (65, 72-77), REAR SUSPENSION AWD: 850 1997-
Wheel imbalance
Background:
On the 855/V70 All-Wheel Drive (AWD) snow may become lodged in the rear wheel rims and become so tightly pack
This can be avoided by installing a bracket with lug, which cleans snow from the wheel rims.
Materials.
Left lug 919 1547-0

Right lug 919 1549-6
2 nuts 971 099-7
Rustproofing agent 116 1030-0
Special tool: Tensioner 999 5659-1
Remove:
- Rear wheels.
Install:
- Tensioner 999 5659.
See TP 6502201, Section 6, 7(65, 72-77)Rear suspension All-wheel drive (AWD) 850 1997-Chapter. General, usin
Remove:
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance > Page
1760

- Screw and washer for stay.
- Nut for lower control arm mounting.
Install:
- Bracket.
-
Note!
Screw for stay. Use locking fluid on screw. The washer should not be installed again. Tighten to 80 Nm (59 ft.lbs).
-
Nut for lower control arm mounting. Use a new nut. Tighten to 80 Nm (59 ft.lbs).
- Wheels.
Tightening wheel studs
When installing and tightening wheel studs the following applies.
Ensure that the brake disk and wheel rim mating surfaces are clean. Grease the hub center location dowel for the rim. U
Tighten screws loosely. Then tighten crosswise to 110 Nm (81 ft.lbs).

When tightening with impact wrench, use torque socket 1158147-7.
importantIt is to tighten crosswise to prevent tension being produced in the brake disc.
Note!
The torque socket wrench is designed for tightening wheel studs using standard, air-driven impact tighteners provid
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing d
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance > Page
1761

65906-2 Installing brackets for removing snow 0.6 hr
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > TNN77-18 > May > 07 > Tires - Pressure R
Tires: All Technical Service BulletinsTires - Pressure Requirements/Recommendations

NO: 77-18
DATE: 5-15-2007
MODEL: All
MODEL YEAR: All
SUBJECT: Tire Pressures, Requirements and Recommendations
REFERENCE:VIDA, SMB 17-006, owners' manuals
Description
Tire pressure is a critical element of vehicle performance. Correct tire pressure is important for:
^ achieving good fuel economy
^ achieving optimum comfort and good driving characteristics
^ helping to prevent flat-spotted tires due to low tire pressures
As stated in the Model Year 2007 owners' manuals:
^
Under-inflation is the most common cause of tire failure and may result in severe tire cracking, tread separation, or
^ Under-inflated tires reduce the load carrying capacity of your vehicle.
Over-inflation is also undesirable. Over-inflated tires can be stiff and unyielding, and will cause the vehicle to ride mor
Under-inflation or over-inflation may cause uneven treadwear patterns.
There are many opportunities for the Volvo retailer to check and maintain proper tire pressure, from new vehicle storag
Service
GENERAL:
Tire pressures should always be checked cold. Tires are considered to be cold when they have the same temperature as
After driving a distance of approximately 1 mile (1.6 km), tires are considered to be hot.
When the weather temperature changes, tire inflation pressures also change. A 10-degree F (5-degree C) temperature d
TRANSPORT PRESSURE:
All new Volvo vehicles are delivered from the port to the retail facility with tires at 'transport pressure', which is 43 psi
Note!
Failure to maintain transport pressure in tires may result in tire damage not covered by the tire manufacturer's warra
CPS (CUSTOMER PREPARATION SERVICE):

> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > TNN77-18 > May > 07 >
Tires - Pressure Requirements/Recommendations > Page 1767

SMB 17-006 also gives detailed information regarding operations to conduct during the CPS (Customer Preparation Se
Note!
CPS should only be completed just prior to actual retail delivery of the vehicle to the customer.
Model Year 2007 U.S. specification vehicles have only one recommended tire pressure. This is the case whether the ve
Canadian specification vehicles continue to use labels with both a cold tire pressure and an optional tire pressure.
In all cases:
Use the recommended cold inflation pressure for optimum tire performance and wear.
NITROGEN:
There have been reports in the industry regarding the use of nitrogen for inflating tires. Volvo's position is that nitrogen
CALIBRATION OF TIRE PRESSURE MEASURING EQUIPMENT:
VIDA can be used to check a vehicle's tire pressures.
This is the path in VIDA to follow:
Diagnostics > Vehicle communication > UEM> Advanced > Quick Test
As the tire pressure displayed in VIDA is extremely accurate, this display can be used to 'calibrate' tire pressure measur
TPMS (TIRE PRESSURE MONITORING SYSTEM):
TPMS (Tire Pressure Monitoring System) was optional on certain Model Year 2005 and 2006 vehicles fitted with SST
The system must be regarded as a driver aid to maintain the correct tire pressure. TPMS does not take the place of good
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 4460005 > Jan > 01 > Wheels/Tires - AWD
Tires: All Technical Service BulletinsWheels/Tires - AWD Information & Function Test
850 1997/S70/V70/V70 XC 1998-2000/V70 XC 2001-1997-
Section4
Group46
No.0005
Year01
Month01
Vehicles involved:AWD/XC
AWD Wheels/Tires, Information and function test
BackgroundThis service bulletin contains information to ensure that the all-wheel drive (AWD) system is not damaged
Wheels and Tires, Information and function test
Information about wheels and tires and function test
Note!
To prevent deterioration in the function of the power transmission system on All-wheel drive (AWD) cars, it is imp
All Wheel Drive vehicles have special requirements for tires and wheels. It is very important that the tire replacement g
Always drive on tires of identical brand, size, construction (radial), tread pattern, load-, speed-, traction-, temperature-,
Never drive on mixed tires, except for brief periods when the temporary spare tire is in use.
Always use properly inflated tires of correct dimensions. Tire size and inflation pressures are shown on the tire pressur
Caution!
Failure to always drive on properly inflated, identical tires of correct dimensions may result in a circumference diffe
2
Replacing the tires
When tire replacement is necessary, Volvo strongly recommends replacing all four tires at the same time with identical
If only one or two tires are replaced, the new tire(s) must be identical to the tires with which the car was built, and mus
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 4460005 > Jan > 01 >
Wheels/Tires - AWD Information & Function Test > Page 1772

Spare wheel Temporary spare
The temporary spare tire is for temporary, low-speed, short-distance use only Do not drive on the temporary spare at sp
Snow chains all-wheel drive (AWD)
On all-wheel drive cars, (AWD), snow chains must only be mounted on the front wheels. Only snow chains intended fo
Viscous coupling function
The viscous coupling transmits driving power to the rear wheels when necessary. In normal driving conditions on dry a
Because of the viscosity of the oil and the difference in speed between the plates, the oil transmits power to the rear wh
Viscous coupling test method
Ensure that the viscous unit remains at room temperature.
- Raise the left or right-hand front wheel so that it rotates freely. The other wheels must be in contact with the ground
- Select neutral.

- Position a torque wrench horizontally as illustrated. Read the torque value.
Note!
It is important that the torque wrench points towards the center of the wheel to provide the correct torque reading.
- Turn the torque wrench half a turn (180) clockwise with even torque for 25 seconds.
- The torque must be GREATER than 50 Nm (37 lb ft) during the entire turn.
The test method assumes that all the other components included in the system function correctly If the torque is below
The function of the freewheel unit
A freewheel unit is connected to the viscous coupling. It is located after the viscous coupling and has two functions:
- Dis-engaging rear-wheel drive during braking.
- Engaging four-wheel drive when reversing.
The freewheel unit has an input and an output shaft. These shafts can be connected via a freewheel and via a centrifuga
The freewheel unit, which has a centrifugal roller lock-up mechanism, also makes it possible to reverse with four-whee
Freewheel
- When driving forward, power can be transmitted from the input shaft to the output shaft (rear axle) via the freewhee
During braking the rear wheels may rotate faster than the front wheels. In this case the freewheel is driven in the (op
-
When reversing, the freewheel is driven by the input shaft in the "opposite" direction. The freewheel is free and can
Centrifugal lock-up mechanism
The centrifugal lock-up mechanism consists of:
- Centrifugal weights in the form of ball bearings.
- A spring-loaded cage with a ball holder. The ball holder has ramps and six small ball bearings.
- Internal cutouts in the input shaft.

At low speeds, the small ball bearings are forced out of the ramps, and engage with the cutouts in the input shaft. Powe
When speed increases, the centrifugal weights are thrown outward.
At approximately 50 km/h (30 mph) the centrifugal weights press back the spring-loaded cage and ball holder. The ball
Testing the function of the freewheel:
Raise the car using a two-post workshop lift so that the wheels rotate freely.
Warning!
Screen off the wheels to prevent stones flying off, or remove stones from the wheels. Ensure that there is nothing in
Start the engine, select reverse gear and accelerate gradually to 50 km/h (30 mph).
Accelerating above 50 km/h (30 mph) disengages the rear wheels and they rotate more slowly than the front wheels.
Depress the clutch pedal (manual transmissions) or release the accelerator pedal (automatic transmissions). Allow the r
It is normal that a loud noise can occur when the rear wheels connect again.
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 665802 > Aug > 97 > Wheel - Imbalance
Tires: All Technical Service BulletinsWheel - Imbalance

SECTION
6
GROUP
65
NO. 802
DATEAug. -97
Wheel imbalance
Background:
Materials.
Left lug 919 1547-0

2 nuts 971 099-7
Remove:
- Rear wheels.
Install:
Remove:
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 665802 > Aug > 97 > Wheel
- Imbalance > Page 1779

Install:
- Bracket.
-
Note!
-
- Wheels.

Note!
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 665802 > Aug > 97 > Wheel
- Imbalance > Page 1780

> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > TNN77-18 > May > 07 > Tires - Pressure Requ
Tires: All Technical Service BulletinsTires - Pressure Requirements/Recommendations

NO: 77-18
DATE: 5-15-2007
MODEL: All
MODEL YEAR: All
SUBJECT: Tire Pressures, Requirements and Recommendations
REFERENCE:VIDA, SMB 17-006, owners' manuals
Description
Tire pressure is a critical element of vehicle performance. Correct tire pressure is important for:
^ achieving good fuel economy
^ achieving optimum comfort and good driving characteristics
^ helping to prevent flat-spotted tires due to low tire pressures
As stated in the Model Year 2007 owners' manuals:
^
Under-inflation is the most common cause of tire failure and may result in severe tire cracking, tread separation, or
^ Under-inflated tires reduce the load carrying capacity of your vehicle.
Over-inflation is also undesirable. Over-inflated tires can be stiff and unyielding, and will cause the vehicle to ride mor
Under-inflation or over-inflation may cause uneven treadwear patterns.
There are many opportunities for the Volvo retailer to check and maintain proper tire pressure, from new vehicle storag
Service
GENERAL:
Tire pressures should always be checked cold. Tires are considered to be cold when they have the same temperature as
After driving a distance of approximately 1 mile (1.6 km), tires are considered to be hot.
When the weather temperature changes, tire inflation pressures also change. A 10-degree F (5-degree C) temperature d
TRANSPORT PRESSURE:
All new Volvo vehicles are delivered from the port to the retail facility with tires at 'transport pressure', which is 43 psi
Note!
Failure to maintain transport pressure in tires may result in tire damage not covered by the tire manufacturer's warra
CPS (CUSTOMER PREPARATION SERVICE):

> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > TNN77-18 > May > 07 > Tires -
Pressure Requirements/Recommendations > Page 1786

SMB 17-006 also gives detailed information regarding operations to conduct during the CPS (Customer Preparation Se
Note!
CPS should only be completed just prior to actual retail delivery of the vehicle to the customer.
Model Year 2007 U.S. specification vehicles have only one recommended tire pressure. This is the case whether the ve
Canadian specification vehicles continue to use labels with both a cold tire pressure and an optional tire pressure.
In all cases:
Use the recommended cold inflation pressure for optimum tire performance and wear.
NITROGEN:
There have been reports in the industry regarding the use of nitrogen for inflating tires. Volvo's position is that nitrogen
CALIBRATION OF TIRE PRESSURE MEASURING EQUIPMENT:
VIDA can be used to check a vehicle's tire pressures.
This is the path in VIDA to follow:
Diagnostics > Vehicle communication > UEM> Advanced > Quick Test
As the tire pressure displayed in VIDA is extremely accurate, this display can be used to 'calibrate' tire pressure measur
TPMS (TIRE PRESSURE MONITORING SYSTEM):
TPMS (Tire Pressure Monitoring System) was optional on certain Model Year 2005 and 2006 vehicles fitted with SST
The system must be regarded as a driver aid to maintain the correct tire pressure. TPMS does not take the place of good
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 4460005 > Jan > 01 > Wheels/Tires - AWD Inf
Tires: All Technical Service BulletinsWheels/Tires - AWD Information & Function Test
850 1997/S70/V70/V70 XC 1998-2000/V70 XC 2001-1997-
Section4
Group46
No.0005
Year01
Month01
Note!
Caution!
2
Replacing the tires
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 4460005 > Jan > 01 > Wheels/
Tires - AWD Information & Function Test > Page 1791

- Select neutral.

Note!
Freewheel
-

Warning!
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1794
Tires: Application and ID

Size .......................................................................................................................................................................................
> Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1795
Tires: Description and Operation

tire Pressures, Cold Tires
1-3 People
Tire Sizes 205/55 R16 and 195/65 R15:
0-160 km/h (0-100 mph)5-Door at :
220 kPa (31.3 psi) 230 kPa (32.7 psi)Front: Rear:

160+ km/h (100+ mph)5-Door at :
Full Load, And Trailer

Tire Sizes 205/55 R16 and 195/65 R15:
0-160 km/h (0-100 mph)5-Door at :

160+ km/h (100+ mph)5-Door at :
Note that the values apply to cold tires (outside temperature). Tires get hot after just a few kilometers drive and press
NOTE: Low tire pressures can affect handling and increase tire wear.
CAUTION:
Wheel sizes must be the same on all wheels. A spare wheel of the "Temporary spare" type must only be used with T
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 4460005 > Jan > 01 > Wheels/Tires - A
Wheels: All Technical Service BulletinsWheels/Tires - AWD Information & Function Test
850 1997/S70/V70/V70 XC 1998-2000/V70 XC 2001-1997-
Section4
Group46
No.0005
Year01
Month01
Note!
Caution!
2
Replacing the tires
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 4460005 > Jan > 01 >

- Select neutral.

Note!
Freewheel
-

Warning!
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 665802 > Aug > 97 > Wheel - Imbalan
Wheels: All Technical Service BulletinsWheel - Imbalance

SECTION
6
GROUP
65
NO. 802
DATEAug. -97
Wheel imbalance
Background:
Materials.
Left lug 919 1547-0

2 nuts 971 099-7
Remove:
- Rear wheels.
Install:
Remove:
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 665802 > Aug > 97 >
Wheel - Imbalance > Page 1811

Install:
- Bracket.
-
Note!
-
- Wheels.

Note!
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 665802 > Aug > 97 >
Wheel - Imbalance > Page 1812

> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance
Wheels: Customer InterestWheel - Imbalance

SECTION
6
GROUP
65
NO. 802
DATEAug. -97
Wheel imbalance
Background:
Materials.
Left lug 919 1547-0

2 nuts 971 099-7
Remove:
- Rear wheels.
Install:
Remove:
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance > Page
1818

Install:
- Bracket.
-
Note!
-
- Wheels.

Note!
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 665802 > Aug > 97 > Wheel - Imbalance > Page
1819

> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 4460005 > Jan > 01 > Wheels/Tires - AWD
Wheels: All Technical Service BulletinsWheels/Tires - AWD Information & Function Test
850 1997/S70/V70/V70 XC 1998-2000/V70 XC 2001-1997-
Section4
Group46
No.0005
Year01
Month01
Note!
Caution!
2
Replacing the tires
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 4460005 > Jan > 01 >

- Select neutral.

Note!
Freewheel
-

Warning!
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1828
Wheels: Service Precautions
Towing, Changing Wheels And Rolling Road/wheel Spinner Test
Towing
CAUTION:
All-wheel drive cars must not be towed with only one pair of wheels off the ground. If the car is towed in the wr
Changing Wheels
All wheel drive cars have an extra jacking point. This is located just in front of the rear axle, see illustration. The
WARNING: All-wheel drive cars must have the same size of wheel all round. A spare wheel of the "Temp
Rolling Road Test

When testing brakes or on a rolling road or wheel spinner or balancing wheels the other wheels must rotate freely
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1829
Wheels: Service and Repair
Special Tools
951 2834
Installing wheels
4 Bolt Wheel
5 Bolt Wheels Tightening Pattern
Ensure that the brake disk and wheel rim mating surfaces are clean. Grease the hub center location dowel for the rim
Use rustproofing agent 1161030-0.
110 NmInstall the wheel studs lightly. Then tighten crosswise to . Use torque socket 951 2834 if an impact wrench is
Crosswise tightening and torque tightening is important to prevent stresses in the brake disc.
Note! 250 - 350 Nm. The torque socket is designed for use with a standard, air-powered impact wrench providing a
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection
Wheel Bearing: Testing and Inspection
Measuring lateral run-out in hub
Special tools:
999 5418999 5507
Preparations
- Get measurement tool set 999 5418.

- Remove brake caliper and brake pads as per Brake disc front, replacement or Brake disc rear, replacement. Then
Note: Mark brake disc up against hub so disc can return to its old position when installing.
- Clean hub flange carefully. Remove rust with steel blade and steel brush.
Installing measurement equipment
- Install measurement equipment as per illustration. Illustration shows testing front.

- Front:Use Me bolts, washers and nuts in bolt set 999 5507 when installing measurement tool bracket to front brak
Note: Make sure that bracket is not lying against driveshaft gaiter, (front only).
- Rear:Use the bolts included in the measurement tool set when installing measurement tool bracket to the rear bra
Measuring lateral run-out

> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1833

- Put the test gauge point against the hub flange as in the illustration.
- Rotate hub gently. Use a wheel wrench as an aid on the front hub.
Note: Illustration shows testing front.
- 0.020 mm (0.00079")Note test gauge run-out. Hub lateral run-out must not exceed .
- 0.020 mm (0.00079")Replace hub if maximum lateral run-out exceeds .
Finishing
-
8 Nm (6 ft. lbs.)Install brake disc on hub, lining up marks.Tighten locating pin and bolt to .
- Go to Brake disc front, replacement or Brake disc rear, replacement.
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications
Axle Nut: Specifications

Driveshaft Nut, Rear
Stage 1 ..............................................................................................................................................................................
Driveshaft Nut, Front
Stage 1 ..............................................................................................................................................................................
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Page 1838
Axle Nut: Service and Repair
Warning The use of protective equipment such as safety goggles is recommended.
If a drive shaft nut that requires staking needs to be re-tightened or removed, a new nut must be installed. Tighten the
Procedure for locking hub:

Clean splines and groove in shaft thoroughly. Remove all oil, anti-rust agent and dirt.
3 - 4 mm (3/16" - 1/4")
Apply wide bead of metal adhesive, P/N 1161370-0 Apply bead around shaft covering approximately 1/3 of splined
Note! Apply adhesive around complete shaft just before installing hub.
120 Nm (89 ft. lbs) + 60

Install hub and new nut.Tighten nut to as specified in service manual.Lock the nut (stake the nut) by tapping outer fl
Note!
From chassis no:s. 854: 219646,855: 121429 a new drive shaft nut has been introduced on all versions of the 850, w
- The nut is reusable

- There is no locking groove in the drive shaft.
- The threads on the shaft end have increased from M20 to M22.
- New self-locking nut with M22 thread.
Note! The nut must be oiled before use.
120 Nm (89 ft. lbs) + 60.The new nut must be tightened to the same torque and protractor angle as previously.
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications

TORQUE SPECIFICATIONS
Wheel Stud .......................................................................................................................................................................
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1842
Wheel Fastener: Service and Repair
Special Tools
951 2834
Installing wheels
4 Bolt Wheel
5 Bolt Wheels Tightening Pattern
Ensure that the brake disk and wheel rim mating surfaces are clean. Grease the hub center location dowel for the rim
Use rustproofing agent 1161030-0.
110 NmInstall the wheel studs lightly. Then tighten crosswise to . Use torque socket 951 2834 if an impact wrench is
Crosswise tightening and torque tightening is important to prevent stresses in the brake disc.
Note! 250 - 350 Nm. The torque socket is designed for use with a standard, air-powered impact wrench providing a
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended

SECTION
2
GROUP
21
NO.842
DATESep. 1998
Background:
Chassi No.:
S70 - 460000
V70 - 395002
Special tools: 999 9689, 115 8540
Compression test
High tension 1
Warning!
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended > Page 1849

Note!
Separate connector
Remove:

- spark plugs.
Remove fuse 11B3 4
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended > Page 1850

Note!

Installing
- components
- fuse 11B3.
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Technical Service Bulletins > Page 1851

Normal value .................................................................................................................................................... 1.3 -
SPECIAL TOOLS
NOTE:
For additional information on special tools and equipment used in this procedure, refer to Service and Repair. See: To
The DI system

NOTE:
1. Remove:
- HT lead cover
Remove
open:-

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Pulley....................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > With VVT
Camshaft Gear/Sprocket: Service and RepairWith VVT
Replacing the camshaft seals/Variable Valve Timing (VVT) unit
Special Tools
951 2050999 5450999 5451999 5452999 5651999 5718999 5719999 5919

Note!
Removing the camshaft seal
The abbreviation VVT stands for:Variable Valve Timing.
Note! Crankshaft or camshafts must not, under any circumstances, be rotated more than is listed below.
Failure to follow these instructions may cause damage to the valves.
Remove
- the cable from the battery negative terminal. Note when disconnecting/connecting the battery lead.
- the charge air pipe over the engine. Seal the openings.
- the upper camshaft belt cover.
- the cover over the ignition coils.
- lift the solenoid valves away from the Air Cleaner (ACL) cover.
- the air intake hose for the Turbocharger (TC) from the Air Cleaner (ACL) cover. Put to one side.
- the upper torque rod bracket.
- the Camshaft Position (CMP) sensor housing.
- the trigger wheel.
- the rear cover for the intake camshaft.
- the servo reservoir and the expansion tank. Lift up and place on top of the engine.
Note!
Take care not to spill servo oil from the bleed hole in the cap. Place paper wipe around the reservoir and th
- 3 nuts for the cable duct at the right suspension turret. Lift the duct away from the screws.
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > With VVT > Page
1860

- the auxiliaries belt.
- the front camshaft belt cover.
Position the engine according to the marking Raise the car.

Remove
- the right front wheel.
- the nuts for the cover in the fender liner.
Install the upper camshaft belt cover.Turn the crankshaft clockwise until the markings on the crankshaft and camshaf
Removing the camshaft belt
Slacken off the belt tensioner.
Slacken off the belt tensioner center screw slightly.Hold the center screw still and turn the tensioner eccentric clockw
Removing the timing gear pulley with the variable Valve Timing (VVT) unit
Use camshaft adjustment tool:
1861

- Install camshaft adjustment tool 999 5452 at the rear edge of the camshafts. First screw in the part of the tool inte
Install the adjustment tools

Screw the camshaft adjustment tools together
1862

ERROR: undefined
OFFENDING COMMAND: ~
STACK:
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > With VVT > Page 1863
Camshaft Gear/Sprocket: Service and RepairWithout VVT
Front Seal
Replacing camshafts seal
Special Tools
999 5199999 5449999 5450999 5451999 5452999 5919

Front seal
Remove
- spark plugs cover

- two fuel lines clamps
- Lift expansion tank place over engine to one side
- right front wheel
Remove right fender liner to expose the vibration damper.
Turn engine crankshaft clockwise

The camshaft pulleys should rotate until all the markings correspond.Remove upper timing cover.
Remove the timing belt
1864

Mark up camshaft pulleys (intake and exhaust respectively).
Remove

- timing belt, turn to one side.
- camshaft pulleys, use counterhold 999 5199
Remove seal then install new camshaft seal
Remove camshaft seal/sealsGrease and install new seal with drift 999 5449, use a copper mallet. (Drift 999 5449 of t
Note!
Later version sealing rings are removed with an extractor 999 5919, because of the reduced space between
Remove
- Air Cleaner (ACL) housing, with hoses
- distributor cover, rotor, holder
- Camshaft Position (CMP) sensor housing and damper
- engine Cooling Fan (FC)
- starter motor
Note! Connectors and hoses for solenoid valve on the Air Cleaner Housing (ACL).
Install gauge 999 5451, 999 5452
1865

Remove blind cover plug and install gauge 999 5451 for the crankshaft, turn the crankshaft counter-clockwise until i
Install
- camshaft pulleys, with two screws so that they precisely act on the pulleys
- timing belt
Note! Check that the camshaft screw holes are centered, see illustration.
Adjusting the mechanical belt adjuster
If a mechanical belt adjuster is being used, adjust accoreding to Adjusting the Mechanical Belt Adjuster See: Timin
Tighten timing belt

Remove the lock pin from the tensioner damping unit.Press hard or knock the belt twice in the direction of arrow (1)
1866

20 Nm
Tighten the camshaft pulley screws tighten to Remove the camshaft locking tool (999 5452) from the rear edge of th
Install

- expansion tank
Install
- Camshaft Position (CMP) sensor housing with damper

- rotor and distributor cover
- spark plugs cover
- starter motor
- fender liner and wheel
Test function
Test run engine.
Rear Seal
Rear seal
Remove
1867

- Air Cleaner (ACL) housing with hoses and connectors
Remove and install new seal
Note!
The seal is usually positioned flush with the inner chamfer edge. If there are grooves on the shaft journal t
Install
Camshaft
- rotor Position (CMP)
and distributor cover sensor housing with damper
-Carefully
Air Cleaner (ACL) housing with hoses and connectors
Test function
new pry out seal with a screwdriver.Clean seal seats and check for shaft end grooving.Grease seal.Install the seal by
Test run engine.
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Tools - Removing Camshafts
Camshaft: Technical Service BulletinsTools - Removing Camshafts

SECTION
2
GROUP
21
NO.0008
YEAR1997
MONTH
12
REFERENCE:TP 2102201, Section 2(21) Reconditioning, Engines B5202, B5204, B5234, B5252, B5254; 850 1992-
This Service Bulletin replaces the earlier SB 21-823 of May 1996 which should be discarded.
Removing camshafts
Background:The tools and method that should be used to remove the camshaft housing cover are shown.
This method prevents damage to the camshaft housing thrust bearing.
Tools:2 valve engines: 999 5508, 999 5454 (x2)

4 valve engines: 999 5453, 999 5454 (x2)
2/4 valve engines: 999 5670 (x1)
Method:Install tool 999 5453 or 999 5508 to secure the front of the camshafts.
Install tool 999 5454 with a few millimeters play to the camshaft housing cover, remove all screws.
Disconnect camshaft cover with pliers 999 5670 at stop lugs. Start with cylinder 1 and work alternately backward.
Open and slacken off tool 999 5454 step by step so that parallel movement is ensured when removing camshaft housing
Changes in Service Manual
The labels in this Service Bulletin must be stuck into the Service Manual according to instructions. After that this page
Applies to Service Manual Section 2(21) Reconditioning Engines B5202, B5204, B5234, B5252, B5254; 850 1992-
C. Cylinder head, removal
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Tools - Removing
Camshafts > Page 1872

Stick over chapter title.
Stick over step 02.
Applies to Service Manual Section 2(20-22, 25-26), B5204, B5234, B5252, B5254 Engines 850 1992-.
AD. Cylinder head gasket, replacement
Stick over chapter title.
Stick over step AD5.

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 1873
Camshaft: Specifications
Camshaft Specifications
Markings:
Intake ..........................................................................................................................................................................
Max. Lift ..........................................................................................................................................................................
NOTE: Always refer to the manufactures latest information.

Camshaft: Application and ID
Markings
Intake: PHIExhaust: PHE
MAX. LIFT: 7.95 mm
NOTE: Always refer to the manufactures latest information.

Camshaft: Tools and Equipment
Volvo Camshaft and Crankshaft Timing Alignment Set
AST tool# V 500
This tool is used for the alignment of the camshafts and crankshafts on all In-line 4, 5 and 6 cylinders twin cam motors
Comparable to Volvo tool numbers: 9995451, 9995452, 9995453 and 9995454.

Applicable to Engines:B6254GS, B6294T, B5234T4, B6294S2, B5244S6, B5204T2, B5234FS, B4184S2, B5254FS M
- Used for Alignment of Camshafts and Crankshafts
- All In-line 4, 5 and 6 Cylinders Twin Cam Motors through 2007, except the 3.2L
- Made in USA


> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Engine Valve Train -
Lifter / Lash Adjuster: Technical Service BulletinsEngine Valve Train - New Tappets
Section2
Group21
No.0009
Year98
Month11
850 S70/V70/C701997
Reference: TP 2101201, Section 2(20-22,25-26) B5234, B5254 Engines; 850 1992-
Vehicles involved: 4-valve gasoline engines
21-0009; New tappets (valve depressors); 98/11
Background:
New tappets (valve depressors) were introduced in the fall of 1997 to maintain valve operation.
The new tappets can also be used on older cars (4 valve gasoline engines).
Engine serial number:
Introduced from engine serial number 1217672.
Chassis no:
Model Factory code Chassis
S70 1 504502
870 2 504502
V70 2 504502
C70 J 504502
Materials
Tappets (valve depressors) (X20) service kit, 270866-7
WARRANTY STATEMENT: Warranty may be submitted under the new car factory warranty when there is a docume
21568-0
Checking and replacing hydraulictappets (valve depressors)
800 Turbo: 5.8 hr
Engine B5254F: 5.2 hr
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 1881
Lifter / Lash Adjuster: Description and Operation
Hydraulic Tappets
The camshafts open and close the valves via hydraulic tappets. Tappets are oil filled and self-adjusting.
A spring inside the tappet cylinder holds the tappet in contact with the camshaft, its spring force is lower than tha
A non-return valve prevents oil from being pressed out when the camshaft is acting on the tappet and oil pressure
Tappet In Contact With The Camshaft Base Circle
Oil from the camshaft bearing housing oil way is pressed into the tappet via a groove and hole in its side. Oil pas
Camshaft Acting On The Tappet
When the tappet is pressed down the oil pressure in the tappet cylinder is higher than engine oil pressure, the non
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page
1882

Tappet Back In Contact With The Camshaft Base Circle
Engine oil pressure is greater than the oil pressure in the tappet cylinder, the non-return valve opens admitting oil
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 1883
Lifter / Lash Adjuster: Testing and Inspection
Tappet Dimensions
A. External Diameter: 32 mm + 0.025 or - 0.041 mmB. External Height: 26 mm 0.5 mm
Distance Between Top Of Tappet And Piston
C. Unloaded: 18.40 mmC. Compressed: 16.15 mm + 0.3 or - 0.1 mm

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications

Connecting Rod Axial Clearance at Crankshaft ..................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Connecting Rod Cap - Revised S
Connecting Rod: Technical Service BulletinsConnecting Rod Cap - Revised Screws
Section2
Group21
No.0004
Year98
Month05
Reference:
TP 2102201, Section 2(21) Reconditioning Engines B5202, B5204, B5234, B5254; 850 1992-
21-0004; New screws for connecting rod cap; 98/02
Background
A new screw for the engine connecting rod cap was introduced from and including model year 1998 for all S70/V70/C
The new screw has a closer pitch of thread.
At the end of model year 1997 production approximately 800 engines were manufactured with this new type of screw.
This Service Bulletin describes how to spot the difference between the old and the new type of screw, and within which
Screw type Engine serial number Notes
Only older screws -1051765

Mixed old and new screws 1051766 - 1052536 A) see below
Only older screws 1052537 - 1059933
Mixed old and new screws 1059934 - 1059984 B) see below
Only new screws 1059985-
A) The following engines have NEW screw:
1051766-1051771, 1051778-1051783, 1051796-1051801, 1051814-1051819, 1051844-1052225, 1052240-1052245, 10

B) The following engines have NEW screw:
1059934-1059935, 1059942-1059947, 1059954-1059959, 1059966-1059977
ToolsThread gauge M9 x 1.0 1158902-5 (or equivalent)

Thread gauge M9 x 1.25 1158901-7 (or equivalent)
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Connecting Rod
Cap - Revised Screws > Page 1892

New screws for connecting rod cap
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Dimensions
Connecting Rod: SpecificationsDimensions
Connecting Rod Specifications
Big End Bearing Seat Diameter ............................................................................................................................... 53.0

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Dimensions > Page 1895
Connecting Rod: SpecificationsTightening
Connecting Rod cap
Stage 1 ........................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling
Connecting Rod: Service and RepairCrank, Pistons and Rods, Dismantling
1. Remove oil pan:

- Remove oil filter.
- Remove pan carefully by tapping it loose with a rubber mallet.
2. Remove oil pan suction pipe:

- Clean and inspect pipe and filter.
- Remove suction pipe O-ring.
- Remove oil passage O-rings.
3. Remove intermediate section:

- Using the illustration above, undo intermediate section 7 mm and 8 mm bolts in sequence from number 6 to n
- Then undo all 10 mm bolts from number 6 to number 1.
- Tap intermediate section loose carefully with a plastic mallet.
- Remove crankshaft rear seal.
CAUTION: Do not allow crankshaft to rotate.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Crank, Pistons and Rods,
Dismantling > Page 1898

4. Remove big end bearing caps:
- Check markings on bearing caps and connecting rods.
Mark with a number punch or die as necessary.
- Check centering of bearing shells in connecting rods and caps.
Do not mix
CAUTION: - up different crankshaft bearing shells.
- Do not rotate crankshaft.
5. Lift crankshaft out of cylinder block:

- Support crankshaft in suitable V-blocks on two outermost main journals.
- Remove remaining main bearing shells from block.
- Mark position of thrust bearing.
CAUTION: Do not mix up different main bearing shells.
6. Remove pistons from block:

- In order to overcome ring friction press pistons carefully out by hand.
- Taking care not to scratch bores, remove pistons and connecting rods from bores.
7. Clean joint faces:

- Clean joint faces on cylinder block, intermediate section and oil pan.
- Scrape surfaces clean carefully with plastic putty knife.
- Use gasket remover if necessary, part No. 1 161 340-3, or equivalent.
NOTE: A fume hood or extractor must be used when using gasket remover.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > P
Connecting Rod: Service and RepairCrank, Pistons and Rods, Measurement
Special Tools:
- Counterhold tool No. 999 2413, or equivalent
- Drift tool No. 999 5309, or equivalent
- Magnetic Stand tool No. 999 9696, or equivalent
- Dial Gauge tool No. 999 9684, or equivalent
- Micrometer tool No. 999 9701, or equivalent
Universal Tools:
- tool No. 998 5424, or equivalent
NOTE:
-
For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Rec
- Crank mechanism, measurement: Steps 1 through 12
- Connecting Rods bushings, replacement: Steps 13 through 16
- Connecting Rods, replacement: Step 17
Procedure
1. Measure crankshaft:
- Use micrometer tool No. 999 9703.
- Measure out-of-round and ovality of bearing journals.
- Take readings at several points around circumference and along length.
2. Crank pins:
- Diameter:
50.000 mm +0 or -0.016 49.750 mmStandard: Undersize:

- 26.000 mm 0.1Bearing Seat Width:
- 0.004 mmMax. Out-of-round:
- 0.004 mmMax. Taper:
Diameter:
Main bearing journals:-

65.000 mm +0.003 or -0.016
49.750 mmStandard: Undersize:
- Bearing Seat Width: 26.000 mm +0 or -0.04
3. Check straightness of crankshaft:

- Use dial gauge tool No. 999 9684 and magnetic stand tool No. 999 9696, or equivalent.
- Put crankshaft with the outermost main bearing journals in the V-blocks.
- Turn crankshaft and measure radial throw of other main bearing journals.
- 0.032 mmMax. Radial Throw (All):
4. Remove piston rings:

- Use piston ring pliers tool No. 998 5424, or equivalent.
- Remove carbon deposits.
Clean piston ring grooves by scraping with a broken off ground section of piston ring.
- Check for:
Damage. Wear. Cracking.

5. Check
- Usepiston
new ring
rings.axial clearance:
- 0.05-0.085 mmUpper compression ring:
- 0.03-0.065 mmLower compression ring:
- 0.02-0.055 mmOil scraper ring:
1.5 mmUpper
Dimensions, compression
version 1 - ring:
- 1.75 mmLower compression ring:
- 3.0 mmOil ring:
1.2 mmUpper
version 2- ring:

- 3.0 mmOil scraper ring:
6. Measure piston diameters:

- Use micrometer tool No. 999 9704, or equivalent and sliding calipers.
- A = Overall piston height.
- B = Height from wrist pin center to crown.
- C = Piston diameter must be measured at right-angles to wrist pin hole and at distance C from edge of skirt.
- D = Diameter.
- Dimensions A, B and C, see table.
Standard
Piston diameter: (D)-
82.98-82.99 mm
82.99-83.00 mm
83.00-83.01 mm
83.017-83.032 mmPiston marked C: Piston marked D: Piston marked E: Piston marked G:
- Oversize
83.177-83.192 mm
83.377-83.392 mmOS1: OS2:
NOTE: 10 g Max. difference in weight between pistons in same engine:

7. Calculate piston clearance:
- Measured:
Cylinder diameter minus Piston diameter = Piston clearance.
0.01-0.03 mmPermissible piston clearance:
NOTE: Measurement of cylinder bore as per steps 1 through 3 of "Cylinder Block, Measurement". See: Service

8. Separate connecting rods and pistons:
- Check that each piston and connecting rod is marked before separating.
NOTE:
Piston markings: Scrape wrist pin clean.
-- Mark with felt-tip pen cylinder no. and an arrow towards the front end of the engine if marking is unclear.
- Connecting Rods markings: as per step 4 of Crank, Pistons and Rods Dismantling.
-
Pry circlip out carefully with a screwdriver. Push wrist pin out by hand. Clean and inspect connecting rods, be
- 55 mmMax. length:
9. Check Wrist pin fit in pistons:

- Wrist pins must not have any play, but should slide through hole without play when pressed by hand.
- Replace piston if there is any play.
10. Check wrist pin fit in connecting rods:
-
Wrist pin should slide through hole easily under thumb pressure. If excessive play, check wrist pin dimension
- Use micrometer tool No. 999 9701, or equivalent.
Wrist pin diameter:

23.0 mm +0 or -0.004B 5202-5254:

11. Check Conrad (big end) bearing seats:
- Check bearing shells visually.
- If any doubt, measure out-of-round.
- Use dial gauge 999 9639, or equivalent.
Bearing seat diameter:

53.0+0.013 mmB 5202-5254:
0.006 mmMax. Out-of-round:
12. Check Conrad in alignment gauge

- Check for straightness and twisting.
Important:
Check that clamping surface of fork is round and free of burrs.
-- Release and tighten expander at big end between each alignment check.
Connecting Rods Bushings, Replacement
13. Press bushing out:

- Use drift tool No. 999 5309, or equivalent.
- Use drift the right way round, with the short end downwards.
- Use drift tool No. 999 2413, or equivalent as counterhold.

14. Press in new bushing:
- Use drift the right way round, with long end downwards.
- Push drift right down.
NOTE: Make sure that hole in bushing lines up with lubricating passage in connecting rod.
15. Check wrist pin fit in new bushing:

- Wrist pin should slide through bushing without noticeable play when pressed gently with thumb.
- Adjust bushing as required.
16. Check connecting rod in alignment gauge:

Check
NOTE: - that clamping surface of fork is round and free of burrs.
- Release and tighten expander at big end between each alignment check.
17. Connecting Rods, replacement:
- Connecting Rods are symmetrical and can be turned over if required.

- 20 Nm (15 ft lbMarkings: Assemble connecting rod, tighten bolts to ) and check that bearing end is turned the
- Put big end in a vice with copper inserts or similar.
Mark both halves with cylinder number using a number punch or die.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > P
Connecting Rod: Service and RepairCrank, Pistons and Rods, Reassembly
Special Tools:
- Standard Handle tool No. 999 1801, or equivalent
- Installation tool No. 999 5430, or equivalent
- Base tool No. 999 5971, or equivalent
Universal Tools:
- Piston Ring Compressor tool No. 115 8281, or equivalent
- Roller tool No. 951 1205, or equivalent
- Piston ring compressor tool No. 998 5424, or equivalent
NOTE:
For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Recondit
Procedure
1. Classification of crankshaft main bearings:

- Clean main bearing seats.
- Check that components are clean and free of damage.
- Check classification markings on cylinder block and crankshaft.
Each -bearing seat is marked with the cylinder no. and a classification letter for the block and crankshaft.
NOTE:
- Use the table below to select the right bearing shells.
2. Selecting bearing shells:
- Install main bearings in cylinder block (See table.).
- Oil bearing shells liberally on crankshaft side.
- Install flanged shells in rear most position.
- Example: Classifying no. 1 bearing.
Marking on block is B. Marking on crankshaft is C. Accordingly, use a red shell in the block and a yellow

3. Intermediate section:
- Apply liquid gasket compound, part No. 1 161 059-9, or equivalent to intermediate section.
Cover surface completely but do not allow to overflow, as this may block channels and bolt holes.
- Use a short-haired roller tool No. 951 1205, or equivalent.
- Put bearing shells in intermediate section.
Bearing seats must be dry.
- Oil bearing shells and flanged shells (at back) liberally.
4. Install crankshaft:
- Install crankshaft.
Do not rotate it until intermediate section is tightly in place.
- Install intermediate section.
- Tighten intermediate section and crankshaft bolts in 5 stages in sequence from the center towards ends.
20 Nm (15 ft lb)
45 Nm (33 ft lb)
24 Nm (18 ft lb)
17 Nm (13 ft lb)
90Complete each stage before starting the next.Skip 8 mm and 7 mm bolts until stages 3 and 4.1st Stage: T
NOTE: Max. Length of 10 mm bolts 118 mm.
5. Measure axial clearance:
- Check that crankshaft rotates smoothly.
- Measure crankshaft axial clearance.
- Use dial gauge, magnetic plate tool No. 999 5971 and magnetic frame tool No. 999 9696, or equivalents.
- 0.08-0.19 mmAxial clearance:

6. Install crankshaft rear seal:
- Use standard handle tool No. 999 1801 and assembly tool No. 999 5430, or equivalents.
- Oil mating surfaces between seating flange and seal, and between seal lips. Place seal on drift.
- If there are any wear marks on the crankshaft, push seal further into the flange than before by removing a spac
- Tap seal in until drift meets crankshaft.
7. Assemble pistons and connecting rods:

- Arrow on piston crown must point towards front, i.e. timing belt, end of engine.
Numerical markings on connecting rod must face towards intake side of block (starter motor side).
Install- wrist pin circlip and check that the circlip springs apart and locks in the groove.
NOTE:
- The circlip opening should point downwards.
CAUTION:
Pistons, replacement:
-
Later Volvo 850s have two different types of piston, which differ in terms of the upper compression ring.V
- Connecting Rods, replacement:
Connecting Rods are symmetrical and can face either way round.
- Markings:
Assemble connecting rod (tighten bolts to 20 Nm) and check that bearing end cap is pointing the right way
8. Install piston rings as follows:
- Turn rings so gaps are approx. 120 apart.
- A. Compression ring: Text upwards

- B. Scraper ring: Bevel downwards
- C. Oil scraper ring: Text upwards
NOTE: Piston rings, dimensions, refer to Crank, Pistons and Rods, Measurement.
- Clean/dry bearing seats in connecting rods and bearing caps.

- Install bearing shells in connecting rods and bearing caps.
- Install guide pins tool No. 999 5502, or equivalent.
CAUTION: If re-using original bearing shells, components must be located in original positions.
9. Fit pistons in bores:

- Use piston ring compressor tool No. 115 8281, or equivalent.
- Oil cylinder bores, pistons and bearing shells.
- When fitting each piston, turn crankshaft so crank pin for that piston is in its lowest position.
- Check that piston classification is correct.
- Press piston into bore (using a hammer shaft).
NOTE: Arrow on piston crown must point towards front, i.e. timing belt, end of engine.
10. Install bearing end caps:

- Remove guide pins tool No. 999 5502, or equivalent and install caps.
Crankshaft
NOTE: - must not rotate until all connecting rods/bearing caps have been tightened.
- Bearing shells may change position.
- Check that markings on crankshaft and bearing caps line up.

- Use new oiled bolts.
- Tighten
20 Nmthem
(15infttwo
lb) stages:
901st Stage: 2nd Stage: Turn through
- Check that connecting rods are free to move laterally.

11. Install oil pump suction pipe:
- Put gasket on pipe.
- Reconnect pipe.
- 17 Nm (13 ft lb)Tighten to .
- Use new oil channel seals.
12. Install oil pan:

- Apply liquid gasket compound part No. 1 161 059-9, or equivalent on pan with short-haired roller tool No. 95
Insert four bolts and align pan flush with rear face of block.
- Permitted tolerance = 0.025 mm.
- Use calipers and feeler gauges.
- 17 Nm (13 ft lb)Tighten bolts from front and rear, tighten to .

- Install new oil filter.
NOTE: -
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Center nut..............................................................................................................................................................................
Vibration damper -2002 Flanged screws x4Stage 1.............................................................................................................
Vibration damper 2002-Flanged screws x4Stage 1..............................................................................................................

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Dimensions
Crankshaft Main Bearing: SpecificationsDimensions
Crankshaft Specifications
General
Max. Throw ................................................................................................................................................................

Connecting Rod Journals [1]
Diameter:
Standard ................................................................................................................................................... 50.000
Bearing Seat Width ....................................................................................................................................................

Main Bearing Journals [1]
Diameter:
Standard ................................................................................................................................................... 65.000
[1] Variation in diameter in individual journals: max. 0.080 mm.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Dimensions > Page 1919
Crankshaft Main Bearing: SpecificationsTightening

Intermediate Section (tighten the screws in sequence from the center outwards):
Stage 1, M10 ....................................................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications
Crankshaft: Specifications
Crankshaft Specifications
General
Max. Throw ................................................................................................................................................................

Diameter:
Standard ................................................................................................................................................... 50.000

Diameter:
Standard ................................................................................................................................................... 65.000

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1923
Crankshaft: Application and ID
Markings
NOTE: Markings are punched into the cylinder block and crankshaft.
Specifications Table
Classifications
Crankshaft: Description and Operation
Construction Of Crankshaft
The crankshaft has six main bearings, no. 5 being a thrust bearing. At the front end of the crankshafts are two spl
The outer joint carries the timing belt pulley and vibration damper. A dummy spline locates and guides the pulley
Connecting rods are forged and the saw tooth joint between connecting rod and bearing cap locates the bearing ca
The B5254 and B5234T engine have forged crankshafts providing maximum strength and minimum noise.
Crankshaft: Testing and Inspection
Crankshaft
Max. Throw (Radial Runout): 0.032 mmMax. Axial Clearance: 0.190 mmMain Bearings, Radial Clearance: 0.019-0.43

Diameter:
Standard: 50.000 mm + 0.000 mm or - 0.016 mmUndersize: 49.750 mm
Bearing Seat Width: 26.000 mm 0.100Max. Out-Of-Round: 0.004 mmMax. Taper: 0.004 mm

Diameter:
Standard: 65.000 mm + 0.003 mm or - 0.0160 mmUndersize: 64.750 mm
Bearing Seat Width: 26.000 mm + 0 or - 0.040 mmMax. Out-Of-Round: 0.004 mmMax. Taper: 0.004 mm

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling
Crankshaft: Service and RepairCrank, Pistons and Rods, Dismantling
1. Remove oil pan:



> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crank, Pistons and Rods,

Do not mix



> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > Page 1
Crankshaft: Service and RepairCrank, Pistons and Rods, Measurement
Special Tools:
Universal Tools:
NOTES:
-
- Crank mechanism, measurement: Steps 1 through 12
- Connecting Rods bushings, replacement: Steps 13 through 16
- Connecting Rods, replacement: Step 17
Procedure:
2. Crank pins:
- Diameter:

Diameter:

65.000 mm +0.003 or -0.016
- 26.000 mm +0 or -0.04Bearing Seat Width:


- Check for:

5. Check
- Usepiston
new ring
1.5 mmUpper
version 1 - ring:
- 3.0 mmOil ring:
1.2 mmUpper
version 2- ring:


- D = Diameter.
Standard
82.98-82.99 mm
82.99-83.00 mm
83.00-83.01 mm
- Oversize
83.177-83.192 mm
83.377-83.392 mmOS1: OS2:


- Measured:

NOTE: Measurement of cylinder bore as per steps 1 through 3 of "Cylinder Block, Measurement". See: Service

NOTE:
-
- 55 mmMax. length:

-
Wrist pin diameter:

23.0 mm +0 or -0.004B 5202-5254:


53.0+0.013 mmB 5202-5254:

Important:




Check

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > Page 1
Crankshaft: Service and RepairCrank, Pistons and Rods, Reassembly
Special Tools:
Universal Tools:
NOTE:
Procedure

NOTE:
- Install main bearings in cylinder block (See table).

20 Nm (15 ft lb)
45 Nm (33 ft lb)
24 Nm (18 ft lb)
17 Nm (13 ft lb)


NOTE:
CAUTION:
-
- Markings:




Crankshaft

- Tighten
20 Nmthem
(15infttwo
lb) stages:

- Reconnect pipe.


NOTE: -
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Vibration damper -2002
flanged screws x4Stage 1.....................................................................................................................................................

Vibration damper 2002-
flanged screws x4Stage 1.....................................................................................................................................................

Center nut..............................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications
Piston: Specifications
Piston Specifications
Standard Diameter:
Piston Marked C .........................................................................................................................................................

Oversize Diameter:
OS1 .............................................................................................................................................................................
Weight:
Standard Weight .........................................................................................................................................................

Piston To Cylinder Clearance:
New Piston .................................................................................................................................................................
Piston Ring Clearance:
Upper Compression Ring ...........................................................................................................................................

Wrist Pins:
Diameter .....................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1948
Piston: Testing and Inspection
Dimensions
A: 59.900 mmB: 35.900 mmC: 16.000 mm
Diameter
Piston Marked C: 82.980-82.990 mmPiston Marked D: 82.990-83.000 mmPiston Marked E: 83.000-83.010 mmPisto
Oversize
OS1: 83.177-83.192 mmOS2: 83.377-83.392 mm
Weight
Standard Weight: 360 5 gramsMax. Difference Between Pistons: 10 grams
Piston Clearance
New Piston: 0.01-0.03 mm
Piston Ring Clearance
Upper Compression Ring: 0.050-0.085 mmLower Compression Ring: 0.030-0.065 mm
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1949

Oil Scraper Ring: 0.020-0.055 mm
Wrist Pins
Diameter: 23.000 + 0 or - 0.004 mm
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling
Piston: Service and RepairCrank, Pistons and Rods, Dismantling
1. Remove oil pan:



> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crank, Pistons and Rods,

Do not mix



> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > Page 1954
Piston: Service and RepairCrank, Pistons and Rods, Measurement
Special Tools:
Universal Tools:
NOTE:
-
- Crank mechanism, measurement: Steps 1 through 12 as follows.
- Connecting Rods bushings, replacement: Steps 13 through 16 as follows.
- Connecting Rods, replacement: Step 17 as follows.
Procedure
2. Crank pins:
- Diameter:

Diameter:

65.000 mm +0.003 or -0.016
- Bearing Seat Width: 26.000 mm +0 or -0.04


- Check for:

5. Check
- Usepiston
new ring
1.5 mmUpper
version 1 - ring:
- 3.0 mmOil ring:
1.2 mmUpper
version 2- ring:


- D = Diameter.
Standard
82.98-82.99 mm
82.99-83.00 mm
83.00-83.01 mm
- Oversize
83.177-83.192 mm
83.377-83.392 mmOS1: OS2:


- Measured:

NOTE: Measurement of cylinder bore as per steps 1 through 3 of Cylinder Block, Measurement. See: Service a

NOTE:
-
- 55 mmMax. length:

-
Wrist pin diameter:

23.0 mm +0 or -0.004B 5202-5254:


53.0+0.013 mmB 5202-5254:

Important:




Check

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crank, Pistons and Rods, Dismantling > Page 1961
Piston: Service and RepairCrank, Pistons and Rods, Reassembly
Special Tools:
Universal Tools:
NOTE:
Procedure

NOTE:
- Install main bearings in cylinder block (See table).

20 Nm (15 ft lb)
45 Nm (33 ft lb)
24 Nm (18 ft lb)
17 Nm (13 ft lb)


NOTE:
CAUTION:
-
- Markings:




Crankshaft

- Tighten
20 Nmthem
(15infttwo
lb) stages:

- Reconnect pipe.


NOTE: -
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Engine - Piston Ring Replacement
Piston Ring: Technical Service BulletinsEngine - Piston Ring Replacement
Cars
Section:
2
Group:21
No.:0050
Year:04
Month:04
Reference:
This service bulletin is a complement to service bulletins 21-0040, 21-0041 and 21-0042. This Service Bulletin applies
Vehicles involved: Vehicles with 4, 5 and 6-cylinder engines.
Piston rings, Replacing
Background
Materials
Description
See tables, below.

Certain piston ring kits stocked by Parts do not contain the latest design of rings These rings must be replaced before th
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Engine - Piston Ring
Replacement > Page 1970

Cylinder Liner and Piston Tables
Changing piston rings
Piston rings, installing 1
Use a piston ring expander.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Engine - Piston Ring

Turn the piston rings so that the gaps are offset relative to each other as illustrated.
A. Compression ring. Text on ring should face upward.
B. Scraper ring. Chamfered edge should face downward.
C. Oil ring. Consists of three separate rings, each with identical sides.
First fit the corrugated expander ring (C) with the other two plain rings on either side. Then fit rings (A) and (B) in thei
Caution!
Ensure that the rings are free to move in their grooves.
Note!
Incorrect installation may result in higher oil consumption.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Page 1972
Piston Ring: Specifications
Piston Ring Specifications

Piston To Ring Clearance:
Upper Compression Ring ...........................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Technical Service Bulletins > Page 1973
Piston Ring: Testing and Inspection
Piston Ring Clearance
Upper Compression Ring: 0.050-0.085 mmLower Compression Ring: 0.030-0.065 mmOil Scraper Ring: 0.020-0.055
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 1978

Installing

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications
Valve Guide: Specifications
Valve Guides Specifications

Diameter:
Standard (0 Grooves) ..................................................................................................................................................

Clearance Between New Components:
Intake ..........................................................................................................................................................................
Max. Clearance, Used Components:
Intake/Exhaust ............................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1982
Valve Guide: Testing and Inspection
Valve Guides, Markings And Dimensions

Diameter:
Standard: 12.0 mm
Oversize 1: 12.1 mm
Oversize 2: 12.2 mm
No. Of Grooves:
Standard: 0
Oversize 1: 1
Oversize 2: 2

Intake: 0.03-0.06 mm
Exhaust: 0.04-0.07 mm

Intake/Exhaust: 0.15 mm
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications
Valve Seat: Specifications
Valve Stem Height
Height: 48.5 mm 0.4 mmMax. Machining Allowance: 0.4 mm
Valve Seats (Reconditioned)

Angles:
Sealing Face Angle: 45Relief Angle, Upper, Intake: 15Relief Angle, Upper, Exhaust: 15Relief Angle, Lower: 60
Valve Seat Width: (a)
Intake: 1.4-1.8 mmExhaust: 1.8-2.2 mm

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications
Valve Spring: Specifications
Valve Spring Specifications

Spring Diameter:
External ......................................................................................................................................................................
Spring Tension:Length / Load N:
L ..................................................................................................................................................................................
NOTE: Check springs in spring tester, tool No. 999 9802, or equivalent.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1989
Valve Spring: Testing and Inspection
Valve Springs, Dimensions

Diameter
External: 27.9 mm 0.2 mmInternal: 20.1 mm 0.2 mm
Length And Load
L: 42.4 mm (0 N)L1: 34.0 mm (270 N 15 N)L2: 24.5 mm (670 N 32 N)

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications
Valve: Specifications
Valve Specifications
Valve Head Diameter:
Intake ..........................................................................................................................................................................
Valve Stem Diameter:
Intake ..........................................................................................................................................................................
Overall Length:
Intake ..........................................................................................................................................................................
Valve Margin thickness:
Intake/Exhaust ............................................................................................................................................................
Sealing Face Angle:
Intake ..........................................................................................................................................................................
Valve Stem Height:
Height .........................................................................................................................................................................
Clearance Between New Valve and Guide Components:
Intake ..........................................................................................................................................................................
Max. Clearance, Used valve and Guide Components:
Intake/Exhaust ............................................................................................................................................................
NOTE: Valve stem height is measured using gauge tool No. 999 5222, or equivalent, placed in cam bearings, and a
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1993
Valve: Testing and Inspection
A. Valve Head Diameter
Intake: 31.00 mm 0.15 mmExhaust: 27.00 mm 0.15 mm
B. Valve Stem Diameter
Intake: 6.97 mm + 0 or - 0.015 mmExhaust: 6.96 mm + 0 or - 0.015 mm
C. Overall Length
Intake: 104.05 mm 0.18 mmExhaust: 103.30 mm 0.18 mmMax. Machining Allowance: 0.4 mm
D. Valve Head Height
Intake/Exhaust: 1.5 mmMin. Height After Grinding: 1.2 mm
E. Sealing Face Angle
Intake: 44.5Exhaust: 44.5

Valve Stem Height
Height: 48.5 mm 0.4 mmMax. Machining Allowance: 0.4 mm

Valve Seats (Reconditioned)
Angles:
Sealing Face Angle: 45Relief Angle, Upper, Intake: 15Relief Angle, Upper, Exhaust: 15Relief Angle, Lower: 60
Valve Seat Width: (a)
Tappets, Dimensions
A. External Diameter: 32 mm + 0.025 or - 0.041 mmB. External Height: 26 mm 0.5 mm
Distance Between Top Of Tappet And Piston
C. Unloaded: 18.40 mmC. Compressed: 16.15 mm + 0.3 or - 0.1 mm

Valve Springs, Dimensions
Diameter
External: 27.9 mm 0.2 mmInternal: 20.1 mm 0.2 mm
Length And Load
L: 42.4 mm (0 N)L1: 34.0 mm (270 N 15 N)L2: 24.5 mm (670 N 32 N)

Valve Guides, Markings And Dimensions
Diameter:
Standard: 12.0 mmOversize 1: 12.1 mmOversize 2: 12.2 mm
No. Of Grooves:
Standard: 0Oversize 1: 1Oversize 2: 2

Intake/Exhaust: 0.15 mm
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams
Drive Belt: Diagrams

DRIVE BELT ROUTING
Early Belt Routing
New Belt Routing
The new auxiliary equipment belt has been introduced into production for the 850 with A/C from engine serial numb
The new belt is routed so that it contacts more of the generator (GEN) drive pulley.
Note: New belt P/N 9434341-5 can be used on early engines if the new routing is followed. No other components ne
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2000
Drive Belt: Description and Operation
Accessory Drive Belt

(P/S)
The accessories (alternator, power steering pump, air conditioning A/C compressor) are driven by a multiple V-b
The tensioner consists of a spring and a friction element. The friction element provides the damping necessary to
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Replacing the Auxiliaries Belt / Be
Drive Belt: Service and RepairReplacing the Auxiliaries Belt / Belt Tensioner
Auxiliaries belt/belt tensioner, replacing
Note!
As the illustrations in this service information are used for different model years and/or models, some vari
Removal
Removing the auxiliaries belt
Remove:
- the plastic cover on the blet tensioner using a small screwdriver. Use a wrench and turn clockwise as far as possib
- the belt.
Replacing the belt tensioner
Remove:
- both mounting screws from the auxiliaries belt bracket for the belt tensioner.
- 25 Nm (18.4 ft lb)the belt tensioner. Install the new belt tensioner. Tighten to
Installation
Installing the auxiliaries belt
Caution! Ensure that the belt is correctly seated in all the grooves on each pulley
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Replacing the
Auxiliaries Belt / Belt Tensioner > Page 2003

Use a wrench and turn the belt tensioner clockwise as far as possible.Install the belt as illustratedInstall the plastic co
Checking work
Start the engine.Check the rotation of the belt and the function of the belt tensioner.
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Replacing the Auxiliaries Belt / Be
Drive Belt: Service and RepairNew Routing of Auxiliaries Belt
New routing of auxiliaries belt
A new auxiliaries belt is being introduced into production for cars with A/C. The new belt has a new routing so that i
Installing auxiliaries belt:
Put A/C compressor

the belt around the crankshaft and then around the auxiliary equipment in the following order:-
- (GEN)Generator
- idler pulley
- servo pump
Carry out a function test

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications
Tensioner Mounting Bolts ..........................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair
Engine Mount: Service and Repair
Special Tools:
- Jack tool No. 998 5972, or equivalent
NOTE:
Procedures
NOTE: Refer to the following for mount replacement:

- Front Engine Mount (Manual): refer to steps 1 through 5
- Front Engine Mount (Automatic): refer to steps 6 through 9
- Right Engine Mount: refer to steps 10 through 11
- Rear Engine Mount: refer to steps 12 through 15
- Tightening Engine Mounts: refer to step 16
Front Engine Mount Replacement (Manual Transmission)
1. Undo torque rod:

- Remove torque rod bolt from engine.
- Slacken torque rod bolt from body mount and push to one side.
2. Remove nut from engine mount.

3. Remove:
- splashguard under engine
- torque rod screw
- engine mount screw
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2011

4. Remove old engine mount and install new mount:
- Raise engine slightly with jack tool No. 998 5972, or equivalent.
- Remove old engine mount and install new mount.
NOTE: Ensure that engine mounting guide pin is correctly located when installing.
5. Install:
- engine mount bolt
- lower torque rod bolts (new bolts). engine mount nut
- upper torque rod bolts (new bolts).
Front Engine Mount Replacement (Automatic Transmission)
6. Remove:
-- torque
engine rod boltbolt
mount

7. Remove:
-
engine cooling fan, as outlined in step 1 of Replacement. See: Cooling System/Radiator Cooling Fan/Radiator
- torque rod/engine bolt and slacken torque rod/body mount bolt, push to one side
8. Remove nut from engine mount and raise engine:

- Remove nut from engine mount.
- Raise engine so that engine mount can be removed.
- Use a wooden block to protect oil sump.
9. Install new engine mounting:

- Lower engine.
- Install:
engine mount nutupper torque rod nutengine cooling fan, as outlined in step 3 of Replacement. See: Cooli
Right Engine Mount, Replacement

10. Remove right front wheel:
- Fold aside wing liner.
- Remove four engine mount bolt.
11. Install new engine mount:

- Raise engine to free engine mount use a wooden block and crowbar.
- Replace engine mount
- Install wing liner.
- Install from wheel.
Rear Engine Mount, Replacement
12. Remove:
- engine mount nut
- torque rod bolt
13. Remove:
- torque rod bolt

- engine mount bolt
14. Raise engine:

- Raise engine max 30 mm. Use jack tool No. 998 5972, or equivalent.
- Remove two engine mount bolts and slacken the third bolt.
WARNING: The inner, left constant velocity joint will be damaged if the engine is raised by more than 30
15. Replace engine mount:

- Remove engine mount by lifting collision shield and engine mount slightly.
- Install new engine mount and the three engine mount bolts to the transmission.
- Install:
engine mount boltnew lower torque rod boltsplashguard under enginenew upper torque rod boltengine mo

Tightening Engine Mounts (Part 1 Of 2)
Tightening Engine Mounts (Part 2 Of 2)
16. Engine mount tightening.

- Refer to the illustration when tightening the engine mounts.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure Specification
0.10 MPa (14 psi)

0.10 MPa (14 psi) 13.3 rps (800 rpm) .......................................................................................................................
0.35 MPa (49.8 psi) 0.70 MPa (100 psi)min .......................................................................................................
0.60 MPa (85.3 psi)Max Oil Pressure .......................................................................................................................
NOTE: 100COil pressures apply at an oil temperature of , which is reached after 10-15 minutes driving.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2024
Engine Oil: Fluid Type Specifications
Engine Oil
Grade .......................................................................................................................................................... API SJ, SJ/CF,

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair
Oil Filter: Service and Repair
Checking Engine Oil

- Park the car on a level surface.
Wipe dipstick before check.
- Oil level should be within the hatched area on dipstick.
1.0 or 1.5 liters (1 or 1.6 qt)The difference between MAX and MIN on the dipstick is about .
- Engine at normal operating temperature:
half a liter (0.5 qt)Wait at least three minutes after turning off the engine so that the oil can run back to th
- Cold engine:
It is best to check the oil when the engine is cold, before starting the car.If the level is at MIN, top up with
1 liters (1 qt)
1.5 liters (1.6 qts) of oil (red dip stick handle) of oil (fluorescent dip stick handle).
Oil Filter Replacement
1. Remove the oil filter

- Remove splashguard under engine.
- Use filter wrench tool No. 999 5458, or equivalent.
- Clean up oil spills with paper.
Avoid prolonged
WARNING: - skin contact with oil!
-
Prolonged and repeated skin contact with oil can remove the skin's natural oils. This can lead to irritati
-
Harmful compounds may be formed when the oil is used:Avoid skin contact, especially with used engin
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Page 2028

2. Install new oil filter:
- Apply oil to the gasket.
- Screw into place by hand until the gasket comes into contact with the mating surface.
Turn a further 1/2 - 3/4 turn.
- Version 2 has a fluorescent dip stick handle (version 1 is red).

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pan: > 22
From One or More Screws
Oil Pan: All Technical Service BulletinsOil Pan - Leak From One or More Screws
Section
2
Group
21
No.0014
Year
99
Month
06
850 S70/V70/C701993-
Vehicles involved: B52XX
Oil pan, front edge screws
Background:
On some vehicles oil may drip form one or all of the three screws at the front edge of the oil pan. If oil drip is occuring
S70 1 519297-
S70 2 517297-
V70 2 478524-
V70 AWD 2 478524-
C70 J 002600-
Materials:
Screw 3 981684-4
Removing screws and replacing with new screws with thread sealant
Note!
Replace one screw at a time.
Remove:
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Oil Pan: > 2210014 > Jun > 99 > Oil Pan - Leak From One or More Screws > Page 2037

- the screws x3 (A).
Install:
- new screws, P/N 981684-4. Tightening torque 17 Nm (12.5 ft.lbs).
21914-2 Replacing oil pan screws 800 1993 0.2 hr

800 1994- 0.1 hr
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Pan: > 2210014 > Jun
More Screws
Oil Pan: Customer InterestOil Pan - Leak From One or More Screws
Section
2
Group
21
No.0014
Year
99
Month
06
850 S70/V70/C701993-
Vehicles involved: B52XX
Background:
On some vehicles oil may drip form one or all of the three screws at the front edge of the oil pan. If oil drip is occuring
S70 1 519297-
S70 2 517297-
V70 2 478524-
V70 AWD 2 478524-
C70 J 002600-
Materials:
Screw 3 981684-4
Removing screws and replacing with new screws with thread sealant
Note!
Replace one screw at a time.
Remove:
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Pan: >
2210014 > Jun > 99 > Oil Pan - Leak From One or More Screws > Page 2043

- the screws x3 (A).
Install:
- new screws, P/N 981684-4. Tightening torque 17 Nm (12.5 ft.lbs).
21914-2 Replacing oil pan screws 800 1993 0.2 hr

800 1994- 0.1 hr
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Page 2044
Oil Pan: Service and Repair
Preparations:
Remove dipstick and raise car. (Older models: Remove engine splashguard).Drain engine oil and remove oil filter.
Detach and remove:
- the three clamps on the servo line

- the two brackets
Detach and remove:
- screws and nuts to the torque rod as indicated by the arrows
Oil pan removal


Carefully move the pipes to one side so they are to the left of the division between the engine and the transmission.U
Cleaning
Wipe off oil and remove any gasket residue from the bottom engine surfaces using gasket solvent P/N 1161440-1 Sc
Note! there are two types of O ring.
If reinstalling the same oil pan, clean off using the same method. In addition, wash the pan in degreasing solvent and
Installation of oil pan.

Apply liquid gasket P/N 1161 059-9 using a short- bristle roller P/N 951 1205 on the oil pan.1. Apply sealing compo

2 - 3 Nm (1.5 - 2.2 ft. lbs.).
25 Nm (18 ft. lbs. 50 Nm (37 ft. lbs.)2. Mount sump in position using all bolts. Do not tighten bolts allow sump to re
17 Nm (12 ft. lbs.).
Do not loosen bolts 1-2, 3, and 4 From rear to front torque all bolts (including 1, 2, 3, and 4) to If there is an oil ther
Reinstall the torque rod
35 Nm (26 ft. lbs. + 60Reinstall the torque rod using new screws and tighten to , use protractor 9512050.
Note! 18 Nm (13 ft. lbs. + 90. Early type M8 screw torque to
65 Nm (48 ft. lbs. + 60.Install nuts and tighten to
Note!
Remarks: The screws can only be reused once, then they must be knocked out of the bracket and replaced with a sta
Attach the oil line to the steering servo

Remove the tie straps holding the oil lines.First reinstall the front clamp without tightening fully.Reinstall both the o
Check for leaks

Raise car and check for oil leaks from the servo line and oil pan.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2051

DDO1 Replacing:
Remove
Carry splash
the car engine.
raised.-
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure Specification
0.10 MPa (14 psi)

0.10 MPa (14 psi) 13.3 rps (800 rpm) .......................................................................................................................
0.35 MPa (49.8 psi) 0.70 MPa (100 psi)min .......................................................................................................
0.60 MPa (85.3 psi)Max Oil Pressure .......................................................................................................................
NOTE: 100COil pressures apply at an oil temperature of , which is reached after 10-15 minutes driving.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Specifications
Oil Pressure Regulator Valve: Specifications
Relief Valve Spring Specifications
Load (N) ...........................................................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > TNN25-14 > Ja
With A/C ON
Intake Manifold: All Technical Service BulletinsEngine - Inconsistent Idle With A/C ON
NO: 25-14
DATE: 1-9-2003
MODEL: All Models Equipped with Turbo Charged Engine and Electronic Throttle Module (ETM)
SUBJECT: Inconsistent Idle Speed, A/C On
REFERENCE: VADIS
DESCRIPTION:
Carbon deposits can form in the coolant nipple (vacuum side), located on the underside of the intake manifold, and the
1. Intake manifold, removing
Remove the intake manifold, see VADIS:
Repair and Installation Function group 25 Replacing the intake manifold/gasket. Remove the banjo bolt. Lift out
2. Nipple Cleaning
Disconnect the hose (1) from the nipple.
Blow the hose clean using compressed air (2). Loosen hose from opposite end and ensure air is flowing through h
3. Preparations, ETM Cleaning

Remove the ETM from the intake manifold
4. Cleaning the ETM
Warning!
Use a fume hood or ensure that ventilation is good. DO NOT submerge throttle unit in cleaning solvent. ONL
Important!
Do not scrape or use a rotary wire brush to clean the unit.
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: >
TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 2069

Clean the ETM bore using cleaner H (P/N 1161436-9) and a soft bristle brush. Ensure that all the residue is remo
5. Carefully wipe the bore clean on both sides of the throttle plate.
6. Flush the ETM bore using cleaner H on both sides of the throttle plate.
Check that there is no residue in the bore or on the throttle plate. Any remaining residue can promote new residue
Repeat the procedure if necessary.
Install the throttle body (TB) on the intake manifold using a new gasket.
7. Intake manifold, installing
Install the new gasket for the intake manifold. Lift in the intake manifold. Install the banjo bolt with the new seal
Install the intake manifold, see VADIS:

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: >
TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 2070

Repair and Installation Function group 25 Replacing the intake manifold/gasket.
Warranty Information
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > TNN25-14 > Jan > 03 > Eng
Intake Manifold: Customer InterestEngine - Inconsistent Idle With A/C ON

NO: 25-14
DATE: 1-9-2003
REFERENCE: VADIS
DESCRIPTION:
2. Nipple Cleaning

4. Cleaning the ETM
Warning!
Important!
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > TNN25-14 >
Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 2076


> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > TNN25-14 >
Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 2077

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2078
Intake Manifold: Specifications
Manifold Bolts ............................................................................................................................................................
Intake Manifold: Service and Repair
Special Tools:
- Holder tool No. 999 5533, or equivalent
NOTE:
-
For additional information on special tools and equipment used in this procedure, refer to Service and Repair. See
- The intake manifold is stocked complete with throttle housing and damper spindles for engines with damper spin
Procedure
1. Undo fuel distribution manifold with injectors:

- Remove throttle cable and injector cover. Remove throttle cable.
- Disconnect connectors and clips from injectors.
- Remove two clips holding the fuel pipes and remove distribution manifold mounting screws.
- Install five holders 999 5533, or equivalent, carefully pull up injectors together with distribution manifold.
- Disconnect hose from purge valve.
- Carefully place distribution manifold with injectors on engine.
NOTE: Ensure that injectors and needles are not damaged.
2. Disconnect:
- throttle linkage from pulley
- (TB)intake air hose to throttle body
- multi-nipple
- throttle pulley with bracket and idle speed control valve
- EGR-hose clamp (turbo)
- pressure hose to turbo-instrumentation/EGR valve control vacuum hose
- brake servo hose

3. Undo:
- dipstick bracket
- intake manifold screw in lower bracket
- lower intake manifold screws a few turns.
4. Remove:
- remove upper intake manifold screws.
-
(TC)intake manifold by lifting it approx. 20 mm. (Allow the crankcase ventilation hose run through the intake
NOTE: Check that there are no foreign bodies in the intake manifold before installing it.
5. Install:
- new gasket which is held in place by the lower intake manifold screws. (Do not forget the clamp on the fourth
-
intake manifold. (Do not forget the crankcase ventilation hose which comes up through the gap between the s
- 20 Nm (14.8 ft lb)three upper screws and tighten all screws from center outwards to .
Part 1 Of 2

Part 2 Of 2
6. Install:
- EGR-valve (if fitted) with new gasket
- TB and new gasket
- throttle pulley
- with bracket
- multi-nipple and connect hoses
- fuel distribution manifold and two clips
- wiring and injector cover
- screw for bracket under intake manifold
- dipstick bracket screw
- brake servo hose
- air inlet hose
- idle air control valve
- throttle linkage and throttle cable
- throttle linkage cover
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > With VVT
Camshaft Oil Seal: Service and RepairWith VVT
Special Tools
951 2050999 5450999 5451999 5452999 5651999 5718999 5719999 5919

Note!
Remove
Note!
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > With VVT > Page 2087


Remove


- Carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool ca
- Screw the camshaft adjustment tools together as illustrated.
Remove the timing gear pulley
Remove
Exhaust camshaft pulley:
- The plug at the front edge of the variable Valve Timing (VVT) unit (TORX 55).
The center screw from the variable Valve Timing (VVT) unit (TORX 55).

Carefully pull out the timing gear pulley with the variable Valve Timing (VVT) unit.
Intake camshaft pulley:
Remove the screws and remove the timing gear pulley.
Replace the camshaft seal
- Carefully press in tool 999 5651 between the sealing ring and the camshaft. Carefully pry out the seals.
Install a new seal:
- Grease the new seal.
- Install the new seal for the intake camshaft using drift 999 5719
- Install the new seal for the exhaust camshaft using drift 999 5718.
Remove the engine Cooling Fan (FC)
Remove

- detach the brake vacuum hose from the intake.
- (ACL)the air duct for the control module box and the Air Cleaner air intake hose.
- (CP)the connectors, relays and Canister Purge valve from the fan shroud.
Place the wiring to one side.
- the screws for the fan shroud and the relay holder mounting.
Lift up the relay holder and remove the upper hose between the charge air cooler and the intake.Seal the openings.Sl
Secure the crankshaft position
Install the adjustment tool

Pull the charge air pipe forwardRemove the 3 starter motor screws for the starter motor mounting.Place the starter m
Reinstall
Install the variable Valve Timing (VVT) unit with the toothed belt pulley:
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable Valve Timing (VVT)

Install the center screw which secures the variable Valve Timing (VVT) unit to the camshaft. Do not tighten yet!Inst
120 Nm (88 ft lbs).
35 Nm (26 ft lbs).Check that the timing gear pulley is still in the limit position in the oval holes.Tighten the center sc
Install the timing gear pulley on the intake camshaft:
Install the timing gear pulley on the intake camshaft with two screws, but do not tighten.Check that the markings on
Installing the timing belt
5 Nm (4 ft lbs).
Tighten the center screw on the camshaft belt tensioner to Turn the variable Valve Timing (VVT) unit clockwise un
Hold the variable Valve Timing (VVT) unit secure at the clockwise limit position when the belt is being install

As illustrated.
Install the belt in the following order:
- Install the camshaft belt over the pulley on the crankshaft.
Then install the belt as follows
1. Idler pulley.2. Intake cam pulley.3. Exhaust cam pulley.4. Water pump.5. Belt tensioner.
Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Tighten the timing belt
Adjust the belt tensioner:
Note! 20C/68F
This adjustment is to be made with a cold engine. A suitable temperature is . At a higher temperature, for e
10 Nm (7.4 ft lbs)
20 Nm (15 ft lbs)Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise
Note! (VVT)The variable Valve Timing unit must not be released from the limit position until after the timing g
Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant temperatur

20C
20 Nm (15 ft lbs)
At the needle must be centered in the window.See the illustration above.Hold the eccentric secure and tighten the ce
As illustrated.If the indicator is not in the correct position, a new alignment must be carried out.
Remove
40 Nm (29 ft lbs)the camshaft adjustment tools.the crankshaft stopper. Install the plug with a new sealing washer.Tig
Checking the markings and belt tension
Check:
Press the belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover.Turn the crankshaft two turns and check that the markings on the crankshaft and c
Reinstall
Install

- 12 Nm (8.8 ft lbs)the front camshaft belt cover. Tighten to
- 8 Nm (6 ft lbs)the upper camshaft belt cover. Tighten to
- the cable duct. 3 nuts.
- the expansion tank.
- the servo reservoir.
Wipe clean.Check the level and top up as necessary.
Note! Check that the hoses are correctly positioned.
- the starter motor.
40 Nm (29 ft lbs) 25 Nm (18 ft lbs)Tighten the screws at the transmission to Tighten the support bracket screw to
- the engine Cooling Fan (FC).
- the hose between the charge air cooler and the intake.
Remove the seals.Tighten the clamp on the charge air pipe at the Throttle Body (TB).
- screw the relay bracket and the fan shroud into place.
- the Canister Purge (CP) valve, relays and connectors.
- the air ducts.
- the brake vacuum hose.
17 Nm (12 ft lbs)Tighten to
- the Camshaft Position (CMP) sensor housing and a new cover.

Tighten the screws.
- the torque rod bracket.

- the upper torque rod.
35 Nm (26 ft lbs) 90 degreesTighten to Angle-tighten

- the charge air pipe over the engine.

Remove the seals.
- the Air Cleaner (ACL) cover and the intake air hose.
- the solenoid valves on the Air Cleaner (ACL) cover.

- the cable to the battery negative terminal. Note when disconnecting/connecting the battery lead.
- The cover in the fender liner.
- The front wheel.
Checking work
Check the engine function by test driving the car.Wipe clean and check the engine compartment.Wipe the steering w
Camshaft Oil Seal: Service and RepairWithout VVT
Front Seal
Special Tools
999 5199999 5449999 5450999 5451999 5452999 5919

Front seal
Remove
- spark plugs cover

- right front wheel


Remove

Note!
Remove
Remove camshaft
- Camshaft seal/sealsGrease
Position (CMP) sensorand installand
housing newdamper
seal with drift 999 5449, use a copper mallet. (Drift 999 5449 of t
- starter motor
Install gauge 999 5451, 999 5452

Install
- timing belt
Tighten timing belt

Remove the lock pin from the tensioner damping unit.Press hard or knock the belt twice in the direction of arrow (1)

20 Nm
Tighten the camshaft pulley screws tighten to Remove the camshaft locking tool (999 5452) from the rear edge of th
Install

- expansion tank
Install

- spark plugs cover
- starter motor
Test function
Test run engine.
Rear Seal
Rear seal
Remove

Carefully
Note!
Install
- Camshaft
rotor Position (CMP)
and distributor cover sensor housing with damper
Test function
Test run engine.

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - Rear Main Seal R
Crankshaft Main Bearing Seal: Technical Service BulletinsEngine - Rear Main Seal Replacement
NO: 21-17
DATE: 10-15-2002
MODEL/YEAR: All 1992 and Later Equipped with 4, 5 and 6 Cylinder White Engines
AFFECTED ENGINES: B41xx, B52xx, B62xx, B63xx
SUBJECT: Crankshaft Seal, Rear, Replacing
REFERENCE: VADIS/TNN 21-13 Oil Weepage, Rear Engine Seal, Flywheel Retaining Bolts
DESCRIPTION:
Several recommended method changes have been made to the rear crankshaft seal replacement procedures in VADIS. R
Information Manager/Function group 2/Repair and installation/ 21 Engine/Crank Mechanism/Seal Rear, Replacing.
The changes include:
^ New Special Tools
^ New cleaning methods
^ New seal lubrication recommendations
^ New flywheel attachment procedure
From this time on we strongly recommend this new method be put into practice however not all tools are currently avai
SERVICE:
Special Tools: 9995112 extractor, tool and 9995678 Special Screws are not available at this time.
Continue to use extractor 9995919 until further notice and be especially careful not to scratch the engine block or crank
Removed flywheel screws can be used as a substitute for Special Screws 9995678.
Remove all remaining sealant from the threads and mark the screw heads using paint or a punch mark so they can easil
Cleaning cloth 9511024 is available from Volvo parts. It is extremely important that there is no thread sealant residue o
Lubrication, Only Volvo Approved engine oil may be used to lubricate the new seal. Under no circumstances should gr
Warranty Note:
Below you will find the applicable operation number and labor description for the above repair. Labor Time h
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine -
Rear Main Seal Replacement > Page 2105

Warranty Claim Information
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 2106
Crankshaft Main Bearing Seal: Service and Repair
Special Tools:
- Handle tool No. 999 1801, or equivalent
- Gear Sector tool No. 999 5112, or equivalent
- Driver tool No. 999 5430, or equivalent
NOTE:
Procedure
NOTE: Proceed with transmission removed as described under Transmission Removal, refer to Transmission and Driv
1. Remove flywheel/drive plate:

- Use gear sector 999 5112, or equivalent.
2. Replace seal:
- Remove seal using a groove-cut chisel.
NOTE: Do not damage contact surfaces. Note the position of seal in relation to sealing flange.
- Oil seal contact lip.

- Install seal using driver tool No. 999 5430 and handle tool No. 999 1801, or equivalents.
- Knock in seal until the driver hits the crankshaft.
3. Reinstall flywheel/carrier plate:
- Use gear sector tool No. 999 5112, and special screws tool No. 999 5593, or equivalents.
45 Nm
Manual (33 ft lb)Reinstall the flywheel using the three special screws and tighten (diagonally) to:
Transmission:-
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 2107

- 45 Nm (33 ft lb)Install the other standard screws, using new screws, and tighten to .
- 45 Nm (33 ft lb)Replace the three special screws with new standard screws and tighten diagonally to:
- 65Angle tighten all screws an additional:
Install the
Automatic drive plate, tighten in two stages:
Transmission:-
45 Nm (33 ft lb) 50Tighten to: Angle tighten:

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Specifications
Cylinder Head Gasket: Specifications
Tighten Lower Cylinder Head Bolts In Three Stages Working Outwards From Center:
1st Stage .....................................................................................................................................................................

NOTE: Use angle gauge tool No. 951 2050, or equivalent
Tighten Upper Cylinder Head Bolts Working Outwards From Center:

Tighten to ...................................................................................................................................................................
Apply- liquid gasket part No. 1 161 059-9, or equivalent, on the upper half of the cylinder head, use roller.
NOTE:
- Take care not to get gasket compound in oil ways.
- A thin coating is sufficient for a seal.
- Lock front of camshaft with holder tool No. 999 5453 and rear with locking tool No. 999 5452, or equivalent
- Locate upper half of cylinder head, then pull down towards cylinder head with press tools 999 5454, or equiva
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Specifications > Page 2111
Cylinder Head Gasket: Service and Repair
Special Tools:
- Angle Gauge tool No. 951 2050, or equivalent
- Locking tool No. 999 5451, or equivalent
- Locking tool No. 999 5452, or equivalent
- Press tool No. 999 5454, or equivalent
NOTE:
For additional information on special tools and equipment used in this procedure, refer to Tools For Engine Service an
Procedure:
1. Drain coolant and undo front exhaust pipe:
- Remove battery negative lead.
- Remove expansion tank cap.
- Remove splash-guard under engine.
- Open engine and radiator nipples, use hose to collect coolant.
- Close nipples.
- Remove exhaust manifold/front pipe nuts.
2. Remove exhaust manifold and fuel distribution manifold:

- Remove:
Exhaust Manifold, as outlined in steps 1 and 2 of Exhaust System Inspection/Replacement. See: Exhaust
- Lift fuel distribution manifold and injectors and put to one side.
Use holder tool No. 999 5533, or equivalent, for the injectors.
- Remove the two ground strips from engine.
NOTE: Ensure that injectors and needles are not damaged.

3. Remove:
- Engine coolant fan and intake manifold
- Upper radiator hose from thermostat housing
Holder tool No. 999 5453 or tool No. 999 5408 3, or equivalent to secure the front of the camshafts
Install:-
- Press tool 999 5454-7, or equivalent with a clearance of a few millimeters (inches) between them and the cam
4. Remove rear components:

- (ACL)air cleaner with hoses
- (CMP)camshaft position sensor and damper
- distributor cap, HT leads and rotor
- extension arm with brackets
5. Remove upper half of cylinder head:

- Remove all bolts from center outward
- Carefully knock the cover up at all the corners using Puller 999 5402-6.
- Open and remove press tool No. 999 5454-7, or equivalent little by little to ensure an even lift.

6. Remove cylinder head:
- Remove coolant pipe screws (2).
- Undo cylinder head screws (working inwards).
- Remove cylinder head.
- Remove cylinder head gasket.
7. Clean:
- mating faces exhaust manifold/cylinder head
- engine block gasket face
- coolant pipe gasket face
- gasket face between upper/lower halves of cylinder heads
Do not
NOTE: - use a metal scraper.
- Use a soft putty knife and gasket solvent part No. 1 161 340-3, or equivalent.
- Surfaces must be completely clean to ensure a seal.
WARNING: If gasket solvent is being used a fume hood or extractor must be used.
8. Align crankshaft timing marks:
- Remove starter motor.
- Remove plug.
- Install locking tool No. 999 5451, or equivalent.
- Turn crankshaft counterclockwise until it stops.

9. Install lower half of cylinder head:
- Replace cylinder head gasket
- Oil screws.
- Tighten screws in three stages as follows, working outwards:
20 Nm (15 ft lb)
60 Nm (44 ft lb)
1301st stage 2nd stage 3rd stage, use angle gauge tool No. 951 2050, or equivalent
- Install coolant pipe with new gasket.
- Replace O-rings in spark plug wells.
- Remove No.1 and No. 5 spark plugs.
10. Apply liquid gasket:

- Apply liquid gasket part No. 1 161 059-9, or equivalent, on the upper half of the cylinder head, use roller.
NOTE:
Take care not to get gasket compound in oil ways.
-- A thin coating is sufficient for a seal.
- Install camshafts.
Lock front of camshaft with holder tool No. 999 5453 and rear with locking tool No. 999 5452, or equival
11. Install upper half of cylinder head:
- Locate component.
- Pull down towards cylinder head with press tools 999 5454, or equivalent (2).
- 17 Nm (13 ft lb).Tighten upper half working outwards, tighten to
- Remove holder tool No. 999 5453 and press tool No. 999 5454, or equivalent

12. Install front camshaft seals:
- Grease seal.
- Tap seal into place.
- The most recent model of drift tool No. 999 5449, or equivalent is made of plastic.
13. Install camshaft pulley

- Locate upper timing cover
- Install camshaft pulley, align timing marks.
- Tighten the two screws until they are just touching the camshaft pulley.
- Remove upper timing cover.
NOTE: Check that the camshaft screw holes are centered, as illustrated.
14. Install timing belt:
- 25 Nm (18 ft lb)Install tensioner, tighten to .
- Place belt over camshaft pulleys, around water pump and press belt over the tensioner pulley.
- Slacken the two camshaft pulley screws.
- Remove locking pin from tensioner.
- Push the belt hard or strike it twice with a plastic mallet in the directions indicated by arrows 1 and 2.

15. Tighten camshaft pulleys:
- 20 Nm (15 ft lb)Install third screw and tighten to .
- Install inner timing cover screw.
- Install upper timing cover.
16. Remove locking tools:

- Remove crankshaft locking tool No. 999 5451, or equivalent and install plug
- Install starter motor.
- Remove camshaft locking tool No. 999 5452, or equivalent.

17. Check timing marks:
- Turn engine crankshaft two revolutions.
- Check that timing marks on crankshaft and camshaft pulleys are aligned.
- Install outer timing cover.
18. Install rear camshaft seal:

- Grease seal.
- Press seal into place.
NOTE:
Seal is normally installed flush with the inner chamfer edge.
-- If there are grooves on the shaft end the seal can be pressed in a further 2 mm by reversing the sleeve.

19. Install:
- extension arm, with brackets
- rotor
- (CMP)camshaft position sensor and damper.
- spark plugs
- distributor cap and HT leads
- ACL with all hoses and connectors
20. Install:
- Exhaust Manifold, as outlined in step 3 of Exhaust System Inspection/Replacement. See: Exhaust System/Ser
- Intake manifold and engine coolant fan.
- Fuel distribution manifold
- Ground strip to engine
- Exhaust pipe
- Splashguard under engine
21. Fill with coolant/Change oil and oil filter:

- Install battery negative lead
- with oil.system.
Fill cooling
- Run the engine until the thermostat opens and top up if necessary.
- Check for leaks.
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Specifications
Front Crankshaft Seal: Specifications
Crankshaft Center Bolt ...............................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Specifications > Page 2122
Front Crankshaft Seal: Service and Repair
Special Tools
NOTE:
-
For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Serv
-
If low oil pressure/oil pump faults are suspected take oil pressure reading. Refer to "Engine Lubrication, Testing
- Carry out steps 1, 2 and 4 of Timing Belt Replacement. See: Timing Components/Timing Belt/Service and Repai
Procedure
1. Remove vibration damper:

- Remove splashguard.
- Remove vibration damper, use counterhold tool No. 999 5433, or equivalent.
2. Remove crankshaft belt pulley:

- Use universal puller and two vibration damper bolts.
- Tighten two screws by hand until they contact the pulley.
- Install puller so that the claws pull the bolts (not the pulley).
NOTE: Make sure that the claws do not damage the pulley teeth.
3. If replacing front oil pump seal only:
- Remove the old seal using a groove-cut chisel.

- Clean mating surfaces.
- Replace seal, use drift tool No. 999 5455, or equivalent, grease seal.
- Press in seal using the crankshaft center nut.
4. Remove the oil pump:

- Undo the four oil pump bolts.
- Carefully pry out oil pump, use a groove-cut chisel behind pry lugs.
- Clean seal face and mating surfaces.
5. Dismantle oil pump:
Clean and check all components:-

Check for wear and damage, pay particular attention to the crescent shaped insert (surface between suction an
- Separate parts are available for the relief valve.
Spring Tension (Part 1 Of 2)
6. Test relief valve spring Load (N):

-
82.13 mm
Load (N) / Length (mm)0:
59 4: 56.10 mm
- 108
0.60 8: 39.90
MPa (85 psi)mm
Relief valve opens:

7. Install pump wheel in housing and check for play:
- Place large pump wheel in housing with markings upwards.
- Install the small pump wheel.
- Check for play. If there is too much play replace pump. Assemble pump
NOTE: -
100C(212F) If the play between the outside surfaces and the oil pump housing are greater than 0.35 mm and o
- Measure play with a feeler gauge.
8. Install oil pump:

- Use new gasket.
-
Use drift tool No. 999 5455, or equivalent when installing pump.Use screws as guide.
- Pull in the oil pump with the crankshaft center nut.
- 10 Nm (84 inch lbs.)Tighten screws crosswise to .
- Install crankshaft belt pulley using center nut and a spacer.
9. Install timing belt:

- 25 Nm (18 ft lb)Install belt tensioner screws, tighten to: .
-- Place
Place belt
belt around the crankshaft
over camshaft pulley. and right idler pulley.
- Place belt around water pump and press belt over the tensioner pulley.

10. Install vibration damper:
- Pull locking pin out of belt tensioner.
- Install vibration damper.
- 180 Nm (133 ft lb)Tighten center nut to .
- Use counterhold 999 5433, or equivalent.
- 25 Nm (18 ft lb)Remove counterhold (999 5433, or equivalent) and tighten screws to: .
- Install upper timing cover.
- Turn the crankshaft two revolutions and check that timing marks on crankshaft and camshaft pulley are aligne
- Install spark plug cover.
11. Install:
- vibration damper guard front timing cover
- auxiliaries belt
- two fuel pipe clips
- expansion tank
- wing liner and wheel
Test run engine.
> Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications


> Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2130

DDO1 Replacing:
Remove
Carry splash
the car engine.
raised.-
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Pulley....................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > With VVT
Camshaft Gear/Sprocket: Service and RepairWith VVT
Special Tools
951 2050999 5450999 5451999 5452999 5651999 5718999 5719999 5919

Note!
Remove
Note!
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > With VVT > Page 2139


Remove



ERROR: undefined
OFFENDING COMMAND: ~
STACK:
Camshaft Gear/Sprocket: Service and RepairWithout VVT
Front Seal
Special Tools
999 5199999 5449999 5450999 5451999 5452999 5919

Front seal
Remove
- spark plugs cover

- right front wheel


Remove

Note!
Remove
Remove camshaft
- Camshaft seal/sealsGrease
Position (CMP) sensorand installand
housing newdamper
seal with drift 999 5449, use a copper mallet. (Drift 999 5449 of t
- starter motor
Install gauge 999 5451, 999 5452

Install
- timing belt

Tighten timing belt

20 NmRemove the lock pin from the tensioner damping unit.Press hard or knock the belt twice in the direction of arr

Remove the camshaft locking tool (999 5452) from the rear edge of the camshafts.Remove crankshaft locking tool 9
Install

- expansion tank
Install

- spark plugs cover
- starter motor
Test function
Test run engine.
Rear Seal
Rear seal
Remove

Carefully
Note!
Install

Test function
Test run engine.

> Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Center nut..............................................................................................................................................................................
Vibration damper -2002 Flanged screws x4Stage 1.............................................................................................................
Vibration damper 2002-Flanged screws x4Stage 1..............................................................................................................

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Mechanical Camshaft Belt Tensioner - Adjusting
Timing Belt: Technical Service BulletinsMechanical Camshaft Belt Tensioner - Adjusting

Section
2
Group
21
No.0015
Year
99
Month
06
S70/V70/C701998-
Background:
Engine serial no.:
S70/V70/C70 1266128-

4
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Mechanical Camshaft Belt
Tensioner - Adjusting > Page 2154

5
Note!
8 Note!
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 2155
Timing Belt: Specifications

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 2156
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Replacement, W/Mechanical Tensioner
Timing Belt: Service and RepairReplacement, W/Mechanical Tensioner
Important Note -Please Read-
Volvo changed the camshaft alignment (timing) marks during the 1998 model year. This vehicle will use one of the fo

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Replacement, W/Mechanical Tensioner >
Page 2159

REPLACING TIMING BELT/IDLER PULLEY/BELT TENSIONER
Special Tools: 999 5433
Note:
Remove components
Caution! Remove the ignition key from the ignition switch before beginning work.
Note!
Crankshaft or camshaft must not be rotated under any circumstances more than is listed below. Failure to
Page 2160

upper timing belt cover.
Remove:-
- servo reservoir and expansion tank.
- Lift up and place on top of engine.
Note!
Take care not to spill servo oil from the bleed hole in the cap.Place paper wipe around the reservoir and th
- auxiliaries belt.
- front camshaft belt cover.
Position engine according to marking
Remove
Raise right front wheel.
the car.-
- Remove the nut for the cover in the fender liner.
- Install the upper camshaft belt cover.
- Turn crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
- Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The marking
- Remove upper camshaft belt cover.
Page 2161

Slacken
Slacken off belt
off belt tensioner center screw slightly.
tensioner-
- 6 mm (15/64")Hold the center screw still and turn the tensioner eccentric clockwise with a allen key to "10 o'clo
- Remove the camshaft belt from the belt tensioner, camshaft pulley and idler pulley and the water pump.
Remove vibration damper
Remove
Raise the car-vibration damper. Use counterhold 999 5433. Work the vibration damper loose.
- Remove camshaft belt
Checking the belt tensioner and idler pulleys
Replace
Check if necessary.
bearing wear:-
IdlerSpin the idler pulley and listen for noise.

pulley:-
- 24 Nm (18 lb ft)If replacing with a new idler pulley, tighten to
Tension pulley:
Page 2162

- When replacing, screw the tension pulley into place with the center screw.
- Screw in the center screw by hand.
- Ensure that the tensioner fork is centered over the cylinder block rib.
- Ensure that the allen hole on the eccentric is at "10 o'clock".
Installing camshaft belt
Install
Install the new camshaft belt over crankshaft pulley wheel.
belt as follows:-
- 180 Nm (133 lb ft)
25 Nm (18 lb ft) and angle tighten 30 degreesInstall vibration damper. Tighten the center nut to Use counterho
Then install the new belt in the following order:1. idler pulley.2. intake camshaft pulley.3. exhaust camshaft pulley.4
Tighten timing belt
This adjustment is always carried out on a cold engine.Suitable temperature is approximately 20C/68F.
At higher temperatures, for example with engine at operating temperature or at higher ambient temperature, the need
Page 2163

- Turn crankshaft clockwise carefully until the camshaft belt is tensioned.
- The belt must be tensioned between intake camshaft pulley, idler pulley and crankshaft.
-
Hold the belt tensioner center screw secure and turn the belt tensioner excenter counter clockwise until the tensio
- Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant tempera
- 20C (68F)At the needle must be centered in the window.
- See figure above.
- 20 Nm (15 lb ft)Secure the eccentric and tighten the center screw to
Check that the needle is in the correct positionIf this is not the case a new alignment must be carried out.
Check
Press the
Checking belt to see that the indicator on the tensioner moves easily.
markings:-
- Install the upper timing belt cover.
- Turn crankshaft 2 turns and check that the markings on the crankshaft and camshaft pulley correspond.
- Check that the indicator on the belt tensioner is within the marked area.
Page 2164

Reinstall components
12 Nm (8.8 lb ft)Front camshaft belt cover. Tighten to

Reinstall-
- 8 Nm (6 lb ft)Upper camshaft belt cover. Tighten to
- Auxiliaries belt.
-
Servo reservoir.Wipe clean.Check the level and top up as necessary.

- Expansion tank.
Note! Ensure that hoses are correctly positioned.
- Wipe clean and check engine compartment.

- Cover in fender liner.
- Front wheel.
Checking work
Note! Write the date and mileage on the decal and stick it on the camshaft belt cover.
Test drive
Function test:-engine.
- Wipe dry steering wheel and gear selector lever.
Note:
This procedure uses depictions of a timing belt with a hydraulic tensioner. The procedure is the same for timing belts
Special Tools: 998 8500, 999 5456

Remove:
- spark plug cover
- auxiliaries belt
Page 2165

5 minutes
not
Wait3.5-4.6
998
-
2.5-4.0 units
Page 2166

lower screw
Remove:-
- timing belt

Remove:-
- Tension pulley
Sleeve
Install:-
Page 2167

30 Nm (22 ft lb)

If a mechanical belt tensioner is being used, adjust according to "Adjusting the Mechanical Belt Tensioner" See: Tim
25 Nm (18 ft lbs)
Page 2168

Secure drive belt
Page 2169

20 Nm
Install
- accessory belt
- spark plug cover
- expansion tank
Test function
Test run engine.
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Replacement, W/Mechanical Tensioner > Page 2170
Timing Belt: Service and RepairReplacement W/Hydraulic Tensioner
Special Tools: 998 8500, 999 5456
Remove:
- spark plug cover
- auxiliaries belt
Page 2171


5 minutes
not
Wait3.5-4.6
998
-
2.5-4.0 units
lower screw
Remove:-
- timing belt
Page 2172

Remove:-
- Tension pulley
Sleeve
Install:-
- Tension pulley
30 Nm (22 ft lb)

If a mechanical belt tensioner is being used, adjust according to "Adjusting the Mechanical Belt Tensioner" See: Tim
Page 2173


25 Nm (18 ft lbs)
Secure drive belt
Page 2174

20 Nm
Install
- accessory belt
- spark plug cover
- expansion tank
Test function
Test run engine.
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Mechanical Camshaft Belt Tensioner - A
Timing Belt Tensioner: Technical Service BulletinsMechanical Camshaft Belt Tensioner - Adjusting
Section
2
Group
21
No.0015
Year
99
Month
06
S70/V70/C701998-
Background:
Engine serial no.:
S70/V70/C70 1266128-

4
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Mechanical Camshaft
Belt Tensioner - Adjusting > Page 2179

5
Note!
8 Note!
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Page 2180
Timing Belt Tensioner: Specifications

Timing Belt Tensioner: Description and Operation
Mechanical Camshaft Belt Tensioner

- All B52XXX engines are equipped with a mechanical camshaft belt tensioner which replaces the old hydraulic te
- Rationalization: quality improvement.
- The camshaft belt tensioners are adjusted using an eccentric to obtain the correct belt tension.
Check belt tension at every 30,000 mile / 45,000 km service.
The timing belt and camshaft belt tensioner replacement interval is 80,000 miles / 120,000 km as before.
Forare
There 102valves = Yellow
new timing beltstext
for(138 teethbelt
the new x 0.9 in.) depending on engine variant:-
tensioner
- For 20 valves = Red text (142 teeth x 0.9 in.)
Timing Belt Tensioner: Adjustments
ADJUSTING THE MECHANICAL BELT TENSIONER
As the illustrations in the information are used for different model years and/or models, certain variations may occur. H
Adjusting The Camshaft Belt Tensioner And Camshaft Belt

- Install timing belt.
- Ensure that belt is tight between crankshaft and intake pulley, if not reinstall.
- 5 Nm (4 ft/lb)Tighten the center screw to .
-
Holding the center screw stationary, turn the eccentric (A) with a 6 mm (15/64") Allen key counter-clockwise un
- Turn the eccentric (A) clockwise until the indicator (C) reaches the correct position based on the temperature of t
- 20 Nm (15 lb.ft)Hold the eccentric secure and tighten the center screw to .
Note: When setting the final adjustment the needle (C) must enter the adjustment window (B) from the right. If the
left, it must be readjusted past the window so that it enters from the right.
- Press on the timing belt and verify that the indicator moves in response to the pressure
Note: 20 Nm (15 ft lb) If the bolts holding either cam wheel had been loosened, tighten them at this time to .
- Press the camshaft belt and check that the camshaft belt tensioner needle moves freely.
The position of the needle at different temperatures
20C (168F)
This adjustment is to be made with a cold engine.A suitable temperature is approximately .At a higher temperature, f
The position of the indicator when aligning the camshaft belt tensioner at different temperatures is shown in the illus
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner
Timing Component Alignment Marks: LocationsWith Mechanical Tensioner

Note: Volvo changed the camshaft alignment (timing) marks during the 1998 model year. This vehicle will use one o

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner
> Page 2187

Note:
Note:
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > With Mechanical Tensioner > Page 2188
Timing Component Alignment Marks: LocationsWith Hydraulic Tensioner

Note:
Note:
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications

Air / Fuel Mixture
[1]CO Content ..................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 2197

Air / Fuel Mixture

CO Content .........................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 2198

Notes:
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2202


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair
Preparation
- Removing pipes
-
Remove:

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair > Page 2206


Installing pipes

Install:

Install:
- Fill and bleed the brake system. See: Brakes and Traction Control/Hydraulic System/Brake Fluid/Service and Re
200 Nm
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page
2214

Installing

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications

IGNITION CABLE
Resistance:

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2228


4.5K ohms 20%

4.0K ohms 20%
3.3K ohms 20%

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Specifications

IGNITION ROTOR
Resistance ...................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2239

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2240

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amen

SECTION
2
GROUP
21
NO.842
DATESep. 1998
Background:
Chassi No.:
S70 - 460000
V70 - 395002
Special tools: 999 9689, 115 8540
Compression test
High tension 1
Warning!
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins >
Compression Test - Amended > Page 2245

Note!
Separate connector
Remove:

- spark plugs.
Remove fuse 11B3 4
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins >
Compression Test - Amended > Page 2246

Note!

Installing
- components
- fuse 11B3.
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Page 2247

Normal value .................................................................................................................................................... 1.3 -
SPECIAL TOOLS
NOTE:
The DI system

NOTE:
1. Remove:
- HT lead cover
Remove
open:-

> Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Water Pump Bolts ......................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2253
Water Pump: Service and Repair
Special Tool:
- Press Tool No. 999 5456, or equivalent
NOTE:
Procedure
1. Drain coolant:
- Raise car.
- Open engine and radiator nipples. Use hoses to collect coolant.
- Close nipples.
2. Remove:
- spark plug cover
- lift up expansion tank and lay on engine
- right front wheel
Undo wing liner to expose vibration damper.Turn engine crankshaft to align timing marks.
3. Remove:
- Belt tensioner
Undo timing belt and put to one side.

Compress tensioner using tool 999 5456, or equivalent.
4. Remove water pump and clean gasket face and mating surfaces
- Carefully clean and scrape off gasket residues from cylinder block.
5. Install water pump:

- Use new gasket.
- 20 Nm (14.8 ft lb)Tighten screws to .
6. Install:
- belt tensioner
- timing belt
Pull locking pin from belt tensioner.Turn crankshaft two revolutions until timing marks line up.
7. Install:
- expansion tank

- spark plug cover
Fill with coolant.Run engine warm and top up if necessary.Check for leaks.
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity Specification

Coolant volume ..........................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2261
Coolant: Fluid Type Specifications
Coolant Specifications
Genuine Volvo or equivalent type C coolant diluted 50/50 with pure water.
> Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Service and Repair

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instruc

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2292
Radiator Cooling Fan Motor: Description and Operation
Engine Coolant Fan
The engine has a large cooling system with an electronically controlled engine coolant fan. This fan draws air thr
The engine coolant fan runs at two speeds depending on engine temperature and pressure in A/C system.
The fan is electronically controlled via a fan control (FC) relay operated by the fuel/DI system control module.
The fan is self-starting.

WARNING:-
- The fan can start even when the ignition is switched off.
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2293
Radiator Cooling Fan Motor: Service and Repair
1. Remove engine coolant fan:

- Remove four screws holding fan shroud.
- Hold up shroud, pull up relay holder and disconnect fan connectors.
- (ACL)Remove control module and air cleaner air ducts.
- Remove fan and shroud.
2. Remove the old engine coolant fan and install new fan:
- Undo four screws and remove engine coolant fan from shroud.
- Install and tighten new engine coolant fan.
3. Reinstall engine coolant fan and shroud

- Install relay holder, relays, connect connectors.
- Install air intakes.
- Tighten fan shroud to radiator.
- Install control module and ACL air ducts.
- Install battery negative lead.
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations
Fuses
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2297

Panel Locations

Relays

Panel Locations

Other Relays
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instruction

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Informatio
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifi

Resistance

> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifi


> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagra
Instructions

> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


ECT ECM
FC
NTC
- Drain off coolant

- Test sensor.
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagram
Instructions
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair
Heater Core: Service and Repair
Replacing the heat exchanger
Special tools:
115 8957
Before starting work on heat exchanger
NOTE! When replacing a heat exchanger, always replace the O-rings in the pipes.
Replacing heat exchanger
Removing
Work in the engine compartment
- Clamp the heating hoses. Use lock grip pliers 115 8957
Operations in passenger compartment

- Remove soundproofing panels right and left-hand sides
- Remove left and right-hand side carpet mountings.
- Remove RTI bracket or amplifier bracket if applicable.
- Remove knee bolster if applicable.
- Detach drain hose and push it to one side.
- Remove the screws on the left and right-hand side of the cover for the heat exchanger.
- Remove the screw for the pipe flange for the heat exchanger
NOTE! Put plenty of absorbent paper under and around the pipe flange.
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 2359

- Remove the heat exchanger and its cover.
- Remove the heat exchanger from cover.
Installing

- Before starting work on heat exchangerFirst read
- Install the heat exchanger in the cover.
NOTE! Check the seal when installing.
- Install the heat exchanger with cover. Align the pipes in the flange
- Install the screw in the pipe flange on the heat exchanger
- Install drain hose.
Operations in engine compartment

- Remove the grip locl pliers 115 8957 from hoses.
- Top up coolant.
- Test for leaks.

- Install bracket for RTI or amplifier if installed.
- Install knee bolster, if any.
- Install carpet support on the left and right-hand sides.
- Install soundproofing panels right and left-hand sides.
> Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Service and Repair
Temperature Gauge: Service and Repair
DDF1 Removing Tachometer, Temperature Gauge, Fuel Gauge and Speedometer:
instrument housing. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service a
Remove:-
- screws to remove tachometer, temperature gauge, fuel gauge and speedometer.
- Carefully pry up and release the tachometer, temperature gauge, fuel gauge and speedometer using a weatherstrip
DDF2 Installing:
- Position gauges on their guides and press into place.
NOTE: Press the trip odometer/odometer reset button into place.
> Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Service and Repair > Page
2364

screws.
Install:-
- instrument housing.
> Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications
Radiator: Specifications
Tightening Specification
Radiator ......................................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2368
Radiator: Service and Repair
Special Tool:
- Pressure Tester tool No. 998 5496, or equivalent
NOTE:
Procedures
- Radiator, replacement: steps 1 through 9
- (ECT)Engine coolant-temperature sensor: step 10
Cooling System, Check For Leaks

Test pressure of cooling system
- Use pressure tester 998 5496.
- Connect tester to expansion tank cap.
- Pump up pressure and check for leaks.
pressure should be 150 kPa (22.5 psi). pressure in the system should be stable.
NOTE: Allow the pressure to stabilize for a few minutes.

1. Drain coolant:

- Remove guard under radiator.
- Open radiator drain cock. Collect coolant with a hose on the drain cock.
- Close drain cock.
2. Detach the upper and lower radiator hoses:

- Remove the engine coolant fan FC.
- Detach the upper and lower engine radiator hoses
- Turbo: Detach the oil cooler hoses from the right side of the oil cooler.
- Automatic: Detach the oil cooler hoses from the left side of the oil cooler.
Cars Fitted With A/C:
3. Remove upper A/C-condenser bolts

- Remove two upper bolts holding condenser to radiator.
- Hang up radiator with a cord as illustrates.
4. Remove lower A/C-condenser screws

- Remove two lower bolts holding condenser to radiator.
5. Disconnect radiator:

- Remove two bolts holding radiator.
CAUTION: Hold radiator to avoid damaging it.
6. Install radiator:
- 30 Nm (18 ft lb)Tighten radiator to .
- Finger tighten two lower bolts holding A/C-condenser.
7. Tighten radiator/A/C-condenser:
- Install two upper screws for radiator/condenser.
8. Install radiator hoses and engine coolant fan:

- Install upper and lower radiator hoses.
- Install engine cooling fan.
- Raise car and tighten lower screws holding AC condenser to radiator.
- Reinstall splashguard.

9. Fill coolant:
- Fill cooling system through expansion tank.
- 7.2 l (7.6 US qt.)Total coolant capacity is about .
- Run engine warm and top up if necessary.
- Check for leaks.
Engine Coolant Temperature Sensor
10. Location engine coolant-temperature sensor:

- The sensor is located in the thermostat housing.
- The sensor sends a signal to both the ignition and fuel systems and the combined instrument temperature gaug
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Inform

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations
Fuses
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page
2389

Panel Locations
2390

Relays
2391

Panel Locations
2392

Other Relays
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Informatio

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Service and Repair

> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Com
Specifications

Resistance



Diagrams > Diagram Information and Instructions

> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/
Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2415

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

Diagrams > Page 2424

ECT ECM
FC
NTC
- Drain off coolant

- Test sensor.
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Sw
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan
Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2430

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Service and Repair
Temperature Gauge: Service and Repair
DDF1 Removing Tachometer, Temperature Gauge, Fuel Gauge and Speedometer:
instrument housing. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service a
Remove:-
- screws to remove tachometer, temperature gauge, fuel gauge and speedometer.
- Carefully pry up and release the tachometer, temperature gauge, fuel gauge and speedometer using a weatherstrip
DDF2 Installing:
- Position gauges on their guides and press into place.
NOTE: Press the trip odometer/odometer reset button into place.
> Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Service and Repair > Page 2442

screws.
Install:-
- instrument housing.
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications
Thermostat: Specifications
Opening Temperature Specifications
Marking ......................................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2446
Thermostat: Testing and Inspection
NOTE:
- Drain off about two liters of coolant. Remove expansion tank cap.
- Open nipple on left underside of radiator, use hose to collect coolant. Close nipple.
Thermostat Replacement
1. Removal/installation thermostat:
- Remove thermostat housing cover hose and remove thermostat and gasket (Torx 40).
- Clean thermostat housing gasket surfaces.
- Install new thermostat seal.
- Install thermostat in housing, install and tighten cover and hose.
- Fill with coolant and run engine warm until the thermostat opens. Top up if necessary.
- Check for leaks.
Thermostat Check
2. Check opening function:
- Thermostat can be tested in hot water.
- Maximum opening should occur within two minutes in water at opening temperature.
- Marking: 87
87C (189F)
102C (216F)Starts to open at: Fully open at:
- Marking: 90
90C (194F)
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2447
Thermostat: Service and Repair
NOTE:
- Drain off about two liters of coolant. Remove expansion tank cap.
- Open nipple on left underside of radiator, use hose to collect coolant. Close nipple.
Thermostat Replacement
1. Removal/installation thermostat:
- Remove thermostat housing cover hose and remove thermostat and gasket (Torx 40).
- Clean thermostat housing gasket surfaces.
- Install new thermostat seal.
- Install thermostat in housing, install and tighten cover and hose.
- Fill with coolant and run engine warm until the thermostat opens. Top up if necessary.
- Check for leaks.
Thermostat Check
2. Check opening function:
- Thermostat can be tested in hot water.
- Maximum opening should occur within two minutes in water at opening temperature.
- Marking: 87
87C (189F)
- Marking: 90
90C (194F)
> Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications
Water Pump: Specifications
Water Pump Bolts ......................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2451
Water Pump: Service and Repair
Special Tool:
- Press Tool No. 999 5456, or equivalent
NOTE:
Procedure
1. Drain coolant:
- Raise car.
- Open engine and radiator nipples. Use hoses to collect coolant.
- Close nipples.
2. Remove:
- spark plug cover
- lift up expansion tank and lay on engine
- right front wheel
Undo wing liner to expose vibration damper.Turn engine crankshaft to align timing marks.
3. Remove:
- Belt tensioner
Undo timing belt and put to one side.

Compress tensioner using tool 999 5456, or equivalent.
4. Remove water pump and clean gasket face and mating surfaces
- Carefully clean and scrape off gasket residues from cylinder block.
5. Install water pump:

- Use new gasket.
- 20 Nm (14.8 ft lb)Tighten screws to .
6. Install:
- belt tensioner
- timing belt
Pull locking pin from belt tensioner.Turn crankshaft two revolutions until timing marks line up.
7. Install:
- expansion tank

- spark plug cover
Fill with coolant.Run engine warm and top up if necessary.Check for leaks.
> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Application and ID
Catalytic Converter: Application and ID

> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Application and ID > Page 2458

> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Application and ID > Page 2459
Catalytic Converter: Description and Operation
TWC
- The TWC cleans exhaust gases by oxidizing unburned: carbon monoxide (CO) hydrocarbons (HO) nitrogen oxid
- 90-95% of these harmful substances are converted into innocuous: water (H20) carbon dioxide (CO2) nitrogen (N
- The active surface area of the unit is about 43,000 m2 and the noble metal content of about 3.5 grammes platinum
NOTE: Lead in fuel will damage the TWC, quickly making it unserviceable.
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications
Exhaust Manifold: Specifications

TIGHTENING TORQUE
Exhaust manifold to cylinder head .............................................................................................................................

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > NHTSA98V254000 > Nov > 98 > R
With Tailpipe
Exhaust Pipe: RecallsRecall 98V254000: Passenger Contact With Tailpipe
NHTSA CAMPAIGN ID Number: 98V254000Component: EXHAUST SYSTEM: PIPE: EXHAUSTManufacturer: V
Year: 1998, 1999Make: VOLVOModel: V70Year of Recall: '98Type of Report: Vehicle Potential Number of Units Af
Summary:
Vehicle Description: Station wagons equipped with third seats. Users of the third seat, when exiting the vehicle, can co
Contact with the tailpipe can result in personal injury.
Dealers will inspect the length of the vehicle's tailpipe and, if necessary, repair the tailpipe.
Owner notification began November 16, 1998. Owners who take their vehicles to an authorized dealer on an agreed up
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > 2531 > Nov > 98 > Recall - Tailpipe
Exhaust Pipe: RecallsRecall - Tailpipe Inspection/Adjustment w/Child Seat
GROUP:25
NO:31
ISSUING DEPARTMENT:Customer Support
DATE:November 1998
TITLE:
Recall 89:
V7O Tailpipe Inspection/Adjustment (w/installed Child Auxiliary Seat or Third Seat)
REFERENCE BULLETINS:SB 25-0012
BULLETIN REFERENCE
A. RECALL CAMPAIGN 89 DESCRIPTION
F. VEHICLES in RETAILER INVENTORY
I. CLAIM FORMAT INFORMATION
J. RETAILER ALLOWANCE

Volvo Cars of North America, Inc. and Volvo Canada ltd. have announced a Recall Campaign affecting certain model
Due to production variability, the tip of the tailpipe in some of these vehicles may protrude beyond the contour of the re
Owners of all potentially affected vehicles will by notified by mail during the week of November 16, 1998.
B. VEHICLES INVOLVED (EQUIPPED WITH A CHILD AUXILIARY SEAT)
Only 1998 & early production 1999 V70 vehicles equipped with the CHILD AUXILIARY SEAT (third seat) are subje
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > 2531 > Nov > 98 >
Recall - Tailpipe Inspection/Adjustment w/Child Seat > Page 2475

following VIN number span.
NOTE:
FOR THIS RECALL ONLY, DCS VEHICLE INQUIRY WILL NOT INDICATE VEHICLE ELIGIBILITY.
ASSY PLANT: 2 CHASSIS RANGE
875 342001 - 559060

876 342001 - 559060
ASSY.PLANT: 3 CHASSIS RANGE
875 356958 - 550366

876 356958 - 550366
"A Retailer Vehicle Campaign List" will NOT be sent to retailers as there are no records to indicate which vehicles are
NO parts are required in the repair procedure for this Recall Campaign.
During the week of November 16, 1998 an announcement letter will be sent directly to Volvo owners. A copy of this le
F. STOCK VEHICLES
All vehicles in retailers' inventory and qualifying for this recall campaign must be inspected /repaired prior to a custom
All claims should be submitted using the LONG FORM application for retailed and stock vehicles eligible for this reca

To insure claim acceptance, your claim must contain ONLY the information listed below:
REPAIR: INSPECTION ONLY
ALL STOCK (NEW & USED) VEHICLES (HAVING A CHILD AUXILIARY SEAT or third seat) AT U.S. RETAIL
CLAIM FORMAT: LONG FORMCLAIM TYPE: 01SYMPTOM CODE: 6ACAUSE CODE: 01FAILED PART: (LEA
* * OR * *
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > 2531 > Nov > 98 >
Recall - Tailpipe Inspection/Adjustment w/Child Seat > Page 2476

REPAIR: INSPECT/ADJUST
Note:
To insure claim acceptance, your claim must contain ONLY the information listed in the CLAIM FORMAT section
REPAIR LABOR PARTS

DESCRIPTION TIME AMOUNT
INSPECT ONLY 0.3 N/A
(includes 0.1 for the inspectionand 0.2 to cover minimum claimallowance time)
INSPECT/ADJUST 0.3 N/A

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > 2250012 > Oct > 98 > Recall - Tailp
Recall - Tailpipe Adjustment
Section 2
Group 25
No.0012
Year98
Month10
V70/V70 AWD1998 - 1999
Recall no.89 Tailpipe, Adjustment
Background:
Due to normal production variability, the tip of the tailpipe may protrude beyond the contour of the rear bumper cover.
Model Assembly plant Chassis No:
V701V70 AWD 2 342001 - 559060

V701V70 AWD 3 356958 - 550366
Checking measurement
Check measurement (A) and note reading:
1. If A>/=20 mm (3/4") - No action needed.
2. If A<20 mm (3/4") - Try first to move the tail pipe by doing following steps:
- Loosen the clamp/screw which holds the tail pipe.
- Move the tail pipe carefully (if possible) further in under the car.
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Recalls for Exhaust Pipe: > 2250012 > Oct > 98
> Recall - Tailpipe Adjustment > Page 2481

- Check measurement (A) again.
If A>/=20 mm (3/4") - No further actions needed.
If A<20 mm (3/4") - Adjust according to one of the following methods below.
A. V70 Turbo (excluded AWD)
B. V70 (excluded Turbo and AWD)
C. V70 AWD (excluded chassi no.386581-403738)
D. V70 AWD (Chassis no.386581-403738)
A. V70 Turbo (Excluded AWD)

A1
Loosen the clamp/screw which holds the tail pipe.
Remove the tail pipe.
A2
Cut off the exhaust pipe 25 mm (1") (A) from the end.
Hint: Use chain style exhaust pipe cutter or equivalent.
A3

Perform this step If applicable.
Grind/file the welding spot from the exhaust pipe.
A4
Burr the newly cut surface.
A5
Note!
Both the tail pipe and the clamp are to be reused after modification.
SAFETY GLASSES MUST BE WORN WHEN PERFORMING THIS STEP.
Carefully grind off the tack weld holding the clamp to the tail pipe.
Remove as little material as possible from the pipe and the clamp.
Carefully sand off any remaining part of the tack weld from tail pipe and clamp, so the clamp can be refitted after tail p
A6

Increase the length of the three slots for the tail pipe.
The slots length (A) should be increased no longer than 35 mm (1 3/8") or the same amount as was removed from the e
A7
Install the tail pipe on exhaust pipe and align according to illustration.
A8
Adjust tail pipe so that the end is 20 mm (3/4") in from the contour of the bumper cover previously measured.
A9

Position the clamp on the tail pipe so the clamp aligns with bulge/shoulder on the exhaust pipe.
Tighten clamp
No further action needed.

B. V70 (Excluded Turbo and AWD)
B1
B2
B3

Refit the tail pipe.
Make sure that the distance (A) reads 20 mm (3/4") according to the illustration.
B4
Make sure that the oval opening is turned so that the axis (B) is horizontal.
Tighten the tail pipe.

C. V70 AWD (Excluded Chassi No. 386581-403738)
C1

C2
C3
Refit the tail pipe and knock it into position.
Check measurement (A) according to step C1.
If A>/-20 mm (3/4") - Go to step C4.If A<20 mm (3/4") - Go to step C6.
C4
V70 AWD (A >/= 20 mm (3/4"))

C5
No further actions needed.
C6
V70 AWD (A < 20 mm (3/4"))
Note!
Both the tail pipe and the clamp are to be reused after modification. SAFETY GLASSES MUST BE WORN WHEN

C7
Cutoff the tail pipe 35 mm (1 3/8 ") (A) as per the illustration.
C8
Make a slot in 3 places with (B) = 120 in between.
The slots (A) should be approximately 30 mm (1 1/4 ").
C9
Grind away:
- rust and burrs from the inner and outer sections of the clamp
- rust and burrs from the outer section on the tail pipe (1) and the edge (2)

- burrs from the slots (4) on the outside of the tail pipe
- burrs from the slots (3) and the edge (2) inside the tail pipe.
Refit the clamp on the tail pipe.
Make sure it is even with the edge (2).
C10
Cut the tail pipe so that (A) is as big as possible without effecting the threaded area which the screw passes through.
Burr the inner and outer cut surfaces.
C11
C12


D. V70 AWD (Chassis No. 386581-403738)
D1
Loosen the clamp (1) which holds the tail pipe.
D2
Markup 25 mm (1") (A) around the cross-cut end.
Hint: Use a sliding calipers as a parallel marking gauge.
D3

Cut accurately and carefully along the marked gauge.
D4
Burr the outer section of the tail pipe and the edge. Burr the edge inside the tail pipe.
D5
D6


Dealer Letter
November, 1998
To: All Volvo Retailers - US & CANADA
Re: Recall Campaign 89
OWNER NOTIFICATION
A notification letter will be sent to the owners of all potentially affected vehicles during the week of November 16, 199
RETAILER RESPONSIBILITIES
Retailers are asked to perform this campaign on eligible vehicles regardless of miles/kilometers or vehicle age. All wor
In the event that a customer does not have a notification letter, the owner is not to be refused this important campaign w
A complete description of the campaign requirements and claim submission procedures will be sent under separate cov
^ Service Manager Bulletin

^ Service Bulletin
^ GOwner Notification Letter
Your cooperation in completing this important campaign is greatly appreciated.

Volvo Cars of North America, Inc. and Volvo Canada Limited have announced a Recall Campaign affecting certain 19
Owner Letter
November 1998
IMPORTANT RECALL NOTICE
Dear Volvo Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
What is the reason for this program?Volvo Cars of North America, Inc. has determined that a defect, which relates to m
Due to normal production variability, the tip of the tailpipe in some of these vehicles may protrude beyond the contour
All vehicles equipped with a child auxiliary seat accessory (third seat) must have the tailpipe inspected. An adjustment
What should you do?Please call your authorized Volvo Retailer as soon as possible to schedule an appointment for an i
Who should you contact?If you have any questions please contact your Volvo Retailer, or Volvo Customer Service at P
We have advised the National Highway Traffic Safety Administration (NHTSA) that we are conducting this recall. If y
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee
Your continued safety and satisfaction with Volvo and the Volvo organization are very important to us. We apologize f
Please note:
According to Insurance institute for Highway Safety president Brian O'Neill, "It is very important that owners of vehic
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > NHTSA98V
98V254000: Passenger Contact With Tailpipe
Exhaust Pipe: All Technical Service BulletinsRecall 98V254000: Passenger Contact With Tailpipe
NHTSA CAMPAIGN ID Number: 98V254000Component: EXHAUST SYSTEM: PIPE: EXHAUSTManufacturer: V
Year: 1998, 1999Make: VOLVOModel: V70Year of Recall: '98Type of Report: Vehicle Potential Number of Units Af
Summary:
Vehicle Description: Station wagons equipped with third seats. Users of the third seat, when exiting the vehicle, can co
Contact with the tailpipe can result in personal injury.
Dealers will inspect the length of the vehicle's tailpipe and, if necessary, repair the tailpipe.
Owner notification began November 16, 1998. Owners who take their vehicles to an authorized dealer on an agreed up
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 2531 > Nov
Adjustment w/Child Seat
Exhaust Pipe: All Technical Service BulletinsRecall - Tailpipe Inspection/Adjustment w/Child Seat
GROUP:25
NO:31
ISSUING DEPARTMENT:Customer Support
DATE:November 1998
TITLE:
Recall 89:
V7O Tailpipe Inspection/Adjustment (w/installed Child Auxiliary Seat or Third Seat)
REFERENCE BULLETINS:SB 25-0012
BULLETIN REFERENCE
F. VEHICLES in RETAILER INVENTORY

Volvo Cars of North America, Inc. and Volvo Canada ltd. have announced a Recall Campaign affecting certain model
Due to production variability, the tip of the tailpipe in some of these vehicles may protrude beyond the contour of the re
Owners of all potentially affected vehicles will by notified by mail during the week of November 16, 1998.
B. VEHICLES INVOLVED (EQUIPPED WITH A CHILD AUXILIARY SEAT)
Only 1998 & early production 1999 V70 vehicles equipped with the CHILD AUXILIARY SEAT (third seat) are subje
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe:
> 2531 > Nov > 98 > Recall - Tailpipe Inspection/Adjustment w/Child Seat > Page 2503

following VIN number span.
NOTE:
FOR THIS RECALL ONLY, DCS VEHICLE INQUIRY WILL NOT INDICATE VEHICLE ELIGIBILITY.
ASSY PLANT: 2 CHASSIS RANGE
875 342001 - 559060

876 342001 - 559060
ASSY.PLANT: 3 CHASSIS RANGE
875 356958 - 550366

876 356958 - 550366
"A Retailer Vehicle Campaign List" will NOT be sent to retailers as there are no records to indicate which vehicles are
NO parts are required in the repair procedure for this Recall Campaign.
During the week of November 16, 1998 an announcement letter will be sent directly to Volvo owners. A copy of this le
F. STOCK VEHICLES
All vehicles in retailers' inventory and qualifying for this recall campaign must be inspected /repaired prior to a custom
All claims should be submitted using the LONG FORM application for retailed and stock vehicles eligible for this reca

To insure claim acceptance, your claim must contain ONLY the information listed below:
REPAIR: INSPECTION ONLY
ALL STOCK (NEW & USED) VEHICLES (HAVING A CHILD AUXILIARY SEAT or third seat) AT U.S. RETAIL
* * OR * *
> 2531 > Nov > 98 > Recall - Tailpipe Inspection/Adjustment w/Child Seat > Page 2504

REPAIR: INSPECT/ADJUST
Note:
To insure claim acceptance, your claim must contain ONLY the information listed in the CLAIM FORMAT section
REPAIR LABOR PARTS

DESCRIPTION TIME AMOUNT
INSPECT ONLY 0.3 N/A
(includes 0.1 for the inspectionand 0.2 to cover minimum claimallowance time)
INSPECT/ADJUST 0.3 N/A

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 2250012 > O
Adjustment
Recall - Tailpipe Adjustment
Section 2
Group 25
No.0012
Year98
Month10
V70/V70 AWD1998 - 1999
Recall no.89 Tailpipe, Adjustment
Background:
Due to normal production variability, the tip of the tailpipe may protrude beyond the contour of the rear bumper cover.
Model Assembly plant Chassis No:
V701V70 AWD 2 342001 - 559060

V701V70 AWD 3 356958 - 550366
Check measurement (A) and note reading:
1. If A>/=20 mm (3/4") - No action needed.
2. If A<20 mm (3/4") - Try first to move the tail pipe by doing following steps:
- Loosen the clamp/screw which holds the tail pipe.
- Move the tail pipe carefully (if possible) further in under the car.
> 2250012 > Oct > 98 > Recall - Tailpipe Adjustment > Page 2509

- Check measurement (A) again.
If A>/=20 mm (3/4") - No further actions needed.
If A<20 mm (3/4") - Adjust according to one of the following methods below.
A. V70 Turbo (excluded AWD)
B. V70 (excluded Turbo and AWD)
C. V70 AWD (excluded chassi no.386581-403738)
D. V70 AWD (Chassis no.386581-403738)
A. V70 Turbo (Excluded AWD)

A1
A2
Cut off the exhaust pipe 25 mm (1") (A) from the end.
A3

Perform this step If applicable.
A4
Burr the newly cut surface.
A5
Note!
Both the tail pipe and the clamp are to be reused after modification.
SAFETY GLASSES MUST BE WORN WHEN PERFORMING THIS STEP.
A6

Increase the length of the three slots for the tail pipe.
The slots length (A) should be increased no longer than 35 mm (1 3/8") or the same amount as was removed from the e
A7
Install the tail pipe on exhaust pipe and align according to illustration.
A8
Adjust tail pipe so that the end is 20 mm (3/4") in from the contour of the bumper cover previously measured.
A9

Position the clamp on the tail pipe so the clamp aligns with bulge/shoulder on the exhaust pipe.
Tighten clamp

B. V70 (Excluded Turbo and AWD)
B1
B2
B3

B4

C. V70 AWD (Excluded Chassi No. 386581-403738)
C1

C2
C3
Refit the tail pipe and knock it into position.
Check measurement (A) according to step C1.
If A>/-20 mm (3/4") - Go to step C4.If A<20 mm (3/4") - Go to step C6.
C4
V70 AWD (A >/= 20 mm (3/4"))

C5
C6
V70 AWD (A < 20 mm (3/4"))
Note!
Both the tail pipe and the clamp are to be reused after modification. SAFETY GLASSES MUST BE WORN WHEN

C7
Cutoff the tail pipe 35 mm (1 3/8 ") (A) as per the illustration.
C8
Make a slot in 3 places with (B) = 120 in between.
The slots (A) should be approximately 30 mm (1 1/4 ").
C9
Grind away:
- rust and burrs from the inner and outer sections of the clamp
- rust and burrs from the outer section on the tail pipe (1) and the edge (2)

- burrs from the slots (4) on the outside of the tail pipe
- burrs from the slots (3) and the edge (2) inside the tail pipe.
Refit the clamp on the tail pipe.
Make sure it is even with the edge (2).
C10
Cut the tail pipe so that (A) is as big as possible without effecting the threaded area which the screw passes through.
Burr the inner and outer cut surfaces.
C11
C12


D. V70 AWD (Chassis No. 386581-403738)
D1
Loosen the clamp (1) which holds the tail pipe.
D2
Markup 25 mm (1") (A) around the cross-cut end.
Hint: Use a sliding calipers as a parallel marking gauge.
D3

Cut accurately and carefully along the marked gauge.
D4
Burr the outer section of the tail pipe and the edge. Burr the edge inside the tail pipe.
D5
D6


Dealer Letter
November, 1998
To: All Volvo Retailers - US & CANADA
Re: Recall Campaign 89
OWNER NOTIFICATION
A notification letter will be sent to the owners of all potentially affected vehicles during the week of November 16, 199
RETAILER RESPONSIBILITIES
Retailers are asked to perform this campaign on eligible vehicles regardless of miles/kilometers or vehicle age. All wor
In the event that a customer does not have a notification letter, the owner is not to be refused this important campaign w
A complete description of the campaign requirements and claim submission procedures will be sent under separate cov
^ Service Manager Bulletin

^ Service Bulletin
^ GOwner Notification Letter
Your cooperation in completing this important campaign is greatly appreciated.

Volvo Cars of North America, Inc. and Volvo Canada Limited have announced a Recall Campaign affecting certain 19
Owner Letter
November 1998
IMPORTANT RECALL NOTICE
Dear Volvo Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
What is the reason for this program?Volvo Cars of North America, Inc. has determined that a defect, which relates to m
Due to normal production variability, the tip of the tailpipe in some of these vehicles may protrude beyond the contour
All vehicles equipped with a child auxiliary seat accessory (third seat) must have the tailpipe inspected. An adjustment
What should you do?Please call your authorized Volvo Retailer as soon as possible to schedule an appointment for an i
Who should you contact?If you have any questions please contact your Volvo Retailer, or Volvo Customer Service at P
We have advised the National Highway Traffic Safety Administration (NHTSA) that we are conducting this recall. If y
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee
Your continued safety and satisfaction with Volvo and the Volvo organization are very important to us. We apologize f
Please note:
According to Insurance institute for Highway Safety president Brian O'Neill, "It is very important that owners of vehic
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest: > TNN25-26 > Jan > 07 > Ex
Noises
Exhaust Pipe/Muffler Hanger: Customer InterestExhaust System - Squealing/Pinging Noises
NO: 25-26DATE: 1-25-2007MODEL: 850 / S60 / S70 / V70 / XC70 / S80 / XC90YEAR: 1993-SUBJECT: Exhaus
1. 2001- AWD Cars (S60/V70/XC70/S80/XC90)
When driving through puddles of water, slush or snow, the exhaust may cool down fast enough to change shape a
25 Nm (18 ft/lbs)Remove the existing cross-member and install the new one. Tighten bolts to .
Install the clamp on the exhaust pipe with the screw hand-tight.
Install the rubber blocks and adjust the clamp so that the rubber blocks are vertical.
25 Nm (18 ft/lbs)Tighten bolts to .
Kit for 2001- S60 / V70 / XC70 / S80 / XC90 cars except S60R/V70R....PN 30742265Kit for S60R/V70R...........
2. 850/S60/S70/V70/XC70/C70/S80
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest: > TNN25-26
> Jan > 07 > Exhaust System - Squealing/Pinging Noises > Page 2530

Exhaust clamp kits are available as a service solution for damaged or missing hangers. These kits allow a repair t
Kits are not currently available for 1998-2000 V70 XC, 2004-S60R/V70R, and XC90.
Kit for 2001- S60/V70/XC70/S80/XC90 cars except S60R/V70R......PN 30742265Kit for S60R/V70R.................
3. 2001- AWD Cars (S60/V70/XC70/S80/XC90)
A single 'knock' or 'ping' may be heard at engine start. In the case of a customer complaint, adjust the shields on e
Press the shields on each side in toward the body by hand to increase clearance for the exhaust brace.
2001- S60R/V70R4.
The bracket underneath the exhaust can be removed at a customer's request for increased ground clearance. This
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest: > TNN25-26
> Jan > 07 > Exhaust System - Squealing/Pinging Noises > Page 2531

24 Nm (18 ft/lbs)Remove the bracket. Install the two plates. Tighten the bolts to
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe
> 07 > BULLETIN CANCELLATION NOTIFICATION
Exhaust Pipe/Muffler Hanger: All Technical Service BulletinsBULLETIN CANCELLATION NOTIFICATION
NO: 25-25DATE: 2-1-2007MODEL: 20N/AM.YEAR: N/ACHASSIS:SUBJECT: Cancel Notice / 25-25REFEREN

This Tech Note supersedes the previous 25-25 dated 8-10-2006. Please update your files.
CANCELLATION NOTICE
Tech Net Note 25-25, "Exhaust Clamp Kits Available for Repair" dated 8-10-2006
25-25 has been deleted from the TNN databaseas the information is now obsoleteand the same information can now be
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe
> 07 > Exhaust System - Squealing/Pinging Noises
Exhaust Pipe/Muffler Hanger: All Technical Service BulletinsExhaust System - Squealing/Pinging Noises
NO: 25-26DATE: 1-25-2007MODEL: 850 / S60 / S70 / V70 / XC70 / S80 / XC90YEAR: 1993-SUBJECT: Exhaus
1. 2001- AWD Cars (S60/V70/XC70/S80/XC90)
When driving through puddles of water, slush or snow, the exhaust may cool down fast enough to change shape a
25 Nm (18 ft/lbs)Remove the existing cross-member and install the new one. Tighten bolts to .
Install the clamp on the exhaust pipe with the screw hand-tight.
Install the rubber blocks and adjust the clamp so that the rubber blocks are vertical.
25 Nm (18 ft/lbs)Tighten bolts to .
Kit for 2001- S60 / V70 / XC70 / S80 / XC90 cars except S60R/V70R....PN 30742265Kit for S60R/V70R...........
2. 850/S60/S70/V70/XC70/C70/S80
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Exhaust Pipe/Muffler Hanger: > TNN25-26 > Jan > 07 > Exhaust System - Squealing/Pinging Noises > Page 2541

Exhaust clamp kits are available as a service solution for damaged or missing hangers. These kits allow a repair t
Kits are not currently available for 1998-2000 V70 XC, 2004-S60R/V70R, and XC90.
Kit for 2001- S60/V70/XC70/S80/XC90 cars except S60R/V70R......PN 30742265Kit for S60R/V70R.................
3. 2001- AWD Cars (S60/V70/XC70/S80/XC90)
A single 'knock' or 'ping' may be heard at engine start. In the case of a customer complaint, adjust the shields on e
Press the shields on each side in toward the body by hand to increase clearance for the exhaust brace.
2001- S60R/V70R4.
The bracket underneath the exhaust can be removed at a customer's request for increased ground clearance. This
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Exhaust Pipe/Muffler Hanger: > TNN25-26 > Jan > 07 > Exhaust System - Squealing/Pinging Noises > Page 2542

24 Nm (18 ft/lbs)Remove the bracket. Install the two plates. Tighten the bolts to
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Pipe/Mu
> BULLETIN CANCELLATION NOTIFICATION
Exhaust Pipe/Muffler Hanger: All Technical Service BulletinsBULLETIN CANCELLATION NOTIFICATION
NO: 25-25DATE: 2-1-2007MODEL: 20N/AM.YEAR: N/ACHASSIS:SUBJECT: Cancel Notice / 25-25REFEREN

This Tech Note supersedes the previous 25-25 dated 8-10-2006. Please update your files.
CANCELLATION NOTICE
Tech Net Note 25-25, "Exhaust Clamp Kits Available for Repair" dated 8-10-2006
25-25 has been deleted from the TNN databaseas the information is now obsoleteand the same information can now be
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information >
Page 2555
Instructions

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

A1-A9

A10-A23

A24-A35

A36-A43

B1-B8

B9-B24

B25-B38

B39-B43
Connector A
Connector B

SYSTEM OVERVIEW
FC
EVAP
ECM
ECT
TP
HO2S
DTCs
OBD SIGNALS
INPUT
TWC

RPM
CMP
MAF
ECT
TP
HO2S
HO2S
KS
TCM
TCM
MIL TCM
Pressostat
PAIR
CONTROL FUNCTIONS

IDM
IAC
IAC
FC
CP
MIL
HO2S
TCM
TCM
TCM
RPM
ECT

- (ECM) (DTCs)
-

-

- (IAC)

-


-
Erase diagnostic
NOTE:
AST tool# V9995722
- Made in Germany

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component In

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

2585
Fuses
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System)
> Component Information > Specifications > Page 2586

Panel Locations

Relays

Panel Locations

Other Relays
2590

MAIN RELAY
ECM
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Spe

Resistance ...................................................................................................................................................................
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Spe
Fuses
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specifi

FUEL PUMP RELAY

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specifi
Fuses
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagra
Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagra
FUEL PUMP CONTROL
one second
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component In

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

2624
Fuses
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) >

Panel Locations

Relays

Panel Locations

Other Relays
2629

MAIN RELAY
ECM
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information
Recalls: > 2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 2640

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose
> Page 2647

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles
> Page 2648


Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor -
Rerouting Wiring Harness > Page 2653



Check
Other Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting
Wiring Harness > Page 2660



Check
2662


Approx ..................................................................................................................................................................
2663

and Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


Injection period
170C
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Informa


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


ECM

- Leak diagnostic

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Informatio


and Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


CMP ECM
RPM
12 V
0V
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Compute
Specifications

Resistance




> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch
(For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2713

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


ECT ECM
FC
NTC
- Drain off coolant

- Test sensor.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information >

ENGINE SPEED SENSOR

Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


ENGINE SPEED SENSOR
RPM
0.1 V 55 V
ECM

1. Remove:
- Battery
- ACL bracket.


- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Dia
Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Informati



In the fuel tank.

and Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


Preparations
5-door models:
4-door models:

Removing Fuel Tank



- Remove the screw
- Remove clamp
- Disconnect hose.
SqueezeClamp:
Removing clamp with
Press inClamp:


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Infor


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


- Leak diagnostic
NTC
5 Volts
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifi

KNOCK SENSOR

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifi

KNOCK SENSORS

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagram
Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Techn
New routing of wiring
Bulletin:2250010
Group:25
Date:02/01/2000
Models:850, S70/V70/C701997-1998
Background:
Materials
Materials
Materials

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component

Preparation
Remove:
Remove:



> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specif

Resistance;
NOTE:

Page 2819

OXYGEN SENSOR
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagra
Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all




Front Oxygen Sensor
TWC
Rear Oxygen Sensor
This is to:
Function
285C
12 V
350C


HO2S
DTC
ECM
TWC
period.

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information

Idle position ..........................................................................................................................................................


and Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


TP ECM

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Comp
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/
Sensor, A/T > Component Information > Adjustments > Page 2858

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Comp
Page 2860

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >
Specifications



Speed Sensor ..............................................................................................................................................................

Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


- Preparation:
Ignition OFF
- Remove:

- Preparation:
Ignition OFF
- Remove:
(MAF)

- Remove:
Unhook the parts.
- Oil the O-ring.
- Install sensor.
5.5 Nm.Tighten to:
- Install:

5.5 Nm.Tighten to:
Connector.
- Install:

- Install:
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vertical Acceleration Sensor > Component Inform

ACCELERATION SENSOR


ACCELEROMETER


ACCELEROMETER
5 V ECM 2.5 V

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information >
Recalls: > 2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor >

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Page 2903

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles
> Page 2904


Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:




Check
Other Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:




Check
2918


Approx ..................................................................................................................................................................
2919

and Instructions


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


Injection period
170C
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information

Idle position ..........................................................................................................................................................


and Instructions

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


TP ECM

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > S

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams >

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information
> Diagrams > Diagram Information and Instructions > Page 2958

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams >

CMP ECM
RPM
12 V
0V
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bul
Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 2976

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 2981


starter wheel
switch; covers.
Caution!

3301 > May > 98 > Campaign - Malfunctioning Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
Technical Service Bulletins > Recalls for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 2987

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
Technical Service Bulletins > Recalls for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 2992


starter wheel
switch; covers.
Caution!

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram I


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram I
3005
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > S
Start switch
Removal
Note!
Preparations
Start switch
Installation
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > S
Removal
Preparations
Installation
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3

KNOCK SENSORS

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram In

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3024
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3025

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations

> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications

Air / Fuel Mixture
[1]CO Content ..................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 3037

Air / Fuel Mixture

CO Content .........................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 3038

Notes:
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications

> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3042


> Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair
Preparation
- Removing pipes
-
Remove:

> Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair > Page 3046


Installing pipes

Install:

Install:
200 Nm
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3054

Installing

> Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications

IGNITION CABLE
Resistance:

> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 3068


4.5K ohms 20%

4.0K ohms 20%
3.3K ohms 20%

> Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Specifications

IGNITION ROTOR
Resistance ...................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3079

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3080

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test - Amended

SECTION
2
GROUP
21
NO.842
DATESep. 1998
Background:
Chassi No.:
S70 - 460000
V70 - 395002
Special tools: 999 9689, 115 8540
Compression test
High tension 1
Warning!
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test -
Amended > Page 3085

Note!
Separate connector
Remove:

- spark plugs.
Remove fuse 11B3 4
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Compression Test -
Amended > Page 3086

Note!

Installing
- components
- fuse 11B3.
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Technical Service Bulletins > Page 3087

Normal value .................................................................................................................................................... 1.3 -
SPECIAL TOOLS
NOTE:
The DI system

NOTE:
1. Remove:
- HT lead cover
Remove
open:-

> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations > A/C Pressure Sensor
A/C Signal: LocationsA/C Pressure Sensor
A/C PRESSURE SENSOR
A/C Pressure Sensor
The A/C Pressure Sensor is installed in the A/C high-pressure circuit.

> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations > A/C Pressure Sensor > Page 3095
A/C Signal: LocationsA/C Relay

A/C-RELAY:
Behind the glove compartment.

> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Relay
A/C Signal: Description and OperationA/C Relay

A/C RELAY
ECM
Pressostat
The A/C Relay (2/22) is activated if the A/C switch is pressed, the Blower Fan is operating and the Engine Control M
The Compressor is disengaged in the following circumstances to prevent it operating when full power is required, or
^ Full acceleration; when the throttle is fully open the engine control module (ECM) shuts the compressor down
and a minimum of 3 seconds.
^ Risk of overheating. If coolant temperature is above approx. 125C the A/C compressor is prevented from opera
load and avoid further overheating.
^ If pressure exceeds approx. 3,000 kPa.
The engine control module (ECM) also prevents the compressor from engaging before the engine has started properl
> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Relay > Page 3098
A/C Signal: Description and OperationA/C Pressure Sensor
A/C Pressure Sensor
A/C PRESSURE SENSOR
The A/C pressure sensor, which is of a new type delivering a linear signal, supplies the ECM with information regard
TheStarting
purposeofis the engine the
to control cooling fan at functions:^
following low speed
^ Starting of the engine cooling fan at high speed
^ Switch-out of the A/C compressor if the system pressure becomes excessive
^ Idling compensation for A/C load (only normally aspirated engine)
5 Volts 0 5 Volts
The sensor is supplied at by the ECM. The sensor signal may vary from to , depending on the system pressure. Low
The sensor is installed in the A/C high-pressure circuit.

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98 > Campaign -
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98
> Campaign - MAF Connector Loose > Page 3107

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98


> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 3114

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness > Page 3120



Check
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow M
Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness > Page 3127


> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins

Check
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3129


Approx ..................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3130

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
3133

1/1 Battery

2/2 Fog lamp relay

3134

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
3135

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

3136

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

3137


11A/1-9 Main fuses

3138

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

3139



3140

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

3141

C70 all

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3142

Injection period
170C
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3146

> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Page 3149

1/1 Battery

2/2 Fog lamp relay

> Page 3150

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 3151

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 3152

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 3153


11A/1-9 Main fuses

> Page 3154

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 3155



> Page 3156

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 3157

C70 all

> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3158

- Leak diagnostic
NTC
5 Volts
> Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications
> Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 3162

> Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 3165

1/1 Battery

2/2 Fog lamp relay

Page 3166

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 3167

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 3168

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 3169


11A/1-9 Main fuses

Page 3170

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 3171



Page 3172

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 3173

C70 all

> Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Diagrams > Page 3174

ECM

- Leak diagnostic

> Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Locations
> Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Diagrams > Diagram Information and Instructions
Boost Solenoid: Diagram Information and Instructions

> Page 3180

1/1 Battery

2/2 Fog lamp relay

> Page 3181

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 3182

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 3183

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 3184


11A/1-9 Main fuses

> Page 3185

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 3186



> Page 3187

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 3188

C70 all

> Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Diagrams > Page 3189
Boost Solenoid: Description and Operation
Turbocharger (TC) control valve

Frequency controlled valve. Resistance 29.7
> Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Diagrams > Page 3190
Boost Solenoid: Service and Repair
REPLACING THE TURBOCHARGER (TC) CONTROL VALVE
Removing the turbocharger (TC) control valve

(ACL)
Lift the valve away from the Air Cleaner cover.Remove the connector from the valve.Mark up and pull off the hoses
Installing the turbocharger (TC) control valve
the hoses according to the marking on the control valve

Install-
- the connector on the valve
- (ACL)the valve on the Air Cleaner cover.
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations


> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 3196

1/1 Battery

2/2 Fog lamp relay

Page 3197

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 3198

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 3199

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 3200


11A/1-9 Main fuses

Page 3201

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 3202



Page 3203

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 3204

C70 all

> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3205

CMP ECM
RPM
12 V
0V
> Powertrain Management > Computers and Control Systems > Central Electronics Box > Component Information > Service and Repair > Replacing Control Module Box
Central Electronics Box: Service and RepairReplacing Control Module Box
Removing
GC1 Removing Air Duct, Filler Pipe, Expansion Tank and Security Strap:
Ignition off.
front air duct to control module box.

Remove:-
- washer reservoir filler pipe.
- expansion tank, pull up.
- control module box security strap.
GC2 Removing Control Modules:
control module box cover, pry out the metal clip using a screwdriver.
Remove:-
- control modules from the control module box.
- front mounting screw.
GC3 Removing Middle Section:
> Powertrain Management > Computers and Control Systems > Central Electronics Box > Component Information > Service and Repair > Replacing Control Module Box >
Page 3210

middle section of control module box, pry out metal clips (three) using a screwdriver.
Remove:-
- sleeve connector to control module box air intake.
Lift up control module holder with the cable duct to release it from the clips.
GC4 Disconnecting Connector:
connector at the bottom of the control module box.

Remove:-
- screws for the clamp on the side of the control module box.
Pull up cable on the side of the control module box.
GC5 Removing Lower Section of Control Module Box:

Page 3211

rear mounting screw.
Remove:-
- lower section of the control module box backwards to release it from the metal tab at the front edge of the contro
- clamp for the cable at the side of the control module box.
Installing:
GC6 Installing Lower Section of Control Module Box:
clamp for the cable at the side of the control module box.
Install:-
- lower section of the control module box, insert the front edge under the metal tab.
- rear mounting screw.
GC7 Installing Connector:

Page 3212

connector at the bottom of the control module box.
Install:-
- cable on the side of the control module box.
- screws to the clamp in the side of the control module box.
GC8 Installing Middle Section:
control modules holder, ensure that the clips engage.

Install:-
- cable duct, locate in control module box slot.
- sleeve connector to control module box air intake.
- middle section to control module box.
NOTE: Check that the middle and lower sections of the control module box are sealed and that the clips are properl
GC9 Installing Control Modules:

Page 3213

front mounting screw.
Install:-
- control modules.
- control module box cover, ensure that the clips engage.
GC10 Installing Filler Pipe, Air Duct, Expansion Tank and Security Strap:
control module box security strap according.

Install:-
-
washer reservoir filler pipe.Check that the filler pipe does not leak where it connects with the washer reservoir.
- front air duct to control module box.
- expansion tank.
> Powertrain Management > Computers and Control Systems > Central Electronics Box > Component Information > Service and Repair > Replacing Control Module Box > Page 3214
Central Electronics Box: Service and RepairReplacing Control Module Connector
Removing:
GD1 Removing the Rubber Mat:
NOTE: Disassemble control module box according to GC1 - GC5. See: Replacing Control Module Box
- Remove silicon rubber mat from holder.

- Take apart the holder and told it to release the catch.
GD2 Disconnecting Connector:
- Turn the holders and press together the control module connector pawls.
- Pull the connector out of the holder.
GD3 Removing Terminal Pins:

- Mark the position of the terminal pins in the connector.
- Remove the terminal pins, use an instrument screwdriver to release the catches.
Page 3215

CAUTION: Take care not to deform the terminal pins when removing them.
Installing:
GD4 Installing Terminal Pins

Replace the connector.
-:- Install terminal pins in connector as marked.
GD5 Installing Connector and Rubber Mat:
1 Install connector in holder.

2 Assemble holder.
3 Install silicon rubber mat on holder.
NOTE: Assemble control module box according to GC6 - GC10. See: Replacing Control Module Box
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications

Resistance

> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3219


> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instr

> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3231

ECT ECM
FC
NTC
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3232
- Drain off coolant

- Test sensor.
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations
Data Link Connector: Locations

Data Link Connector
Located in center console.

> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3236
Data Link Connector: Description and Operation
PURPOSE
The data link connector (DLC) is used for communication with the diagnostic functions in the ECM. Communic
- using the OBD II connector and a standard scan tool.- using the Volvo scan tool.
Control function #1
:This control function accesses the fuel injection ECM memory and extracts any recorded faults.
Faults stored in the ECM are read via "fault codes".
Control function #2
:This function tests selected input components in the fuel injection system.
Control function #3
:This function tests selected output components. Components are automatically tested and activated to check for
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 3241
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3244

1/1 Battery

2/2 Fog lamp relay

3245

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
3246

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

3247

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

3248


11A/1-9 Main fuses

3249

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

3250



3251

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

3252

C70 all

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3253
A1-A9
3254

A10-A23
3255

A24-A35
3256

A36-A43
3257

B1-B8
3258

B9-B24
3259

B25-B38
3260

B39-B43
Connector A
Connector B
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3261

SYSTEM OVERVIEW
FC
EVAP
ECM
ECT
TP
HO2S
DTCs
OBD SIGNALS
INPUT
TWC

RPM
CMP
MAF
ECT
TP
HO2S
HO2S
KS
TCM
TCM
MIL TCM
Pressostat
PAIR
CONTROL FUNCTIONS

IDM
IAC
IAC
FC
CP
MIL
HO2S
TCM
TCM
TCM
RPM
ECT

- (ECM) (DTCs)
-

-

- (IAC)

-


-
Erase diagnostic
NOTE:
AST tool# V9995722
- Made in Germany

> Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications

ENGINE SPEED SENSOR

> Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 3271
> Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
3274

1/1 Battery

2/2 Fog lamp relay

3275

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
3276

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

3277

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

3278


11A/1-9 Main fuses

3279

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

3280



3281

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

3282

C70 all

> Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Page 3283

ENGINE SPEED SENSOR
RPM
0.1 V 55 V
ECM

1. Remove:
- Battery
- ACL bracket.


- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications


> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 3302

In the fuel tank.

> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 3305

1/1 Battery

2/2 Fog lamp relay

Page 3306

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 3307

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 3308

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 3309


11A/1-9 Main fuses

Page 3310

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 3311



Page 3312

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 3313

C70 all

> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3314

Preparations
5-door models:
4-door models:

Removing Fuel Tank



- Remove the screw
- Remove clamp
- Disconnect hose.
SqueezeClamp:
Removing clamp with
Press inClamp:


> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications

IDLE AIR CONTROL VALVE
Resistance between terminals;
1 and 2 ...................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Description and Operation > Overview
Idle Speed/Throttle Actuator - Electronic: Description and OperationOverview

IDLE AIR CONTROL VALVE CONTROL - OVERVIEW
ECM IAC
There are two reasons that the Engine Control Module () controls the Idle Air Control () Valve. To maintain a consta
The engine control module (ECM) computes the output signals to the idle air control (IAC) valve (7) using informati
TP
ECT
RPM
Pressostat
- Throttle Position () Sensor (1)- Engine Coolant Temperature () Sensor (2)- Engine Speed () Sensor (3)- Pressure
Information from the transmission control module (TCM) (5) regarding gear selector position is also used.
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Description and Operation > Overview > Page 3334
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Operation
IDLE AIR CONTROL VALVE - OPERATION
The throttle position (TP) sensor supplies the engine control module (ECM) with a signal describing the throttle angl
When the throttle position (TP) sensor signals closed throttle position (CTP) and the engine is idling, the engine cont
Control of idling speed by the engine control module (ECM) offers the following advantages:
- Idling speed does not require adjustment (due to aging or fouling of components).
- Low idling speed and low fuel consumption is achieved by continuous compensation for changes in load.
The engine control module (ECM) idling control function is adaptive. The engine control module (ECM) learns how
In the event of an idle air control (IAC) valve control fault, the valve will assume a higher or lower idling speed than
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Engine Braking
IDLE AIR CONTROL VALVE - ENGINE BRAKING
CTP ECM IAC

During engine braking and at Closed Throttle Position (), the Engine Control Module () controls the Idle Air Control
^ maintain the negative pressure in the inlet manifold within bounds^ improve combustion and reduce emissions^
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Diagram
IDLE AIR CONTROL VALVE - DIAGRAM
IACThe Idle Air Control () Valve has a linear function.
The valve consists of the following components:
^ Inlet (1) ^ Outlet (2) ^ Rotor (3) ^ Permanent Magnet (4) ^ Valve (5)
The idle air control (IAC) valve rotor (3) is equipped with an opening and a closing coil, and with a permanent magnet
> Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3340

KNOCK SENSORS

> Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3352
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Specifications

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Specifications > Page 3360
Fuses

Panel Locations

Relays

Panel Locations

Other Relays

MAIN RELAY
ECM
> Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
If the lamp comes on (or stays on after the vehicle has started), the engine diagnostic system has detected a possible f
NOTE:
If the fuel filler cap is not closed tightly or if the engine is running when the car is refueled, the Malfunction Indicato
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > O2 sensors - New routing of wiring
Bulletin:2250010
Group:25
Date:02/01/2000
Models:850, S70/V70/C701997-1998
Background:
Materials
Materials
Materials

> Page 3373

Preparation
Remove:
Remove:

> Page 3374

> Page 3375

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications

Resistance;
NOTE:

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 3378

OXYGEN SENSOR
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 3379
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3382

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3391



Front Oxygen Sensor
TWC
Rear Oxygen Sensor
This is to:
Function
285C
12 V
350C


HO2S
DTC
ECM
TWC
period.

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Co
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Co
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Di

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Di
Page 3414
A1-A9

A10-A23

A24-A35

A36-A43

B1-B8

B9-B24

B25-B38

B39-B43
Connector A
Connector B
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Pa

SYSTEM OVERVIEW
FC
EVAP
ECM
ECT
TP
HO2S
DTCs
OBD SIGNALS
INPUT
TWC

RPM
CMP
MAF
ECT
TP
HO2S
HO2S
KS
TCM
TCM
MIL TCM
Pressostat
PAIR
CONTROL FUNCTIONS

IDM
IAC
IAC
FC
CP
MIL
HO2S
TCM
TCM
TCM
RPM
ECT

- (ECM) (DTCs)
-

-

- (IAC)

-


-
Erase diagnostic
NOTE:
AST tool# V9995722
- Made in Germany

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > S

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

Fuses
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component

Panel Locations

Relays

Panel Locations

Other Relays

MAIN RELAY
ECM
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Serv
> 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information >
Technical Service Bulletins > Recalls: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 3447

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose > Page 3454

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness > Page
3460


3461

Check
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 2230010 > Apr > 98 > Mass Air Flow Sensor - Rerouting Wiring Harness > Page 3467



Check


Approx ..................................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > D


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Pa

Injection period
170C
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifica
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifica

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Diagrams
Instructions

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Diagrams

ECM

- Leak diagnostic

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams >

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams >

CMP ECM
RPM
12 V
0V
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component

Resistance

3517



> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer
) > Component Information > Diagrams > Diagram Information and Instructions > Page 3520

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all


ECT ECM
FC
NTC
- Drain off coolant

- Test sensor.
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications

ENGINE SPEED SENSOR

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications >
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Dia

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Pag

ENGINE SPEED SENSOR
RPM
0.1 V 55 V
ECM

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Diagrams > Pag
1. Remove:
- Battery
- ACL bracket.


- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Diagra

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specificati


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specificati

In the fuel tank.

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams
Instructions

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams

Preparations
5-door models:
4-door models:

Removing Fuel Tank



- Remove the screw
- Remove clamp
- Disconnect hose.
SqueezeClamp:
Removing clamp with
Press inClamp:


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specif
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specif

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagra
Instructions

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagra

- Leak diagnostic
NTC
5 Volts
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3

KNOCK SENSORS

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram In

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3612
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3613

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bul
wiring
Bulletin:2250010
Group:25
Date:02/01/2000
Models:850, S70/V70/C701997-1998
Background:
Materials
Materials
Materials

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information >
Technical Service Bulletins > O2 sensors - New routing of wiring > Page 3621

Preparation
Remove:
Remove:



> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Elect

Resistance;
NOTE:

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Elect

OXYGEN SENSOR
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3639



Front Oxygen Sensor
TWC
Rear Oxygen Sensor
This is to:
Function
285C
12 V
350C


HO2S
DTC
ECM
TWC
period.

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specification

Idle position ..........................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specification

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > D

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > P

TP ECM
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > P

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Informati
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T >
Component Information > Adjustments > Page 3665

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Informati

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications >


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications >

Speed Sensor ..............................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Dia

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Pag

- Preparation:
Ignition OFF
- Remove:

- Preparation:
Ignition OFF
- Remove:
(MAF)

- Remove:
Unhook the parts.
- Oil the O-ring.
- Install sensor.
5.5 Nm.Tighten to:
- Install:

5.5 Nm.Tighten to:
Connector.
- Install:

- Install:
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vertical Acceleration Sensor > Component Information > Specific

ACCELERATION SENSOR


ACCELEROMETER


ACCELEROMETER
5 V ECM 2.5 V

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications

Idle position ..........................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3697

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 3700

1/1 Battery

2/2 Fog lamp relay

Page 3701

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 3702

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 3703

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 3704


11A/1-9 Main fuses

Page 3705

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 3706



Page 3707

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 3708

C70 all

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3709

TP ECM
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3710

> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 3714

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Electrical Specifications


> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 3724

Speed Sensor ..............................................................................................................................................................

> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
3727

1/1 Battery

2/2 Fog lamp relay

3728

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
3729

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

3730

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

3731


11A/1-9 Main fuses

3732

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

3733



3734

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

3735

C70 all

> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3736

- Preparation:
Ignition OFF
- Remove:

- Preparation:
Ignition OFF
- Remove:
(MAF)

- Remove:
Unhook the parts.
- Oil the O-ring.
- Install sensor.
5.5 Nm.Tighten to:
- Install:
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3737

5.5 Nm.Tighten to:
Connector.
- Install:

- Install:
> Powertrain Management > Computers and Control Systems > Vertical Acceleration Sensor > Component Information > Specifications

ACCELERATION SENSOR

> Powertrain Management > Computers and Control Systems > Vertical Acceleration Sensor > Component Information > Specifications > Page 3741

ACCELEROMETER

> Powertrain Management > Computers and Control Systems > Vertical Acceleration Sensor > Component Information > Specifications > Page 3742

ACCELEROMETER
5 V ECM 2.5 V

> Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair
Air Injection Pump: Service and Repair
Note! (ST)
Check general check should be carried out with the Volvo Scan Tool in mode 3. If that has not indicated a fault and th
Checking ground terminal
Check that the pump is grounded in the ground terminal under the left headlamp.
Checking air pump
Air Pump and Relay

Raise the car and remove the front splashguard, by removing the two screws on each side and then pull the guard and
Caution: The pump should not be operated continuously for more than 120 seconds because of the risk of overheati
If the pump does not function
> Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair > Page 3748

Relay Ground
(ST)
If the pump not work check that the wiring between the relay and the pump are intact and that 12 V and ground are a
Replacing
Remove
- battery and battery shelf

- air hose to engine
Disconnect the airpump intake pipe from the pump.Raise the car.
Remove front splashguard if this has not already been done


Air Pump and Relay
Disconnect connectors.Remove cable ties.Remove the three screws.Lower the car.

Remove the airpump
Disconnect the air hose and ground lead under the left headlamp.
Remove the airpump
Install the airpump
Control Valve
Install in reverse order.Be careful when clamping at the EGR-pipe so that the air hose does not come into contact wit
Checking relief valve

Disconnect the rubber hose to the relief valve and start the engine.Check that no engine exhausts flow backwards int
> Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Specifications

Resistance ...................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Specifications > Page 3754
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Pulsed Secondary Air Injection Control Valve > Component Information > Specif
Pulsed Secondary Air Injection Control Valve: Specifications

PULSED SECONDARY AIR INJECTION SOLENOID
Resistance ...................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Application and ID
Catalytic Converter: Application and ID

> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Application and ID > Page 3766

> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Application and ID > Page 3767
Catalytic Converter: Description and Operation
TWC
- The TWC cleans exhaust gases by oxidizing unburned: carbon monoxide (CO) hydrocarbons (HO) nitrogen oxid
- 90-95% of these harmful substances are converted into innocuous: water (H20) carbon dioxide (CO2) nitrogen (N
- The active surface area of the unit is about 43,000 m2 and the noble metal content of about 3.5 grammes platinum
NOTE: Lead in fuel will damage the TWC, quickly making it unserviceable.
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications
Canister Purge Control Valve: Specifications

CANISTER PURGE VALVE
Resistance ...................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Diagram Information and
Canister Purge Control Valve: Diagram Information and Instructions

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3783
Canister Purge Control Valve: Description and Operation

CANISTER PURGE VALVE
The Canister Purge (CP) Valve (4) is located between the EVAP canister and the engine intake manifold, the
Control
Normally the canister purge (CP) valve is closed and only opens when the engine control module (ECM) is em
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation
Evaporative Emission Control Canister: Description and Operation

EVAP CANISTER
Fuel vapor from the tank passes a bed of activated charcoal in the EVAP Canister (3). The activated charcoal
Control
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation >
Evaporative Emission Control Canister: Service and Repair

Removing EVAP canister
Remove:
- connector/outlet, press in catch and pull
- connector/inlet, press in catch and pull
- outlet hose from EVAP canister bracket.
Removing EVAP canister shut-off valve air hose clamp:

- squeeze clamp with a pipe wrench. Hold in place
- pry apart with a small screwdriver.
- air hose from EVAP canister shut-off valve
- rubber mounting with EVAP canister shut-off valve from EVAP canister bracket
- two front and rear screws.
Remove:
- nut on bracket at fuel filter.
Remove:
- EVAP canister with bracket
- Slacken off screw in underside of bracket (Torx 25).
- EVAP canister from bracket.
Installing EVAP canister
- In reverse order of removal.
25 Nm (18.5 ft.lb) 20 Nm (14.8 ft.lb).Tighten screws to and nut to
Ensure that the EVAP canister:

- engages in the catch at the front
- engages in its groove the bracket.
Note! Use a new screw clip. Check that outlet/inlet connector catches engage.
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Specifications
Leak Detection Valve: Specifications

EVAP CANISTER SHUT-OFF VALVE
Resistance ...................................................................................................................................................................

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Diagram Info
Leak Detection Valve: Diagram Information and Instructions

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3802
Leak Detection Valve: Description and Operation

EVAP CANISTER SHUT-OFF VALVE
Certain markets require the engine control module (ECM) to detect leakages in the tank system, in these mark
In order to check the fuel tank system, cars in these markets have an EVAP Canister Shut-off Valve (5). This
Control
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3803
Leak Detection Valve: Service and Repair
Removing EVAP canister shut-off valve

- Remove 2 clamps by the EVAP canister and rear axle joint.
Removing clamp:
- squeeze clamp with a pipe wrench. Hold in place.
- pry apart with a small screwdriver.
Note: These are reusable.
- Disconnect hoses.
- Remove rubber mounting from bracket.
Installing EVAP canister shut-off valve

- In reverse order of removal.
Installing clamp:
- squeeze the clamp with a pipe wrench until it locks.
Note! Use a new screw clip at the EVAP canister. Reuse clamp at the rear axle joint.
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Service and Repair
Oil Separator: Service and Repair

OIL TRAP SEAL REPLACEMENT
Remove
Remove the intake
Intake manifold.
Manifold ^
Hose from
Remove: ^ oil trap.
^ Intake manifold bracket.
^ Two oil trap screws.
^ Oil trap.
^ Check that oil trap seal surfaces are clean.
Connect
Install two oil
Oil Trap ^ trap hoses to engine block connecting sleeve.
^ Install upper hose with a new hose clamp and tighten lower hose.
^ 20 Nm (14.8 ft lb)Install and tighten screws to .
^ Install intake manifold bracket, finger tighten lower screw.
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Service and Repair > Page 3808

Re-Install
Install intakethe intake manifold.
manifold ^
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
At the beginning of October 1995, a modified crankcase ventilation system was introduced. The crankcase ventilatio
The vacuum hose has been moved from the multi-nipple to a nipple cover on the intake manifold at the power steerin
At the beginning of November 1995, a further modification was carried out to the crankcase ventilation pipe on engi
On the engines in question, the pipe introduced in October l995 appears as in the illustration.
This pipe is clamped in the intake manifold rear mounting screw.
This hose was mounted on engines with engine serial number between: 5829626-616344 and IS not available as a re
If the above pipe needs to be replaced, the pipe introduced in November 1995 should be used instead, P/N 9179305-9
Part 1 Of 2
Part 2 Of 2
If this pipe is replaced, the fresh air hose must also be replaced according to P/N shown:
> Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Specifications

Resistance ...................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Specifications > Page 38
Fuses
> Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information >

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3829

Installing

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3833


> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications

Air / Fuel Mixture
[1]CO Content ..................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications > Page 3837

Air / Fuel Mixture

CO Content .........................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications > Page 3838

Notes:
> Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair
Preparation
- Removing pipes
-
Remove:

> Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair > Page 3842


Installing pipes

Install:

Install:
200 Nm
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
98 > Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:




Check
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98 > Campaign -
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Recalls: > 2332 > May > 98


> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow M
Mass Air Flow Sensor - Rerouting Wiring Harness
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins


> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins

Check
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3876


Approx ..................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3877

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
3880

1/1 Battery

2/2 Fog lamp relay

3881

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
3882

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

3883

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

3884


11A/1-9 Main fuses

3885

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

3886



3887

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

3888

C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3889

Injection period
170C
> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications
Fuel: Specifications
Recommended Fuel
Premium Unleaded Only ............................................................................................................................................

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Special tools: 981 2270, 981 2273, 981 2282 999 5480, 999 5484
Removing covers

Remove:-
Connecting
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3897

Installing

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Line > Component Information > Tools and Equipment
Fuel Injector Line: Tools and Equipment
17mm Injection Line Wrench
AST tool# H 4550
The AST# H 4550 17mm Injection Line Wrench is an offset, 3/8" drive fuel injection line wrench.
- 17mm Injection Line Wrench

- Offset Wrench
- 3/8"drive
- Made in Germany

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Fuel System - Quick Release Connector
Fuel Line Coupler: Technical Service BulletinsFuel System - Quick Release Connector
850, S70/V70/C70, S90/V90, S40/V40, S60, S801993-
Section2
Group23
No.0052
Year00
Month11
Reference: This Service Bulletin replaces the previous Service Bulletin 230052 from October 2000, which should be di
Connecting the Quick release connector, updated method
BackgroundThis Service Bulletin describes an updated method for connecting the quick-release connectors in the fuel i
Material
Connecting the quick-release connector, updated method
Quick-release connector, fuel system

There are a number of quick-release connectors on the fuel injection system the fuel tank, the fuel filter and the intake m
These quick-release connectors are of differing designs and are taken apart in different ways. For certain quick-release
All quick-release connectors have O-rings as seals
Lubricating when connecting quick-release connectors
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Fuel System - Quick Release
Connector > Page 3906

The quick-release connectors in the marked area (arrow in the illustration) on the fuel line must be lubricated using lub
Note!
Engine oil (mineral oil) may also be used. Do not use synthetic engine oil.
Checking that connection is secure
Check that the quick-release connector has locked. Try pulling the connector apart by hand firmly using approximately
Ensure that there is some ploy in the connector. Press the connector together and pull the connector apart.
The illustration displays an example of the connection.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications
Fuel Pressure Regulator: Specifications

FUEL PRESSURE REGULATOR
[1]Fuel System Pressure ............................................................................................................................................
[1] Above intake manifold pressure.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3910
Fuel Pressure Regulator: Locations

FUEL PRESSURE REGULATOR:
Above the right-hand rear portion of the fuel tank.

Fuel Pressure Regulator: Description and Operation

FUEL DISTRIBUTION CONTROL
(S70 FWD shown)
(AWD)
The fuel tank holds 70 liters. The filler pipe is routed outside the passenger and luggage compartments, and is equipp
The fuel filter is located beside the right hand rear axle mounting bracket, beside the roll-over valve. Downstream of
A vent valve upstream of the filter and a suction connection on the fuel rail are provided to prevent spillage, when re
The fuel filter and pump have quick-release connections. These connections are opened by pulling back the outer sle
The fuel pump and level sensor are separate units. The level sensor is tubular and its resistance increases by 5 ohms p
Fuel Pressure Regulator: Service and Repair

FUEL PRESSURE REGULATOR, REPLACEMENT
Removing the fuel pressure regulator
Remove the 3 rubber mats covering the fuel lines on the fuel tank.Disconnect the reference air hose of the fuel pressu
Fitting the fuel pressure regulator
Fit the fuel pressure regulator and fuel lines.Attach the fuel line to the left-hand side of the fuel filter.Attach the fuel
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations
Fuel Pressure Pulsation Damper: Locations

FUEL PULSATION DAMPER
Attached to the fuel rail.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations > Page 3919
Fuel Pressure Pulsation Damper: Description and Operation

FUEL PULSATION DAMPER
Used to dampen shock waves in the fuel system.

Fuel Pressure Pulsation Damper: Service and Repair

REPLACING FUEL PULSATION DAMPER
Special Tools: 999 5533 (5)
Drain Fuel Injection System
- Fuel TankDrain the fuel injection system before replacing pulsation damper. See: .
- Remember the fire risk and observe strict cleanliness when working on components in the fuel injection syste
Removing
Fuel rail
Remove: - cover.
- Injector connectors.
- Fuel line clips.
Installing Holders
Holder
Install: - 999 5533 on injectors.

- Press in holder to ensure that it is seated firmly against the injector.
- Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another h
Removing Fuel Rail
Screws- holding fuel rail. Lift fuel rail with injectors.

Remove:
- 90Remove fuel rail from fuel line by twisting it approx. and pulling it away from the fuel line.
- Place paper wipe under the connector to absorb fuel spills.
Removing Pulsation Damper
Screws- holding mounting rail to fuel rail.

Remove:
- Mounting rail.
- Pulsation damper.
Installing New Pulsation Damper
- Lubricate the new pulsation damper 0-ring with a thin layer of petroleum jelly.
- Install the new pulsation damper.
- Remove holders from all injectors,
- Install mounting rail.

- Pull injector nozzles out a few millimeters from the fuel rail to install mounting rail.
- Tighten mounting rail on fuel rail.
Installing
Fuel -rail on intake manifold.

Install:
- 10 NmUse new screws and tighten to .
- Fuel line clips.
- Fuel rail and throttle pulley covers.
- START engine and check for fuel leakage.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Specifications

FUEL PUMP RELAY

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Specifications > Page 3931
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions

> Page 3938

1/1 Battery

2/2 Fog lamp relay

> Page 3939

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 3940

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 3941

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 3942


11A/1-9 Main fuses

> Page 3943

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 3944



> Page 3945

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 3946

C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3947
FUEL PUMP CONTROL
one second
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel Rail - Recommended Replacement Method
Fuel Rail: Technical Service BulletinsFuel Rail - Recommended Replacement Method
850/S70/V70/C701995-
Section
2
Group
23
No.0018
Year98
Month
09
Vehicles involved:B52XXS, B52X4T
23-0018; Fuel delivery system ; 98/09
Background:
The following method is recommended when replacing fuel rail to ensure correct installation. This is a supplement to s
Materials:
Mounting screws 2 969339-1

Fuel hose 1 9155869-2
O-ring. 1 968007-5
The 0-ring P/N 968007 MUST be replaced when the system has been disassembled.
Replacing fuel rail, delivery/return lines, injectors and pressure regulator
Corrective action when replacing fuel rail, delivery/return lines injectors and pressure regulator
Draining the fuel system 1
Drain fuel system See other manual: Draining fuel injection system Section 2 (23, 28) TP 2308202.
Replacing fuel rail 2
Remove:
- cover over fuel rail.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel Rail - Recommended Replacement
Method > Page 3952

- injector connectors.
- 2 fuel lines clamps to prevent pipes bending, see illustration.
Note!
Carefully remove both retaining clamps for the fuel pipes to prevent fuel spillage when the fuel rail is removed.
Remove:
Note!
Ensure that the pipe surface is not damaged when removing the return hose.
- pressure regulator vacuum hose.
(The above text listed under Remove:, applies only to cars with fuel return system).
- fuel rail mounting screws.
Carefully work off fuel rail.
Disconnect the fuel rail from the fuel line by twisting it through 90 and carefully pulling if away from the fuel line.
Place paper under the connection to absorb any fuel leakage.
Note!
Do not pry out claw connection using a fool. Twist pipe according to the above text.
Replacing nozzles and pressure regulator 3
Model year - 1997.
See other manual: Injector valve, replacement Section 2 (23, 28). Procedures TA1-TA5, TB1-TB3.
TP 2301201
Disconnecting injectors and pressure regulator 4
Model year 1997-.
Remove:
- screws holding mounting rail to fuel rail.
Method > Page 3953

- mounting rail.
- pressure regulator for cars with fuel return system.
- injectors.
Note!
Handle injectors carefully to avoid damage to nozzles and needles.
Installing injectors 5
Install nozzles and pressure regulator in the new fuel rail. Lubricate nozzle 0-rings with petroleum jelly.
Locate mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.
Install mounting rail to fuel rail. (Tightening torque 6 Nm (53 in. lbs)).
Note!
The nozzles have two channels at the top against the fuel rail. The mounting rail must sit in the uppermost channel.
Installing fuel rail 6
Install a new O-ring on the pressure pipe.
Note!
Lubricate nipple O-ring with petroleum jelly.
Carefully press in pipe and nipple into fuel rail.

Turn fuel rail 90 and ensure that the lock facing on the nipple is in the correct position in the fuel rail.
Caution!
Take care not to bend lock facing.
Method > Page 3954

Secure delivery line with tool no. 999 5620. See illustration
Lubricate injector O-rings with petroleum jelly.
Install fuel rail on intake manifold. Make sure that the injectors locate correctly.
Screw fuel rail into place. Use new screws. (Tightening torque 10 Nm (7.3 ft. lbs)).
Remove tool securing nipple.
Install:
- vacuum hose on pressure regulator.
Note!
New return hose.
(The above two points apply only to cars with return fuel system)
- fuel line clamps
- injector connectors. Check that that each connector has a rubber seal.
- covers over fuel rail and throttle pulley.
That there is no leakage.

Replacing return line 7
Draining the fuel system
Remove:
Method > Page 3955

- the 2 fuel line clamps. See illustration.
- the return line hose mounting on the pressure regulator which is located in the fuel rail.
- the return line joint on the hose under the car. Install the new return line in reverse order.
Note!
New return hose.
Removing the rail with injectors 8
Remove:
- fuel rail cover.
- 2 fuel lines clamps to prevent pipes bending, see illustration.
Note!
Install:
Method > Page 3956

- holder 999 5533 on injectors.
Press in the holders so that they are in good contact with injectors.
Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.
The illustration shows holder 999 5620 for securing the nipple which is positioned closest to the fuel delivery line (late
Remove:
- vacuum hose from pressure regulator.
(The above point applies only to cars with return fuel system)
- screws holding fuel rail.
Lift up fuel rail and carefully turn upwards. Check that the pipe does not bend and hook the center injector behind the g
Note!
Handle injectors carefully to avoid damage to nozzles and needles. Retain any damping rubbers on the intake manif
Replacing delivery lines 9
Draining the fuel system
Removing delivery lines

Remove:
Method > Page 3957

- cover over fuel rail.
- 2 fuel lines clamps to prevent pipes bending, see Illustration.
Note!
Remove:
- the return pipe at the pressure regulator.
- pressure regulator vacuum hose.
- fuel rail mounting screws.
Carefully work off fuel rail.
Remove:
- delivery line from the delivery line under the car at the sub-frame. The delivery line is marked with yellow tape.
Installing delivery lines

Install a new O-ring on the delivery line.
Disconnect the fuel rail from the fuel line by twisting it through 90 and carefully pulling it away from the fuel line. Plac
Carefully press in pipe and nipple into fuel rail.
Note!
Lubricate nipple 0-ring with petroleum jelly.
Method > Page 3958

Turn fuel rail 90 and ensure that the lock facing on the nipple is in the correct position in the fuel rail. Take care not to
Secure delivery line with tool no. 999 5620.
Lubricate injector O-rings with petroleum jelly.
Screw fuel rail into place.
Use new screws. (Tightening torque 10 Nm (7.3 ft. lbs)).
Remove tool no. 999 5620 securing nipple.
Install:
- vacuum hose on pressure regulator.
Note!
New return line.
- fuel line clamps
- injector connectors. Check that each connector has a rubber seal.
- covers over fuel rail and throttle pulley.

23712-2 Replace fuel rail 0.6 hr

23415-3 Replace front delivery line 0.2 hr
23418-3 Replace front return line 0.1 hr
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3959
Fuel Rail: Locations
Fuel System
FUEL RAIL
6The Fuel Rail is located over the intake manifold ().

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit - Installation
Fuel Gauge Sender: Technical Service BulletinsFuel Sending Unit - Installation
Section2
Group23
No0046
Year00
Month01
850/S70/V70/C70 Coupe'1994-
Reference: This Service Bulletin replaces the previous Service Bulletin 23-0046 from October 1999, which should be d
Background
The new type of sending unit can be installed on S70/V70/C70 vehicles and on the 800 series vehicles from chassis No
850-4 drs Turbo 1, 3 131664-

850-5 dr Turbo 2 037635-
850-4 drs w/o Turbo 1,3 043709-
850-5 drs w/o Turbo 2 048625-
Gauge 1 9463238
Fuel sending unit, replacement Special tools: 999 5486
Preparations Station wagon

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit
- Installation > Page 3965

Pull away carpeting and fold down rear seat back rest
Sedan
Remove:
-
Trunk carpet, and pull away right side wheel housing panel (On some vehicles the panel is made of hard material an
- Wire and connector attachments. The attachment is secured with two clips over the access cover for the sending uni
-
Protective cap covering sending unit retaining nut (if applicable). In some cases it may be necessary to loosen fuel t
Caution!
Mark up

Harness
Note!
4

Caution!
Caution!
Note!
Lubricate the top surface of the sending unit to avoid twisting white tightening the retaining nut. Use petroleum jelly or

Install the retaining nut and torque to 30 Nm (22 ft. lbs). Check installation of sending unit with gauge as per illustratio
Route harness
Attach the string to the connector of the sending unit. Carefully pull the harness over to the access hole for the fuel pum

Install:
- Protective cap over sending unit If applicable.
- Torque screws for fuel tank straps 25Nm (20 ft.lbs) if applicable.
- Cover plates for access holes.
- Harness bracket and connectors.
- Panels and carpeting over spare wheel.

38618-2 Fuel sending unit replacement according to SB 23-00460.5 hr
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Sending Unit - Installation >
Fuel Gauge Sender: Technical Service BulletinsFuel Sending Unit - Replacment
Section2
Group23
No.0046
Year99
Month10
850/S70/V70/C70 Coupe1994-
Background
The new type of sending unit can be installed on S70N70/C70 vehicles and on the 800 series vehicles from chassis No.

850 -4 drs Turbo 1,3 131664-
850 -5 drs Turbo 2 037635-
850 -4 drs w/o Turbo 1,3 043709-
850 -5 drs w/o Turbo 2 048625-

Gauge 1 9463238
Fuel sending unit, replacment
1
Preparations
Station wagon

Pull away carpeting and fold down rear seat back rest.
Sedan
Remove:
Trunk carpet, and pull away right side wheel housing panel (On some vehicles the panel is made of hard material and m
- Wire and connector attachments. The attachment is secured with two clips over the access cover for the sending unit.
- Protective cap covering sending unit retaining nut (if applicable). In some cases it may be necessary to loosen fuel tan
clamp for filler neck, and reposition tank to remove protective cap.
Caution!
2
Mark up

3
Harness
Note!
4
Caution!
Caution!

5
Note!
Lubricate the top surface of the sending unit to avoid twisting while tightening the retaining nut. Use petroleum jelly or
6

Install the retaining nut and torque to 30 Nm (22 ft. lbs).

Check installation of sending unit with gauge as per illustration.
7
Route harness
Attach the string to the connector of the sending unit.
Carefully pull the harness over to the access hole for the fuel pump.
8
Install:- Protective cap over sending unit If applicable.- Torque screws for fuel tank straps 25 Nm (20 ft.lbs) if applicab

23903-2 Fuel sending unit replacment according 0.5 hr
to SB 23-0046
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3975
Fuel Gauge Sender: SpecificationsVolume/Resistance (AWD Vehicles)

Volume/Resistance (AWD Vehicles)
Fuel Level Sensor Empty Fuel Tank (0 US Gallons) 322.5 - 332.5 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 5 -15 ohms
Fuel Pump (FP) Unit Sensor Resistance Empty Fuel Tank (0 US Gallons) 157.5 - 162.5 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 2.5 -7.5 ohms
Ejector Sensor Resistance Empty Fuel Tank (0 US Gallons) 165 - 170 ohms
Full Fuel Tank, Driveable Volume (18.5 US Gallons) 2.5 - 7.5 ohms
Fuel Gauge Sender: Adjustments
Fuel Level Sensor Not Centered:
JA6 Preparations:
If the level sensor nut is not centered in the hole in the panel, the fuel tank should be slackened off and centered.
JA7 Adjusting Fuel Tank:
- Raise the car.

- Slacken off fuel tank straps and press the tank forward by hand as far as it will go.
- Lower the car.
JA8 Further Adjustment:

-
If the fuel tank needs further adjustment use the shaft of a hammer as a lever between the nut and panel. Take car
- Remove the nut and level sensor. See: Service and Repair
JA9 Tightening Fuel Tank:

- When work on the level sensor is finished tighten the fuel tank straps.
- Raise the car.
- Press the fuel tank forwards so that the level sensor nut is centered in the hole in the panel.
- Tighten the fuel tank.
- Lower the car.
- Reinstall. See: Service and Repair
Fuel Gauge Sender: Service and Repair
NOTE
: There are certain differences when replacing the fuel level sensor in 4-door and 5-door models. Start the procedure fo

- Remove hatches and panels and cargo compartment carpet.
- Remove right wheel arch panel. In variants with a soft panel lift up the corner of the panel.
- Disconnect fuel level sensor and separate wiring.

- (FP)Remove covers over fuel level sensor and fuel pump .

- Remove the rear hatch and both side panels.
- Fold up the front hatch, unscrew the two screws on each side, pull the hatch backward and lift up.
- Fold back cargo compartment carpet to the left.
- Disconnect fuel level sensor connector, SB, and separate wiring.

- Remove plastic cover over fuel level sensor cover. Put to one side.
- Remove covers over fuel level sensor and fuel pump (FP).
DDL7 Removing Fuel Level Sensor:

Wrench 999 5486
- Pull fuel level sensor cable out through the hole by the fuel level sensor.
- Remove the plastic fuel level sensor collar. Use tool 999 5486-9.
- Lift up the fuel level sensor.
- Remove gasket.
CAUTION: Reinstall the collar, otherwise the pipe sleeve may swell making the collar hard to reinstall.
DDL8 Installing Fuel Level Sensor:
- Use a new rubber gasket.

- Lubricate the inside and top of the rubber gasket with petroleum jelly.
- Install gasket on fuel tank sleeve.
- Install fuel level sensor with electrical connections along the car.
- 30 Nm (22.1 ft.lb)Tighten nut to .
- Turn fuel level sensor cables to the left and thread them through the hole by the fuel pump (FP).
- Put all cables together in the protective tube. Wind insulating tape around the protective tube.
- Connect fuel level sensor.
- Reinstall covers, hatches and cargo compartment carpet in reverse order. Check that no cables are trapped.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure Release Valve > Component Information > Description and Operation
Fuel Tank Pressure Release Valve: Description and Operation
PURPOSE
The Fuel Tank Pressure Relief Valves are located in the fuel filler cap. Two safety valves prevent damage to the fuel
OPERATION
One Fuel Tank Pressure Relief Valve opens in the event of fuel tank over-pressure, the other Pressure Relief Valve o
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications

IDLE AIR CONTROL VALVE
Resistance between terminals;
1 and 2 ...................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Description and Operation > Overview
Idle Speed/Throttle Actuator - Electronic: Description and OperationOverview

IDLE AIR CONTROL VALVE CONTROL - OVERVIEW
ECM IAC
There are two reasons that the Engine Control Module () controls the Idle Air Control () Valve. To maintain a consta
The engine control module (ECM) computes the output signals to the idle air control (IAC) valve (7) using informati
TP
ECT
RPM
Pressostat
- Throttle Position () Sensor (1)- Engine Coolant Temperature () Sensor (2)- Engine Speed () Sensor (3)- Pressure
Information from the transmission control module (TCM) (5) regarding gear selector position is also used.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Description and Operation > Overview > Page 4000
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Operation
IDLE AIR CONTROL VALVE - OPERATION
The throttle position (TP) sensor supplies the engine control module (ECM) with a signal describing the throttle angl
When the throttle position (TP) sensor signals closed throttle position (CTP) and the engine is idling, the engine cont
Control of idling speed by the engine control module (ECM) offers the following advantages:
- Idling speed does not require adjustment (due to aging or fouling of components).
- Low idling speed and low fuel consumption is achieved by continuous compensation for changes in load.
The engine control module (ECM) idling control function is adaptive. The engine control module (ECM) learns how
In the event of an idle air control (IAC) valve control fault, the valve will assume a higher or lower idling speed than
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Engine Braking
IDLE AIR CONTROL VALVE - ENGINE BRAKING
CTP ECM IAC

During engine braking and at Closed Throttle Position (), the Engine Control Module () controls the Idle Air Control
^ maintain the negative pressure in the inlet manifold within bounds^ improve combustion and reduce emissions^
Idle Speed/Throttle Actuator - Electronic: Description and OperationIdle Air Control Valve - Diagram
IDLE AIR CONTROL VALVE - DIAGRAM
IACThe Idle Air Control () Valve has a linear function.
The valve consists of the following components:
^ Inlet (1) ^ Outlet (2) ^ Rotor (3) ^ Permanent Magnet (4) ^ Valve (5)
The idle air control (IAC) valve rotor (3) is equipped with an opening and a closing coil, and with a permanent magnet
> Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Testing and Inspection
Intake Air Heater: Testing and Inspection
NOTE: Check attachment and seal of:

- preheating hose
- air filter housing
- inlet hose
- air intake (in front of radiator)
- fresh air hose
(ACL)1. Check air cleaner and remove throttle housing:

- Remove the air filter.
- Check inside ACL, clean if necessary.
- Undo air duct connections.
- Carefully pull housing from mountings.
- (TB)Remove throttle body from ACL by pressing two snap fasteners and pulling housing at the same time.
2. Check throttle function:

- bearings and mountings
- spring
- thermostat, cool thermostat (with a spray for example)
Throttle position at various temperatures:
+5C (41F)
+10C (50F) +15C (59F)A = greater than or equal to (preheated air only)B = about C = less than or equal to
3. Assemble ACL:
- Assemble the TB.
- Install ACL in car.
- Connect all hoses and connectors.
> Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Testing and Inspection > Page 4006

- Reinstall the air filter, replace if necessary.
> Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Specifications

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

> Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Specifications > Page 4010
Fuses

Panel Locations

Relays

Panel Locations

Other Relays

MAIN RELAY
ECM
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specifications

FUEL PUMP RELAY

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Specifications > Page
Fuses
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information >

Panel Locations

Relays

Panel Locations

Other Relays
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 403
FUEL PUMP CONTROL
one second
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Sp

MAIN RELAY
At 20C (68F) .........................................................................................................................................................

Fuses
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component

Panel Locations

Relays

Panel Locations

Other Relays

MAIN RELAY
ECM
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Serv
> 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information >

874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Bulletins for Air Flow Meter/Sensor: > 2332 > May > 98 > Campaign - MAF Connector Loose
GROUP:23
NO:32
DATE:May, 1998
TITLE:

MAF WIRING HARNESS
BULLETIN REFERENCE
F. STOCK VEHICLES


874 409466-489615 874 408556-489482

875/876 342001 - 434252
874 422325-484420 872 000339-000691

875 356958-428582
Note:
NOTE:
D. Parts Return
F. Stock Vehicles


Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:

4068


4069

Check
Section
2
Group
23
No.0010
Year
98
Month
04
Background:
Model:
Material:




Check


Approx ..................................................................................................................................................................

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Di


1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Pa

Injection period
170C
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specification

Idle position ..........................................................................................................................................................

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specification

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > D

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > P

TP ECM
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > P

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > TNN25-14 >
With A/C ON
Throttle Body: Customer InterestEngine - Inconsistent Idle With A/C ON

NO: 25-14
DATE: 1-9-2003
REFERENCE: VADIS
DESCRIPTION:
2. Nipple Cleaning

4. Cleaning the ETM
Warning!
Important!
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body:
> TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 4119


> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body:
> TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 4120

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: >
Inconsistent Idle With A/C ON
Throttle Body: All Technical Service BulletinsEngine - Inconsistent Idle With A/C ON
NO: 25-14
DATE: 1-9-2003
REFERENCE: VADIS
DESCRIPTION:
2. Nipple Cleaning

4. Cleaning the ETM
Warning!
Important!
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Throttle Body: > TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 4126


> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Throttle Body: > TNN25-14 > Jan > 03 > Engine - Inconsistent Idle With A/C ON > Page 4127

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4128
Throttle Body: Adjustments

ADJUSTMENT OF THROTTLE BODY AND PULLEY
Adjustment of Throttle Body

Disconnect link.
^^ TBRemove Throttle Body () from intake manifold.
^ TPRemove Throttle Position () Potentiometer from TB.
^ Clean TB carefully.
^ Slacken adjusting screw so that throttle closes fully.
^ Slacken throttle disc mounting screws slightly.
NOTE:
Check that disc is correctly installed i.e. is facing in the right direction. Since edge of disc is thin, careful inspec
^ Open throttle about one-third using throttle lever.
^ Release throttle lever quickly so that throttle disc centres itself in throat of opening. Hold TB against light and ch
^
13.85mm 0.3mm(0.55in 0.15in) Check that throttle spindle can be moved backward and forward with slight res
^ 0.8 - 1.0 Nm (0.59 - 0.74 ft lb)Tighten throttle disc mounting screws to .

NOTE: 13.85mm 0.3mm (0.55in 0.15in)
Specified maximum dimension of must not be exceeded, otherwise spindle may bottom against TPpotentiomete
^ Screw in adjusting screw until it is just in contact with lever.

^ Screw in a further quarter turn.
^ Tighten locknut.
^ Mount TP potentiometer on throttle spindle.

^ Insert and tighten switch mounting screws.
NOTE: TP potentiometer is not adjustable.
^ Mount TB on intake manifold.

^ Reconnect all hoses and leads.

ASlackenOf
Adjustment linkLink
locknut
^ () sufficiently to permit link to be separated and to spring back easily to innermost position
^ Mount link in position.
^ B CCheck that throttle spindle is in contact with adjusting screw () and that pulley is seated against idling stop ().
^ ATighten link locknut ().
^ B CRotate pulley to check that link seats against adjusting screw () before pulley seats against idling stop ().
Check / Adjust Throttle Pulley And Cable

Pulley should move easily without sticking.
^^ Lubricate with petroleum jelly if needed.
^ Cable should be taut in idling position but must not affect pulley position.
^ Pulley should seat against idling stop.
^ Adjust cable as required.
^ APPress Accelerator Pedal () to floor and check that pulley seats against full-load stop.
Throttle Body: Service and Repair

Removing Inlet Hose
- Remove throttle pulley cover.
- (ACL)Remove inlet hose to air cleaner .
Removing Inlet Hose

- (TB)Remove fresh air intake between air cleaner and throttle body .
- Remove link between throttle pulley and throttle body.
Removing Throttle Body

- (TP)Remove the connector from the throttle position sensor.
- Remove throttle body from intake manifold.
Installing Throttle Position Sensor
- 2 0.5 NmMove throttle position sensor to new throttle body. Tightening torque .

NOTE: The throttle position sensor is not adjustable.
- Install a new gasket on the throttle body.
Installing Throttle Body

- 7 NmInstall the new throttle body on the intake manifold. Tightening torque .
- Connect connector to throttle position sensor.
Checking Link
- Undo link locknut.
- Pull back link as far as possible, release one end and check that the link springs back easily to innermost position
Installing Link
- Locate link.
- Check that the throttle spindle is in contact with the adjustment screw and that the throttle pulley is in contact wit
- Tighten link locknut
- Open and close throttle, check that the throttle spindle is in contact with the adjustment screw when the throttle is

Adjusting Throttle Cable
- Pulley should move easily without sticking.
-
The cable should be taut in idling position but must not affect throttle pulley position. Pulley should seat against i
- (AP)Press accelerator pedal to floor and check that pulley seats against full-load stop.
Installing Fresh Air Intake

- Install fresh air intake between air cleaner and throttle body.

- Install inlet hose to air cleaner.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications

Idle position ..........................................................................................................................................................

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4137

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 4140

1/1 Battery

2/2 Fog lamp relay

Page 4141

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 4142

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 4143

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 4144


11A/1-9 Main fuses

Page 4145

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 4146



Page 4147

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 4148

C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4149

TP ECM
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4150

> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Locations
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Diagrams > Diagram Information and Instructions
Boost Solenoid: Diagram Information and Instructions

> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Diagrams > Page 4166
Boost Solenoid: Description and Operation

Frequency controlled valve. Resistance 29.7
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Diagrams > Page 4167
Boost Solenoid: Service and Repair
REPLACING THE TURBOCHARGER (TC) CONTROL VALVE
Removing the turbocharger (TC) control valve

(ACL)
Lift the valve away from the Air Cleaner cover.Remove the connector from the valve.Mark up and pull off the hoses
Installing the turbocharger (TC) control valve
the hoses according to the marking on the control valve

Install-
- the connector on the valve
- (ACL)the valve on the Air Cleaner cover.
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Customer Interest for Intercooler: > 22
- Oil Spots Found on Garage Floor
Intercooler: Customer InterestEngine Intercooler - Oil Spots Found on Garage Floor
Section2
Group26
No.0002
Year99
Month06
850/ S70/ V70/ C701994-1998
Vehicles Involved: Turbo
Intercooler, installing nipple
Background:
This Service Bulletin describes how to install a nipple to the drainage hole in the intercooler. This will prevent any oil f
Parts required:
Nipple 1 1332659-0
Cleaner H 0.2 1161436-9
Fast curling adhesive 0.1 1161434-4
Enlarging hole in intercooler
Caution!
Slide a hose over the drill bit to only allowing the drill to enter 10 mm (3/8") into the intercooler tank. Further pene
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Customer Interest for
Intercooler: > 2260002 > Jun > 99 > Engine Intercooler - Oil Spots Found on Garage Floor > Page 4176

Remove the airguide for the radiator.
Drill out the existing hole in the charge air cooler (CAC) with a 9.5 mm (3/8") drill bit.
Wipe clean any drillchips of the hole and the surrounding area with cleaner H, P/N 1161436-9.
Installing the plug
Caution!
Do not over tighten the nipple, to avoid damaging the tank.
Cut of the tip of the nipple so that 5 mm (3/16") remains.

Apply quick drying adhesive (P/N 1161434-4) on the nipple threads.
Screw in the nipple.
Install the air guide for the radiator.
Start engine to ensure engine operation.
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Customer Interest for
Intercooler: > 2260002 > Jun > 99 > Engine Intercooler - Oil Spots Found on Garage Floor > Page 4177

26591-2 Install charge air cooler (CAC) nipple 0.2 hr
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inte
Engine Intercooler - Oil Spots Found on Garage Floor
Intercooler: All Technical Service BulletinsEngine Intercooler - Oil Spots Found on Garage Floor
Section2
Group26
No.0002
Year99
Month06
850/ S70/ V70/ C701994-1998
Vehicles Involved: Turbo
Background:
This Service Bulletin describes how to install a nipple to the drainage hole in the intercooler. This will prevent any oil f
Parts required:
Nipple 1 1332659-0
Cleaner H 0.2 1161436-9
Fast curling adhesive 0.1 1161434-4
Enlarging hole in intercooler
Caution!
Slide a hose over the drill bit to only allowing the drill to enter 10 mm (3/8") into the intercooler tank. Further pene
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Intercooler: > 2260002 > Jun > 99 > Engine Intercooler - Oil Spots Found on Garage Floor > Page 4183

Remove the airguide for the radiator.
Drill out the existing hole in the charge air cooler (CAC) with a 9.5 mm (3/8") drill bit.
Wipe clean any drillchips of the hole and the surrounding area with cleaner H, P/N 1161436-9.
Installing the plug
Caution!
Do not over tighten the nipple, to avoid damaging the tank.
Cut of the tip of the nipple so that 5 mm (3/16") remains.

Apply quick drying adhesive (P/N 1161434-4) on the nipple threads.
Screw in the nipple.
Install the air guide for the radiator.
Start engine to ensure engine operation.
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Intercooler: > 2260002 > Jun > 99 > Engine Intercooler - Oil Spots Found on Garage Floor > Page 4184

26591-2 Install charge air cooler (CAC) nipple 0.2 hr
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Page 4185
Intercooler: Service and Repair
Removal
Remove
(CAC) "Engine, Cooling and Exhaust : Cooling System : Radiator"
- the radiator with the Charge Air Cooler refer to See: Engine, Coolingand Exhaust/Cooling System/Radiator/Se
- (CAC)the four screws securing the Charge Air Cooler to the radiator.
Installation
Install
(CAC)the four screws securing the Charge Air Cooler to the radiator
-- (CAC)the radiator with the Charge Air Cooler .
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Variable Boost Control Solenoid, Turbocharger > Component Information > Technical Service Bulletins > Bo
Checking and Adjusting
Variable Boost Control Solenoid: Technical Service BulletinsBoost Pressure Control Valve - Checking and Adju
SECTION
2
GROUP
25
NO.810
DATESep. -98
Checking and adjusting boost pressure control (BPC) valve on the turbocharger (TC)
850, S70/V70/C70 1994-
REFERENCE: TP 2318201, SECTION 2 (23, 28), ENGINE MANAGEMENT SYSTEM MOTRONIC 4.4; 850 (B525
This Service Bulletin replaces the earlier edition of Service Bulletin 25-810, dated July 1996, which should be discarde
Checking and adjusting boost pressure control (BPC) valve on the turbocharger (TC)
Special tools: Regulator 999 5544-5

Pressure gauge 999 5646-8
Manometer 1
Use a pressure gauge to measure adjusting pressure.
To ensure correct measurements the pressure gauge should always hang vertically when taking readings.
Removing heat deflector plate 2
Remove:
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Variable Boost Control Solenoid, Turbocharger > Component Information > Technical Service
Bulletins > Boost Pressure Control Valve - Checking and Adjusting > Page 4193

- Heat deflector plate over turbocharger (TC).
- Four screws.
Removing pressure regulator hose 3
Remove
- Pressure regulator hose (marked in yellow).
Disconnect the hose at the turbocharger (TC) control valve.
- Fresh air intake from air cleaner (ACL) to access hose clamp.
Only S70/V70/C70:
The turbocharger (TC) control valve position and version have been changed In the S70/V70/C70
Disconnect the hose running backward from the turbocharger (TC) control valve (marked in yellow).
Release boost pressure control (BPC) valve spindle 4
Remove split pin from lever.

Disconnect spindle and lift straight up.
Connecting test equipment 5
Connect:

- pressure gauge to pressure regulator hose.
- pressure regulator 999 5544-5 to pressure gauge.
Note!
To ensure correct measurements the pressure gauge should always hang vertically in its hook when taking readings
Screw out pressure regulator adjusting screw completely.
Connect compressed air to pressure regulator.
Screw in pressure regulator adjustment screw so that the pressure gauge reads the value applicable to the relevant engin
The three-way junction connector has a vent (drilled hole) where it connects to the pressure regulator to facilitate settin
Engine Engine code Adjusting pressure
B5234T 57 12.5 kPa (1.8 psi)

B5234T3 53 30 kPa (4.4 psi)
B5234T4 50 12.5 kPa (1.8 psi
B5234T5 58 12.5 kPa (1.8 psi)
B5254T 56 18 kPa (2.6 psi)
Checking and adjusting 6

Push the boost pressure control (BPC) valve lever towards the turbocharger (TC) housing.
The boost pressure control (BPC) valve should be closed.
Check that the boost pressure control (BPC) valve spindle locates on the lever lug.
If necessary adjust boost pressure control (BPC) valve spindle until it locates.
Note!
The boost pressure control (BPC) valve spindle should be mounted on the lever when the lock-nut is adjusted. Twis

Reinstall/reconnect 7
- Install split pin in lever.
- Tighten lock-nut on boost pressure control (BPC) valve spindle.
- Remove lest equipment.
- Connect hose.
- Fresh air intake to air cleaner (ACL).
- Install heat shield.
Erase diagnostic trouble codes (DTCs).
Test drive the car and check that no DTC:s have been stored.
Operation No. Description Time allowance
25534-2 Load pressure, check/adjust 0.5 hr

28456-2 Self-diagnosis read 0.2 hr
28458-3 Self-diagnosis reset 0.1 hr
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Variable Boost Control Solenoid, Turbocharger > Component Information > Technical Service Bulletins > Pa
Variable Boost Control Solenoid: Specifications

TURBOCHARGER CONTROL VALVE
Resistance ...................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Variable Boost Control Solenoid, Turbocharger > Component Information > Technical Service Bulletins > Pa
Variable Boost Control Solenoid: Locations
The turbocharger (TC) control valve is located behind the air cleaner (ACL) housing.
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair
Wastegate Actuator: Service and Repair

REPLACING BOOST PRESSURE CONTROL VALVE PRESSURE SERVO
Special Tools: 998 5496, 999 5230, 999 5544
Preparations
TCTurbocharger
Remove: - () heat shield.
Removing Pressure Servo
BPCBoost
Remove: - Pressure Control () Valve spindle lock pin.
- Turbocharger (TC) control valve hose.
- MAFresh air hose from turbocharger (TC) and Mass Air Flow (F) Sensor and move to one side.
NOTE! Remove the following in the order specified.
- 1Rear pressure servo screw ()

- 2Front pressure servo screw ().
Installation of Pressure Servo
New -pressure servo.

Install:
- 20 Nm (14.76 ft.lb.)Screws and tighten to .
> Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Page 4201

Basic Adjustment of Pushrod
- Connect manometer 999 5230 and pressure tester 998 5496 to pressure servo.
- 18 1 kPa (2.56 0.14 psi)Pump up pressure to .
- Push boost pressure control (BPC) valve spindle towards turbocharger (TC) housing (closed valve).
- Adjust push rod so that it fits onto spindle lug exactly.
- Install lock pin to boost pressure control (BPC) valve spindle.
- Tighten pushrod locknut.
- Remove manometer and pressure tester.
NOTE! Push rod must not be twisted during adjustment, otherwise pressure servo diaphragm may be damaged.
Reinstall
Hose- on turbocharger (TC) control valve.

Install:
- Fresh air intake between turbocharger (TC) and mass air flow (MAF) sensor.
- Heat deflector plate.
> Powertrain Management > Ignition System > Firing Order > Component Information > Specifications
> Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks
> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations


> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4218

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4227

CMP ECM
RPM
12 V
0V
> Powertrain Management > Ignition System > Ignition Coil Wire > Component Information > Specifications
Ignition Coil Wire: Specifications

COIL WIRE
Resistance: ........................................................................................................................................................................
> Powertrain Management > Ignition System > Ignition Coil Wire > Component Information > Specifications > Page 4231
Ignition Coil Wire: Description and Operation

The coil wire carries high voltage electricity from the ignition coil to the distributor.
Ignition Coil Wire: Testing and Inspection

1. Inspect the Coil Wire for signs of arcing or burning.
2. Check resistance of the wire using an ohmmeter.
2.4K ohms 20%Resistance should be:
3. If resistance is not within specifications, replace th Coil Wire.

Ignition Coil Wire: Service and Repair
Remove coil wire from distributor cap tower and coil tower. When re-installing, ensure that the coil wire is routed prop
> Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Specifications

IGNITION ROTOR
Resistance ...................................................................................................................................................................
> Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications

IGNITION CABLE
Resistance:

> Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 4241


4.5K ohms 20%

4.0K ohms 20%
3.3K ohms 20%

> Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications
Ignition Coil: Specifications

IGNITION COIL
Resistance in primary winding:

Between terminals 1 and 15 ..................................................................................................................................
Resistance in secondary winding:
Between terminals 15 and HT ...............................................................................................................................
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions
Ignition Coil: Diagram Information and Instructions

> Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 4249

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 4261

KNOCK SENSORS

> Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4264

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 4273
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations


> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instru

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4293

CMP ECM
RPM
12 V
0V
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Swit
Malfunctioning Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls
for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 4302

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Swit
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls
for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 4307


starter wheel
switch; covers.
Caution!

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bu
May > 98 > Campaign - Malfunctioning Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:

BULLETIN REFERENCE
F. STOCK VEHICLES
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 4313

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bu
> May > 98 > Campaign - Starter/Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 4318


starter wheel
switch; covers.
Caution!

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4319
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Pa
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Start Switch
Start switch
Removal
Note!
Preparations
Start switch
Installation
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Start Switch > Page 4334
Removal
Preparations
Installation
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications

KNOCK SENSOR

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4338

KNOCK SENSORS

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4350
KNOCK SENSORS
^ Housing (1)
^ Sleeve (2)
^ Washer (6)
^ Nut (7)

Special Tools: 999 5533 (5), 999 5474
Preparations

Remove:
- Throttle cable.
- Spark plug cover.
Fuel rail
Remove: - cover

Front charge
Remove: - air pipe.


Remove:
The large

Knock

- Flame trap hose.


Install:
- Intake manifold.
- Support bracket.
- Dipstick.

Install:

- Fuel rail cover.

Idle air
Installing
Air cleaner
- Throttle cable.
- Spark plug cover.
> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4359

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4360

Spark Plugs
Engine
B 52XX T
18 ft. lb. 272 313 0.030 inch
Engine
B 52X4 T
18 ft. lb. 272 372

> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T >
Specifications
Pressure Regulating Solenoid: Specifications

Line Pressure Solenoid
Resistance .........................................................................................................................................................................
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T >
Pressure Regulating Solenoid: Application and ID

[1]Volvo Number ............................................................................................................................................................
[1] Not available as a separate replacement part. Calibrated together with transmission control system.
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component In
Specifications
Shift Solenoid: Electrical Specifications

Shift Solenoids 1 (S1) and 2 (S2)
Resistance .........................................................................................................................................................................
Shift Solenoid: Mechanical Specifications

Solenoid S1, S2 and SL ..............................................................................................................................................
4373
Shift Solenoid: Application and ID

Volvo Number ..................................................................................................................................................................
Aision Warner Number ....................................................................................................................................................

Shift Solenoid Inspection/Replacement
Shift Solenoid: Service and RepairShift Solenoid Inspection/Replacement

SPECIAL TOOLS:
- Lifting frame tool No. 999 5006, or equivalent
- Support rails tool No. 999 5033, or equivalent
- Lifting hook tool No. 999 5460, or equivalent
- Separator tool No. 999 5477, or equivalent
- Protective Sleeve tool No. 999 5562, or equivalent
- Mobile Jack tool No. 998 5972, or equivalent
- Tool No. 998 8670, or equivalent
- Protractor tool No. 951 2050, or equivalent
-
Refer to special tool section for additional tool information. See: Transmission and Drivetrain/Automatic Transm
PROCEDURE
1. Opening of control system
NOTE:
- Cleanliness is extremely important when working on automatic transmissions.
- Before starting work:
- Before commencing work, clean the transmission and surrounding area, and ensure that the workplace is f
- Components should preferably be dried with compressed air.
- Rags or waste which leave lint or threads must not be used under any circumstances:
- Avoid skin contact with transmission fluid:
- Fluid grade: ATF fluid meeting both Dexron IIE and Ford Mercon specifications.
2. Adjust steering wheel position

- Slacken wheel adjusting lever.
- Press wheel forward into bottom position and angle upward as far as possible.
- Lock wheel in position with lever.
3. Remove:
- Battery
- Battery shelf
- Return hose from control system cover
- Delivery hose at cooler quick-release coupling Plug hose and oil cooler openings with plastic plugs.
- Cable clamp retaining battery negative lead/cable harness on the transmission or sub-frame.
Tie up lead and harness.
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T >
Component Information > Service and Repair > Shift Solenoid Inspection/Replacement > Page 4376

4. Install:
- Support rails tool No. 999 5033, or equivalent, on fender edges.
- Lifting frame tool No. 999 5006, or equivalent, on support.
- Lifting hook tool No. 999 5460, or equivalent, in torque rod bracket.
Pull on hook to relieve load on engine mountings.
5. Remove:
- Left front wheel.
- Front splashguard.
Remove both bolts and press splashguard forward sufficiently to release guide spigot at rear edge.Free spl
- Splashguard under engine. (Early type).
- Unbolt EVAP canister holder from sub-frame
Cut tie securing hoses and hang canister on body.Unhook hose from sub-frame.
6. Oil, drain
- Drain transmission oil.
40 Nm.Reinstall plug with new sealTighten to:
WARNING: Oil may be extremely hot.

7. Remove:
- Steering gear nuts oil pipe bracket screw
- Bolt securing front engine mounting to sub-frame
- Bolts securing torque rod support on transmission
- Screw securing cable conduit to front member of sub-frame.

Unhook conduit from frame.
8. On right-hand drive models:

- Remove:
Steering gear crash guardCrash guard/sub-frame nut
9. Remove:
- Remove link/ball joint from wheel spindle (left side).
- Pull down link to expose ball joint. Install protective sleeve 999 5562 on ball joint.
- If the ball joint is difficult to insert in the wheel spindle tap a chisel in the groove on the spindle.
- Disconnect links from anti-roll bar on each side.
- Remove sub-frame support plate bolts on each side.
10. Removal of sub-frame
- Remove sub-frame from car.
- Position hoist tool No. 998 5972, or equivalent, under sub-frame on left-hand side and raise sufficiently to sup
- Unscrew bolts (two) between frame and body on righthand side by 1-15 mm (0.4"-0.6 inch).
- Remove bolts on left-hand side.

- Lower sub-frame approx. 100 mm (4 inch).
- Ensure that steering gear studs (five) and crash guard plate studs are clear of frame.
- Remove bolts in anti-roll bar bearing cap on left-hand side.
- Slacken bolts on right-hand side until held by just a few threads.
12. Lower sub-frame.
NOTE: Ensure that steering gear and guard plate are separated from frame.
- Lower sub-frame to expose control system housing.

13. Removal:
- Place container underneath transmission.
- Remove oil pipe.
- Undo clip securing oil temperature sensor cable, at point where cable is folded.

- Pull out cable and place to one side.
14. Removal:
- Remove control system cover screws (Torx TX40)
- Clean sealing compound residue from threads (8 x 1.25 mm).
- Remove cover.
- Use separator tool No. 999 5477, or equivalent.
Tap tool carefully into joint between cover and transmission to ensure that cover sealing flange is not disto
- Remove remains of gasket from cover and transmission joint faces
Use scraper.
Ensure
NOTE: - that no debris enter transmission.
- Wash cover thoroughly.
15. Preparation
- Remove:
Solenoid valve connectors.Unclip wiring harness from clips on control system.
Solenoid
NOTE: - S1 and solenoid S2 have two types of cable harness
- See the following operations.
16. Information, performance and combinations

- Solenoid S1
Solenoid S1 is in two variants:
Early types with the connection to the cable harness from the rightLater types with the connection from
- Cable harness
The cable harness can be in two lengths:
One shorter (early type)One slightly longer (late type).

17. Combinations
- The following combinations can occur:
Solenoid S1, early type/cable harness, early typeSolenoid S1, early type/cable harness, late type
Illustration (A)
Solenoid S1, late type/cable harness, late type
Illustration (B).
- Only the early versions of S1 and late versions of the cable harness are available as replacement parts
Illustration (A).

18. Solenoid SL
- Solenoid SL is in two variants:
Early types with the connection to the cable harness from the rightLater types with the connection from th
- Early version and replacement parts
Illustration (C).
- Late versions
Illustration (D).
- Solenoid SL is only available in the early version as a replacement part
Illustration (C).
19. Checking resistance

- Solenoids S1, S2, SL:
- Solenoid
10-15 STH:
ohmsMeasure resistance between pin in solenoid connector and transmission ground terminal. The
2-6 ohmsMeasure resistance between pins in solenoid connector.The correct resistance should be:
20. If solenoid resistances are correct:
-
Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See: Transmission and
-
Check wiring harness between solenoids and-connector on transmission as per step 3 of Solenoid Wire Harne
- If solenoid S1, S2 or SL value is incorrect:
Replace solenoid as outlined in the following steps.
- If solenoid STH value is incorrect:
Replace complete control system as per step 2 of Control System Replacement. See: Transmission and Dr

Transmission/Transaxle/Valve Body/Service and Repair(Solenoid STH is calibrated together with the con
21. Replacing solenoid

- Remove solenoid retaining screws
- The illustration shows solenoids SL, S1 and cable harness, early version.
- Remove solenoids from control system.
- Install new solenoids.
- Lubricate solenoid O-rings (S1, S2, SL) with a little Vaseline.
10 NmInstall solenoids and tighten screws to:
22. Reinstallation of control system

- Reinstall gear selector slide in control system as illustrated.
- Install new seals in transmission.
Use Vaseline to hold seals in position.
23. Install control system in transmission.
- Insert arm on gear selector slide in hole in gear selector cam.
- Install screws.
Note that screws are of different lengths (measured in mm. see illustration).
Tighten
NOTE: - screws alternately.
- 10 NmTighten to:
- Install cover with new gasket.

10 NmTighten to:

24. Connection of wiring harness
- Connect wiring harness connectors to solenoids.
- The illustration shows solenoids SL, S1 and cable harness, early version
Refer to illustrations for steps 16 through 18 for late version.
- Wiring color codes:
Solenoid S1 whiteSolenoid S2 blackSolenoid STH blue/brownSolenoid SL red

- Reinstall cable harness and check that harness is correctly positioned.
25. Assembling of control system

- Tightening of cover
Check that cover mating surface is level.Wipe cleaned joint faces on cover and transmission with methyla
NOTE: Ensure that no dirt enters the transmission.

Place approx. 3 mm (0.12 inch) thick bead of sealing compound part No. 11611409-6, or equivalent, on co

26. Reinstallation of oil cover
- Reinstall control system cover on transmission.
12 Nm
Tighten screws (Torx TX40) diagonally to: Stretch cable up to oil temperature sensor.Ensure that cable is
Fold cable on top of transmission and secure with clamp.
Install oil pipe.

- Raise sub-frame to approx. 100 mm (4 inch) from the body.
- Position steering gear and guard plate in sub-frame.
- 50 NmInstall anti-roll bar bolts on left-hand side and tighten both bearing caps to:
28. Reinstallation of sub-frame
- Reinstall sub-frame.
- Use new bolts (4 x 14 mm).
Lubricate bolt threads.
- Commence on left-hand side.

- Raise sub-frame on hoist.
NOTE: Ensure that steering gear studs are located in holes in sub-frame!
- Install frame and support plate bolts.

- 105 Nm +120 50 NmTighten sub-frame bolts first to and then support plate bolts to .
Use protractor gauge tool No. 951 2050, or equivalent.
- Transfer hoist to right-hand side and repeat procedure.
29. Remove liking hook, liking beam and support rails.

- Install:
Steering gear nuts (five).
50 NmUse new nuts!Tighten to:

Bolt securing front engine mounting to sub-frame.
50 NmTighten to:
- On right-hand drive models:
Guard plate/subframe nut (A).
50 NmTighten to:
30. Install:
- Torque rod support in transmission.
35 Nm + 40.Tighten later version to:
- 18 Nm + 90Tighten early version with 8 mm screw to:
NOTE: Use new bolts.

- Both oil pipe brackets.
25 NmTighten to:
- Cable conduit on sub-frame.

- Install steering gear guard plate.
80 NmTighten the two bolts to:
32. Install:
- EVAP canister holder and hose on sub-frame.
Clip all hoses to frame with a band clamp.
- Splash-guard under engine. (Early type)
- The front cover.
Press into position at front.Press forward and press upward at rear so that guide spigot is seated in slot.Inst
33. Reinstallation of link/ball joint to wheel spindle
- Remove protective sleeve.
NOTE: Take care that the ball joint boot is not damaged.

- Use new lock nut on bolt.
50 NmTighten to:
- Reinstall links to anti-roll bar.
- Use new lock nuts.
50 NmTighten to:
34. Installation of left front wheel

- Lubricate the hub guide for the rim with rust inhibitor part No. 1161030-0, or equivalent.
- Tighten the studs lightly.
110 NmTighten alternately to:
35. Install:
- Return oil hose to control system cover
- Inlet hose to oil cooler quick-release coupling
- Wiring harness/battery lead clip on control system cover
- Battery shelf
- Battery
36. Applies only when replacing wiring harness:
- Tighten air cleaner bracket screws.
Install air cleaner with inlet pipe and connections.
36. Checking oil level

- See Checking/Adjusting Oil Level. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tes
38. Checking DTCs
-
Use a suitable scan tool to check for and erase any Diagnostic Trouble Codes (DTCs). See: Testing and Inspe
Shift Solenoid Inspection/Replacement > Page 4389
Shift Solenoid: Service and RepairSolenoid Wire Harness Inspection/Replacement

SPECIAL TOOLS
-
Refer to special tool section for additional tool information. See: Transmission and Drivetrain/Automatic Transm
1. Preparation
-
Refer to steps 1 through 14 of Open The Control System. See: Transmission and Drivetrain/Automatic Transm
Inspection/Replacement Of Wiring Harness
2. Preparation
- Remove:
ACL complete with inlet pipe.ACL bracket.

- Disconnect transmission connector.
Remember rubber seal.
3. Checking of wiring to
harness
- Use ohmmeter measure resistance between transmission connector and end of appropriate solenoid cable.
0 ohms.Shake harness gently during measurement to locate possible loose connections.The ohmmeter sho
- Connector Pin/Wire Color Codes
Pin No: 21
Solenoid/Color: S1/white
Pin No: 22
Solenoid/Color: S2/black
Pin No: 23
Solenoid/Color: SL/red
Pin No: 24
Solenoid/Color: STH/brown

Pin No: 25
Solenoid/Color: STH, ground/blue
- Replace with new harness as described below if ohmmeter indicates value other than 0.
4. Removal of wiring harness

- Remove:
Gear selector cableLeverGear position sensor screw and retainer for harness gland.
5. Demounting of connector
- Remove:
Connector screwsRetainer for grommet for wiring in transmission.

- Remove sockets from connector housing.
Insert screwdriver between casing and socket and press catch in.At the same time slide the sockets out of t

- Remove socket for wiring to solenoids (5-pin socket).
- Free wiring harness from transmission/control system.
7. Reinstallation of wiring harness

- Install new wiring harness with grommet and O-ring.
- Reconnect solenoid connectors.
- The illustration shows solenoid SL, S1 and cable harness, early version.
See steps 16 through 18 of Shift Solenoid Inspection/Replacement for late version. See:

- Reinstall cable harness in retainer and check that harness is correctly positioned.

8. Install:
- Retainer to cable harness grommet.
- Gear position sensor bracket screw.
- Selector lever.
16 Nm.Tighten to:
- Gear selector cable with washer and retaining clip.
Apply grease part No. 1161241-3, or equivalent, sparingly to lever arm pin.
9. Reinstallation of connector.
- Reinstall sockets to connector.
- Reconnect connector halves.
- Ensure that rubber sleeve is in position.
- Secure harness and rubber sleeve with cable ties.
- Reconnect connector.
- Remember rubber seal.
10. Finishing work
- Install control system.
Refer to steps 22 through 38 of Open The Control System. See: Transmission and Drivetrain/Automatic T
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A
Specifications
Torque Converter Clutch Solenoid: Specifications

Torque Converter Clutch Solenoid
Resistance .........................................................................................................................................................................
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A
Torque Converter Clutch Solenoid: Application and ID

Volvo Number ..................................................................................................................................................................

> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information
of Complete Unit
Shift Indicator: Service and RepairReplacement of Complete Unit
1. Removal
-
Negative battery lead.
Remove:-
- Center console as per steps 3 and 4 of Shift Cable, A/T replacement, refer to Transmission and Drivetrain.
- Gear shift knob as per steps 1 and 2 of Replacement, refer to Shift Lever, A/T.
- Panel and shutter.
Depress catches at front edge of panel and lift slightly. Pry side catches outward, and remove panel and
2. Installation
- Transfer or install new boot (gaiter) to shutter
-
The shutter.
Install:-
Check that the indicator is on correct side of lever.
- The panel.
Start at rear edge and then press into position in middle. Press home catches at front edge.
- Center console as per step 6 of Shift Cable, A/T replacement, refer to Transmission and Drivetrain.
- Gear shift lever knob as per step 3 of Replacement, refer to Shift Lever, A/T.
> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information
of Complete Unit > Page 4403
Shift Indicator: Service and RepairReplacement of Indicator Bulb
AI10 Preparations for Replacing Bulb in the Automatic Transmission Position Indicator:
NOTE: For type of bulb, See: Lighting and Horns/Specifications
- Ignition off.
- Set parking brake.
- Remove tunnel compartment (center console).
AI11 Replacing Bulb in Automatic Transmission Position Indicator:
- Pull down the bulb holder at the side of the gear selector and disconnect connectors.
NOTE: The bulb and holder are a unit and cannot be separated.
- Replace the bulb.

- Reinstall bulb holder.
- Reinstall center console. Take care not to scratch interior.
- Connect connectors.
- Check that bulb lights.
- Screw center console into place and reinstall cover.
> Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Informa
LOCATION

TEMPERATURE
ARC WELDING
REPLACING
Serial Number

1 Volvo P/N
3 Part design
4 Serial number

Serial Number > Page 4413
CAUTION:
- (TCM)
NOTE:
-
2. Removing the TCM

- Ignition OFF
> Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T >
Component Information > Application and ID > Page 4415

- Install new TCM.
- Ignition ON.

(AP)
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Info
1. Preparations
- Remove:

> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T >
Component Information > Service and Repair > Page 4421

3. Removal
4. Reinstallation
- Cars with SRS:
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T >
Component Information > Service and Repair > Page 4422

- Reinstall cover
8. Checking DTCs
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Compo
Operation
ECON MODE (ECONOMY)
SPORT MODE (SPORT)
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Compo
Operation > Page 4426
- Ignition off.
-
EB2 Installing
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T
Adjustments
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position
Switch/Sensor, A/T > Component Information > Adjustments > Page 4430

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T
Adjustments > Page 4432

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Compo

Speed Sensor ..............................................................................................................................................................
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Compo
Page 4439
1. Remove:
- Battery
- ACL bracket.

> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor
, A/T > Component Information > Specifications > Page 4440

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch
Specifications > Electrical Specifications

Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................
Specifications > Electrical Specifications > Page 4445


Volvo Number ..................................................................................................................................................................


1. Preparation
- Remove:
(ACL)

3. Remove:
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature
Sensor/Switch, A/T > Component Information > Specifications > Page 4448

4. Remove:

40 Nm.Tighten to:
- Remove sensor.

- 25 Nm.Tighten to:

9. Installation:


12. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
-
Top up oil and test refer to Checking/Adjusting Oil Level. See: Transmission and Drivetrain/Automatic Trans
13. Checking DTCs
- Check and erase DTCs. See: Testing and Inspection/Initial Inspection and Diagnostic Overview
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Campaign - Transmission Control Module Software Upg
PROM - Programmable Read Only Memory: Technical Service BulletinsCampaign - Transmission Control Mo
Section
3
Group
30
No.0002
Year
01
Month
07
V70 XC/C70 2000
Service Upgrade No. 107,Transmission software upgrade
Background:
To ensure proper overall transmission shift function performance and/or shift quality, software upgrade FID 600 or 601
Cars involved:
Materials:
Service:
Vehicles within the chassis number range listed above should have SW FID 600, P/N 8636776 or SW FID 601, P/N 86
To check if SW FID 600 has been downloaded into the car, ONE of the following unique software pan numbers should
To check if SW FID 601 has been downloaded into the car, ONE of the following unique software part numbers should
After the SW download the adaptive values for the TCM should be reset as per the instructions in VAD IS.
Tools - Updated Use of Flash Programming Equipment
Section2
Group28
No.0006
Year99
Month02
S70/V70/C701998
Updated users manual
Background:
This manual provides updated instructions on the use of the Flash Reprogramming Equipment 8111252-6 after it has b
Materials:
Label 1 9438597
Package Contents and Technical Specifications

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Campaign - Transmission Control
Module Software Upgrade > Page 4456

Flash Programming Equipment
Technical Specifications
Power Supply
-Programmer use AC/DC converter 120V 12V-Laptop-PC use AC/DC converter 120V
Operating Temperature Room temperature (50F to 100F)
Design and Function
Introduction
The Flash programming equipment allows the reprogramming of M4.4.1 ECMs (engine control module). Updated data
This manual provides a step-by-step procedure for operation of the reprogramming equipment.

General Description
The reprogramming equipment requires the ECM part number to be entered, and only allows the programming of ECM
Programming Operation
1. Connect the Lap Top
- Open rear cover from Lap Top PC

- Connect Lap Top PC (# 1) to the Programmer using the V24-cable.
- 9 pin female connects to the Lap Top PC (# 11).
- 25 pin male connects to the Programmer (# 13).
- Connect the power supply to the programmer. Use AC/DC converter 120V-12V (# 3)
- Connect the power supply to the laptop PC. Use AC/DC converter 120V-18.5V (# 5)

2. Remove ECM
Points to observe when removing engine control module (ECM).
- Wait 150 seconds after engine coolant fan has stopped.

- Remove (ECM) fuse no. 1.
S70 / V70
Open engine control module (ECM) box cover and remove Motronic 4.4 engine control module (ECM) (module
890 / V90
See TP2321201, Section UUUH, page 557, Replacing engine control module
Always check the control module and connector on the control module box for bent, damaged pins or sockets.
3. Start Programming
- Slide the power switch on the Laptop-PC.

- The start menu will be loaded.
-- Connect
Switch onthe ECMtotothe
power theprogrammer.
programmer and slide lever to lock position.
- Make sure that <START> is selected.
Note!
Use arrow keys to toggle up or down.
- Press <Enter>.
- Follow the instruction on the Laptop-PC screen.
Programming takes approximately 5 minutes. During this time, prepare the label (Part Number 9438597).
If additional labels are needed, they may be ordered from Volvo using normal parts ordering routines.

4. Place the new on top of the old label.
Note!
Do not cover the Bosch Part Number.
On the new label write the part number listed on the PC-screen, your dealer code, and the programming date.
5. Complete programming
When the ECM is successfully programmed, the LapTop PC screen will display the message "ECM Successfully
6. Switch oft the programmer
7. Disconnect the ECM from the Programmer
8. Install Engine Control Module (ECM) in vehicle

Inspect connector pins sockets for damage
- Reinstall engine control module (ECM).

- Reinstall fuse no. 1.
- Read off any diagnostic trouble codes (DTCs).
- Erase diagnostic trouble codes (DTCs) and reset adaptive functions.
It is important that both diagnostic trouble codes (DTCs) are erased and adaptive functions are reset when the eng

Note!
If using the engine control module (ECM) from another car, diagnostic trouble codes (DTCs) (if any) must be
- Reinstall ECM box cover.
9. To program another ECM
- Connect the ECM to the programmer.

- Switch on power to the programmer.
- Type "Go".
- Press <Enter>, and the start menu will appear.
- Secure that <START> is selected.
- Press <Enter>, and follow the instructions on the laptop PC screen.
- Repeat steps 3 through 7
10. End programming
- Switch off power to the Laptop-PC.
Programming Errors
If something goes wrong
The Lap Top PC system checks for a successful data transfer. If any errors are detected, a second programming proced
This part number is located on the label of the ECM. The number starts with 0 261..
Caution
If the power supply to the programmer is interrupted during the programming procedure, you can reprogram the EC
Hotline
For questions regarding the programming equipment call Bosch Hotline number:
1-888-708-7402
Other questions shall be put forward to your normal field support.
If you are instructed by Bosch to return the kit, please send it to the following address.
Note!
The complete reprogramming kit must be returned. A new kit will be sent to you in return.
Robert Bosch CorporationAttn: UA/ASV62800 S. 25th AvenueBroadview, Illinois 60153
PROM - Programmable Read Only Memory: Technical Service BulletinsEngine Control Module - Motronic 4.4
Section2
Group28
No.0003
Year99
Month02
S70/V70/C701998
Reference: TP 2308202, Section 2(23,28), Motronic 4.4 (MFI) Engine

Management System, 850 1996-
Vehicles involved: B5254S, B5254T, B5234T
M 4.4 Software Upgrade
Background:
An engine control module (ECM) software upgrade is available to enhance overall engine speed performance. This wil
The Service Campaign 81 equipment will be used to perform this one time software upgrade. You will be provided wit
Materials:
Label 1 9438597
Cars involved:
Model Factory Chassis no.
S70 1 486000-557290
S70 2 486000-559255
V70 2 432000-533259
C70 J 000650-006752
C70 Conv J -000562

28410-2 Reprogram Motronic 4.4 ECM 0.6 hr

> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > S

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > S

[1]Volvo Number ............................................................................................................................................................
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications >

Resistance .........................................................................................................................................................................


Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Rep
Replacement

SPECIAL TOOLS:
- Refer to special tool section for additional tool information. See: Automatic Transmission/Transaxle/Tools and E
PROCEDURE
NOTE:

3. Remove:
- Battery
- Battery shelf
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Service and Repair > Shift Solenoid Inspection/Replacement > Page 4477

4. Install:
5. Remove:
- Left front wheel.
6. Oil, drain

7. Remove:

- Remove:
9. Remove:


13. Removal:
- Remove oil pipe.

14. Removal:
- Remove cover.
Use scraper.
Ensure
15. Preparation
- Remove:
Solenoid

- Solenoid S1
- Cable harness

17. Combinations
Illustration (A)
Illustration (B).
Illustration (A).

18. Solenoid SL
Illustration (C).
- Late versions
Illustration (D).
Illustration (C).

- Solenoid
10-15 STH:
-
Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See: Automatic Transm
-
Replace complete control system as per step 2 of Control System Replacement. See: Automatic Transmiss

Body/Service and Repair(Solenoid STH is calibrated together with the control system).


- Install screws.
Tighten
- 10 NmTighten to:

10 NmTighten to:





12 Nm
Install oil pipe.




- Install:

50 NmTighten to:
50 NmTighten to:
30. Install:

25 NmTighten to:

32. Install:
- The front cover.

50 NmTighten to:
50 NmTighten to:

35. Install:
- Battery shelf
- Battery

- See Checking/Adjusting Oil Level. See: Automatic Transmission/Transaxle/Testing and Inspection
38. Checking DTCs
-
Use a suitable scan tool to check for and erase any Diagnostic Trouble Codes (DTCs). See: Transmission Con
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Rep

SPECIAL TOOLS
1. Preparation
- Refer to steps 1 through 14 of Open The Control System. See: Automatic Transmission/Transaxle/Valve Bod
2. Preparation
- Remove:

3. Checking of wiring harness

- Use ohmmeter to measure resistance between transmission connector and end of appropriate solenoid cable.
- 0 ohms.Pin/Wire
Connector Shake harness
Color gently
Codes during measurement to locate possible loose connections.The ohmmeter sho
Pin No: 21
Pin No: 22
Pin No: 23
Pin No: 24
Pin No: 25


- Remove:
- Remove:





8. Install:
- Selector lever.
16 Nm.Tighten to:
10. Finishing work
Refer to steps 22 through 38 of Open The Control System. See: Automatic Transmission/Transaxle/Valve
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > Page

[1]Volvo Number ............................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifica

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifica

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4509

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Shift Solenoid

SPECIAL TOOLS:
- Refer to special tool section for additional tool information. See: Tools and Equipment
PROCEDURE
NOTE:

3. Remove:
- Battery
- Battery shelf
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair >

4. Install:
5. Remove:
- Left front wheel.
6. Oil, drain

7. Remove:

- Remove:
9. Remove:


13. Removal:
- Remove oil pipe.

14. Removal:
- Remove cover.
Use scraper.
Ensure
15. Preparation
- Remove:
Solenoid

- Solenoid S1
- Cable harness

17. Combinations
Illustration (A)
Illustration (B).
Illustration (A).

18. Solenoid SL
Illustration (C).
- Late versions
Illustration (D).
Illustration (C).

- Solenoid
10-15 STH:
- Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See: Valve Body/Servi
-
Replace complete control system as per step 2 of Control System Replacement. See: Valve Body/Service



- Install screws.
Tighten
- 10 NmTighten to:

10 NmTighten to:





12 Nm
Install oil pipe.




- Install:

50 NmTighten to:
50 NmTighten to:
30. Install:

25 NmTighten to:

32. Install:
- The front cover.

50 NmTighten to:
50 NmTighten to:

35. Install:
- Battery shelf
- Battery

- See Checking/Adjusting Oil Level. See: Testing and Inspection
38. Checking DTCs
-
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Shift Solenoid

SPECIAL TOOLS
1. Preparation
- Refer to steps 1 through 14 of Open The Control System. See: Valve Body/Service and Repair
2. Preparation
- Remove:


- 0 ohms.Pin/Wire
Color gently
Pin No: 21
Pin No: 22
Pin No: 23
Pin No: 24
Pin No: 25


- Remove:
- Remove:





8. Install:
- Selector lever.
16 Nm.Tighten to:
10. Finishing work
Refer to steps 22 through 38 of Open The Control System. See: Valve Body/Service and Repair
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications >

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Rear Transmission Cover - Inspect Befor
Rear Transmission Cover - Inspect Before Replacement

Section
4
Group
43
No.0012
Year
99
Month
02
Vehicles involved: Automatic gearbox: AW50-42
Rear transmission cover (AW50-42), replacement
Note!
Before calling Volvo Tech Hot Line, all fault tracing must have been performed. check sheet filled out and pressure
Materials:
Rear Cover Kit 1 9463445
43912-2 Rear cover on gearbox, 2.5 hr

replacement
AA. Checking For Leaks In the Middle Seal Ring on Gearbox

Performance test AA A1
Note!
Before calling Volvo Tech Hot Line: 1-800-500-5570, all fault tracing must have been performed, check sheet filled
- Perform test when the transmission is cold.
Move the gear selector from D to R 2-4 times, waiting at least 3 seconds in D for each D to R application. If engageme
Note!
When repeating the D-R shift one must wait at least 3 sec in D-position to give the C2 clutch accumulator time to e
Is the engagement very hard?
Step: AA A7
Yes:^
Step: AA A2
No:^
Performance test continued AA A2
Move the gear selector from R to D and apply slight throttle.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Rear Transmission Cover
- Inspect Before Replacement > Page 4537

If the vehicle only moves slowly with high rpm. as starting in "winter" mode, and then bangs into the gear, the rear tran
Is the vehicle moving slowly with high rpm?
Step: AA A7
Yes:^
Step: AA A3
No:^
Performance test warm transmission AA A3
- Drive the vehicle so that the transmission reaches normal operating temperature, approx 100C (212F).
In workshop
Check oil temperature by using VST and test mode 5. The test can take up to 20 sec to be performed.
- Ignition on.
- Check the transmission oil temperature by using Diagnostic Test Mode 5. The test will take up to 20 sec.
Move the gear lever from D to R 2-4 times. If the engagement is very hard the seal ring is worn.
Note!

Step: AA A4
Yes:^
Step: AA A5
No:^
Replacement of the complete rear cover including seal ringsAA A4
- Replace the complete rear cover including seal rings, as per Accumulator pistons/sealing rings B2/C2, replacement.
Before calling Volvo Tech Hot Line: 1-800-500-5570, all fault tracing must have been performed, check sheet filled ou

per AB C1 - AB C3
Step:
Then AA A6
continue with:^
Checking leakage of the center seal ring, warm transmission

AA A5
If the engagement from R to D is too hard, pressure readings for C1 clutch and C2 clutch must be performed as per AB
Step:
Then AAA6with:^
continue
Test driving AA A6
After the rear cover of the transmission has been replaced test drive the vehicle and verify that the transmission is opera
Note!
All traffic signs and all posted speed limits.
Fault
Then corrected
continue with:^
Replacement of transmission AA A7
- Replace transmission. as per Transmission/torque converter, replacement.
Fault
Then corrected
continue with:^


AB B. Replacing Rear Cover
Setting steering wheel AB B1
Loosen the lever for the steering wheel adjustment. Push the steering wheel forward and upward and lock it in this posi
Position the wheels in a straight forward direction. Shift the transmission into N (neutral) position. Disconnect the nega
Lock the steering wheel so it cannot turn.
Note!
Ensure the steering wheel is NOT turned. This may cause damage to the SRS contact reel when performing the repa
Remove AB B2
Remove:
- mass air flow connector,

- air cleaner housing assembly with fresh air duct, - cover the fresh air inlet hose with a clean rag. In the following ste
Blow with compressed air in the area around where the cover is going to be split from the transmission case. This is to
Turbos only:
Remove the turbocharge control valve (TC) from the air cleaner housing.
Securing clutch drum before removing rear cover AB B3
Note!
In this step the picture shows the drum without the transmission rear cover. This is to better illustrate how to insert t
Remove the vehicle speed sensor (VSS).
Insert a screwdriver 125 mm (6") with a shank approx. 3 mm (0.118") in the hole for the speed sensor and wedge the cl
Note!
Do not use the hammer to wedge the screwdriver in between the case and the drum. Push only by hand on the screw
AB B4Removing throttle bobbin
Cars with turbo charger:

Remove the cover over the throttle bobbin (arrow).
Disconnect the throttle cable from the bobbin and the bracket.
Remove the air charge pipe between the turbo charger and the intercooler (arrow).
Removing air charge and oil cooler line AB B5
Turbos only
Remove:
- upper air charge pipe/hose from the throttle body,
- upper transmission oil cooler line on the radiator.
Cars with EGR AB B6

Remove the hoses from the controller on the fan shroud bracket.
Removing ground strap AB B7

Remove:
- ground strap from the cowl,
- bolt from the torque arm.
Removing wheel AB B8
Remove:
- left front wheel,
- upper nut for the sway bar link on strut,
- nuts for the wheel well liner and pull back/up,
Note!
Do not pull or bend the well liner excessively.
Removing air box to guide AB B9


Air guide, two bolts (Arrows).
Push air guide slightly forward to release tab from the radiator.
Splash guard on early M/Y:s.
The clamp for the negative battery cable on the sub-frame. (M/Y 1994 and up)
Removing attachment bolt AB B10
Remove attachment bolt for the wire duct/conduit on the sub-frame.
Loosen up the clamp for the exhaust pipes behind the catalyst.
Failing to loosen the clamp may result in leakage at the heater/pipe flange.
Note!
The clamp does not have to be removed.
Removing bolt attaching the universal joint AB B11


Note!
Mark U-joint in the relation to steering rack pinon shaft
Lock pin.
Remove the bolt attaching the universal joint to the steering rack, then push the joint upward off the steering rack.
Drain the oil out of the transmission.
Note!
Ensure the steering wheel does not turn so that the contact reel for the SRS is altered.
Lowering the sub-frame AB B12
Loosen the right side mounting bolts for the sub-frame 3 turns.
Do not use an impact wrench to loosen right side subframe bolts. Bolts may come out too tar.
Support the sub-frame with a transmission jack and remove the two left side attachment bolts.
Remove two bolts for the support bracket for the left rear sub-frame attachment (arrows).
Install tool 999 5517 and tighten to 20 Nm (15 lbs), turndown the flange nuts to 25 mm (1.0") from the bolt head.
Carefully lower the transmission jack to where the sub- frame rests on the flange nuts.
Remove the transmission jack.
Carefully turn the two flange nuts counter clockwise until the transmission cover can be removed without interfering w
Removing cover AB B13

Break loose the four 12 mm plugs for the pressure ports and the TORX plug on the cover. Do not remove the plugs.
Remove all bolts from the cover.
Carefully tap on the cover with a plastic hammer to loosen it from the case.
Then carefully pull and turn at the same time, the cover back and forth to remove it from the clutch drum making sure t
Secure drum AB B14
Important:
Ensure the drum is still secured and cannot move.
Check if the outer bearing race is still in the cover, one should see the needles in the trust bearing (arrow).
A new outer race will come with the new cover.
Carefully clean the contacting gasket surface on the case not damaging the surface. Do not use a razor blade.
Before installing the cover AB B15


Measure the distance between the gasket surface and the clutch drum as shown in the illustration. The measurement mu
In the measurement is more then 39 mm (1.590") one or more of the clutch or steel discs is out of position.
How to correct
Turn the drum back and fourth and tap carefully on the center pant of the drum with a rubber mallet. Several tries migh
Installing new O-rings AB B16
Note!
Secure the drum with a wire or similar so it cannot slide out.
Check if the outer bearing race is still in the cover, one will se the needles in the trust bearing. New race will come with
Clean the containing gasket surface on the case carefully, not damaging the surface. Do not use razor blade.
Install new O-rings (four supplied).
New cover AB B17


Caution!
Make sure no gasket material enters the oil channels. (arrows)
Apply a thin layer of liquid gasket P/N 1161409 on the gasket surface. Make sure gasket material is spread out around
Torque bolts crosswise:
-
M6: 10 Nm(7 lbs)
-
M8: 25 Nm(18 lbs)
Installing the cover AB B18
Make sure that no dowel pin came out with the old cover. If so it has to be transferred back to the transmission case.
The new trust bearing race using petroleum jelly.
Lubricate the seal rings and the grooves generously with Petroleum jelly. This will help keep the seal rings secured whi
Install the cover carefully so that the seal rings enter the drum without binding. The cover will seat against the case whe
Install all pressure port plugs and the TORX plug.
Torque bolts crosswise, M8 25Nm (18 lbs), M6 10 Nm (7 lbs).
Reattaching sub frame AB B19
Note!
New bolts must be used. Grease the bolt threads.
Carefully raise subframe with a transmission jack until it contacts the frame rail.

Remove the two special tools 999 5517.
Install the new M14 bolts and the rear support plate. Install the two support plate bolts loosely.
Torque subframe bolts (four) to 105 Nm (77.5 lbs) + 120.
Torque bolts for the support plate to 50 Nm (37 lbs)
Installing universal joint to steering gear AB B20
Note!
Make sure the markings on the U-joint and the pinon shaft correspond.
Install universal joint to steering gear. Tighten to 20 Nm (15 lbs).
Lock spring.
Installing attachment bolt AB B21

Re-tighten the clamp for the exhaust pipe behind the catalytic converter.

Install attachment bolt for the wire duct/conduit on the subframe.
Installing air guide AB B22
Install:
- Clamp for the negative battery cable.
- splash guard on early M/Y:s,
- air guide, two torx (27 screws).
Re-attach sway bar link AB B23
Re-attach sway bar link and torque the nut 50 Nm (37 lbs).
Install:
- wheel well liner with plastic nuts,
- left front wheel, torque 110 Nm (81 lbs)

Installing bolt and nut for torque arm AB B24

Install bolt and nut for torque arm/torque rod.
Note!
Use new screw and locknut.
Replacement part number lock nut P/N:
- M8 (on early version) p/n 948645-7
- M10 (on late version) p/n 971098-9
Note!
On later version the lock nut is installed.
Tighten to:
- M8: 18 Nm (13 lbs) + 120
- M10: 35 Nm (26 lbs) + 90
Installing air charge pipe/hose AB B25
Install:
- upper transmission oil cooler line on the radiator. Use a new lock clip.
- air charge air pipe/hose to the throttle body.
Cars with EGR AB B26

Install the hose(s) from the controller on the fan shroud bracket.
Installing air charge pipe (turbos only) AB B27
Install:
- the cover over the throttle bobbin (arrow),
- air charge pipe between the turbocharger and the intercooler (arrow).
Installing air cleaner house assembly AB B28

Vehicle speed sensor (VSS) torque screw 10 mm (6 lbs). Remove rag from inlet hose.
Install air cleaner house assembly with fresh air duct.
Install air mass sensor connector.
Turbos only:
Install the turbo charger valve (TC) to the air cleaner housing (only turbocharged engines).

Note!
Make sure the hoses for the TC valve are not pinched while the air cleaner housing is mounted in the bracket.
Filling up transmission AB B29
The transmission must be filled with DEXTRON III/MERCON transmission fluid, 3,5 liters (3.7 qt). Changing oil, Sec
Test drive and check function of the transmission and that no leakage is present after test drive.
Note!
It may be required to add/remove transmission fluid when the fluid has been warmed up after the test drive. Do not
AB C. Measuring Fluid Pressure

Special tools: 951 2782, 999 2531, 999 5074, 999 5114
Note!
Measuring fluid pressure
Measuring fluid pressure C1 and C2 AB C1
Warning!
The pressure must be checked with the engine idling only. Increasing RPM will damage the pressure gauge.
Remove the plug (Torx 55) and install special tool 951 2782 and 999 2531 (1) as per illustration.
Remove the plug and install special tool 999 5074 and 999 5114 (2) as per illustration.
Start the engine and move the gear selector into position N.
Measuring C1 AB C2
Apply the brake pedal.
Move the gear selector into position D.

The C1 gauge should read about 0.4 MPa (57 Psi) and the C2 gauge must read approximately 0 MPa (0 Psi).
Measuring C2 AB C3
Move the gear selector into position N, wait 3 seconds and then move it into position R.
The C2 gauge should approximately read 0.6 MPa (85 Psi) and the C1 gauge must read approximately 0 MPa (0 Psi).
If C2 pressure in step 2, and C1 pressure in step 3 showed other values than 0 MPa (0 Psi), the rear cover of the transm
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Accumulator Pistons/Seals-B2/C2
Accumulator: Service and RepairAccumulator Pistons/Seals-B2/C2

SPECIAL TOOLS
PROCEDURE
1. Preparation
Information At Works With Valves And Pistons
2. Sticking valves and pistons - removal
Cleanliness
NOTE: - Strict cleanliness is important.
- The control system is extremely sensitive to dirt.
- Clean the workplace and tools before commencing work.
- Never use rags, waste or paper which leave lint or threads.
- Dry and clean components with compressed air.
- If necessary to wipe with a cloth, use a chamois.
- Under no circumstances may a valve spool or piston which is sticking or seized be pried out.
Instead, tap the valve housing with a piece of wood or plastic.
- Inaccessible components may often be removed with a magnet.
3. Inspection after disassembly
- Inspect the control system for foreign particles during disassembly.
The presence of such particles often provides an indication of a transmission fault.
4. Measurement/inspection of springs
- Spring specifications may be used only to identify the springs during assembly.
For example, if the free length of a spring does not coincide exactly with the value specified in the table be
NOTE: Always check the transmission designation and engine type when replacing control system components.
> Page 4557

Place control system on clean workbench.
5. Preparations-
- Remove gear selector slide so that it does not fall out and become damaged.
6. Replacing accumulator pistons and seals B2/C2

- Remove:
Cover plate and gasket.
Check that gasket is intact.
Outer spring is attached to piston.

7. Clean and inspect
- Clean valves
all metallic and pistons.
components thoroughly in a suitable cleaning fluid.
Dry with compressed air or lint-free rag.
- Check that valve spools are not abraded or worn.
- Check that there are no abrasion or wear marks on the valves and that they move easily in their bores.
If necessary the valves can be carefully dressed with extremely fine emery cloth.
Control valve, accumulators and spring (1)Spring and modulator valve B2 (2)Spring and modulator valve
> Page 4558

8. Accumulator piston and valve spring specifications
- Refer to the table above.
NOTE: Also refer to step 4
9. Replace accumulator piston seals.

- Lubricate new seals with ATF oil.
- Take care to ensure that seal ends are not damaged!
10. Reinstall accumulator pistons and springs.

- Reinstall valves and springs.
- Reinstall
6.5 Nm.cover plate6and
Tighten gasket.
screws to:
CAUTION: Excessive torque may impose stress on system, causing valves to stick.
11. Finishing
- Reinstall control system.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Accumulator Pistons/Seals-B2/C2 > Page 4559
Accumulator: Service and RepairAccumulator Pistons/Seals-C3

SPECIAL TOOLS
PROCEDURE
1. Preparation
Information At Works With Valves And Pistons
2. Sticking valves and pistons - removal
Cleanliness
NOTE: - Strict cleanliness is important.
- The control system is extremely sensitive to dirt.
- Clean the workplace and tools before commencing work.
- Never use rags, waste or paper which leave lint or threads.
- Dry and clean components with compressed air.
- If necessary to wipe with a cloth, use a chamois.
- Under no circumstances may a valve spool or piston which is sticking or seized be pried out.
Instead, tap the valve housing with a piece of wood or plastic.
- Inaccessible components may often be removed with a magnet.
3. Inspection after disassembly
- Inspect the control system for foreign particles during disassembly.
The presence of such particles often provides an indication of a transmission fault.
4. Measurement/inspection of springs
- Spring specifications may be used only to identify the springs during assembly.
For example, if the free length of a spring does not coincide exactly with the value specified in the table be
NOTE: Always check the transmission designation and engine type when replacing control system components.
> Page 4560

Place control system on clean workbench.
5. Preparations-
- Remove gear selector slide so that it does not fall out and become damaged.
6. Replacing accumulator piston C3

- Remove:
Cover plate and gasket. Check that gasket is intact.Spring and modulator valve (1)Spring and modulator v
Accumulator piston C3 and spring (C3)
7. Clean and inspect valves and pistons.

- Clean all metallic components thoroughly in a suitable cleaning fluid.
Dry with compressed air or lint-free rag.
- Check that valve spools are not abraded or worn.
- Check that there are no abrasion or wear marks on the valves and that they move easily in their bores.
If necessary the valves can be carefully dressed with extremely fine emery cloth.
- Check that hole in valve (2) is clean. Blow clean with compressed air.
> Page 4561

8. Accumulator piston and valve spring specifications
- Refer to the table above.
NOTE: Also refer to step 4
9. Replace accumulator piston seals

- Lubricate seals with ATF oil.
- Take care to ensure that seal ends are not damaged!
10. Reinstall accumulator pistons and springs.

- Reinstall valves and springs.
- Reinstall cover plate and gasket.
6.5 Nm.Tighten 6 screws to:
CAUTION: Excessive torque may impose stress on system, causing valves to stick.
11. Finishing
- Reinstall control system.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Rear Transmission Cover - Inspect Before Replac
Rear Transmission Cover - Inspect Before Replacement

Section
4
Group
43
No.0012
Year
99
Month
02
Vehicles involved: Automatic gearbox: AW50-42
Rear transmission cover (AW50-42), replacement
Note!
Before calling Volvo Tech Hot Line, all fault tracing must have been performed. check sheet filled out and pressure
Materials:
Rear Cover Kit 1 9463445
43912-2 Rear cover on gearbox, 2.5 hr

replacement
AA. Checking For Leaks In the Middle Seal Ring on Gearbox

Performance test AA A1
Note!
- Perform test when the transmission is cold.
Move the gear selector from D to R 2-4 times, waiting at least 3 seconds in D for each D to R application. If engageme
Note!
Step: AA A7
Yes:^
Step: AA A2
No:^
Performance test continued AA A2
Move the gear selector from R to D and apply slight throttle.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Rear Transmission Cover -
Inspect Before Replacement > Page 4566

If the vehicle only moves slowly with high rpm. as starting in "winter" mode, and then bangs into the gear, the rear tran
Is the vehicle moving slowly with high rpm?
Step: AA A7
Yes:^
Step: AA A3
No:^
Performance test warm transmission AA A3
- Drive the vehicle so that the transmission reaches normal operating temperature, approx 100C (212F).
In workshop
Check oil temperature by using VST and test mode 5. The test can take up to 20 sec to be performed.
- Ignition on.
- Check the transmission oil temperature by using Diagnostic Test Mode 5. The test will take up to 20 sec.
Move the gear lever from D to R 2-4 times. If the engagement is very hard the seal ring is worn.
Note!

Step: AA A4
Yes:^
Step: AA A5
No:^
Replacement of the complete rear cover including seal ringsAA A4
- Replace the complete rear cover including seal rings, as per Accumulator pistons/sealing rings B2/C2, replacement.
Before calling Volvo Tech Hot Line: 1-800-500-5570, all fault tracing must have been performed, check sheet filled ou

per AB C1 - AB C3
Step:
Then AA A6
continue with:^
Checking leakage of the center seal ring, warm transmission

AA A5
If the engagement from R to D is too hard, pressure readings for C1 clutch and C2 clutch must be performed as per AB
Step:
Then AAA6with:^
continue
Test driving AA A6
After the rear cover of the transmission has been replaced test drive the vehicle and verify that the transmission is opera
Note!
All traffic signs and all posted speed limits.
Fault
Then corrected
continue with:^
Replacement of transmission AA A7
- Replace transmission. as per Transmission/torque converter, replacement.
Fault
Then corrected
continue with:^


AB B. Replacing Rear Cover
Setting steering wheel AB B1
Loosen the lever for the steering wheel adjustment. Push the steering wheel forward and upward and lock it in this posi
Position the wheels in a straight forward direction. Shift the transmission into N (neutral) position. Disconnect the nega
Lock the steering wheel so it cannot turn.
Note!
Ensure the steering wheel is NOT turned. This may cause damage to the SRS contact reel when performing the repa
Remove AB B2
Remove:
- mass air flow connector,

- air cleaner housing assembly with fresh air duct, - cover the fresh air inlet hose with a clean rag. In the following ste
Blow with compressed air in the area around where the cover is going to be split from the transmission case. This is to
Turbos only:
Remove the turbocharge control valve (TC) from the air cleaner housing.
Securing clutch drum before removing rear cover AB B3
Note!
In this step the picture shows the drum without the transmission rear cover. This is to better illustrate how to insert t
Remove the vehicle speed sensor (VSS).
Insert a screwdriver 125 mm (6") with a shank approx. 3 mm (0.118") in the hole for the speed sensor and wedge the cl
Note!
Do not use the hammer to wedge the screwdriver in between the case and the drum. Push only by hand on the screw
AB B4Removing throttle bobbin
Cars with turbo charger:

Remove the cover over the throttle bobbin (arrow).
Disconnect the throttle cable from the bobbin and the bracket.
Remove the air charge pipe between the turbo charger and the intercooler (arrow).
Removing air charge and oil cooler line AB B5
Turbos only
Remove:
- upper air charge pipe/hose from the throttle body,
- upper transmission oil cooler line on the radiator.
Cars with EGR AB B6

Remove the hoses from the controller on the fan shroud bracket.
Removing ground strap AB B7

Remove:
- ground strap from the cowl,
- bolt from the torque arm.
Removing wheel AB B8
Remove:
- left front wheel,
- upper nut for the sway bar link on strut,
- nuts for the wheel well liner and pull back/up,
Note!
Do not pull or bend the well liner excessively.
Removing air box to guide AB B9


Air guide, two bolts (Arrows).
Push air guide slightly forward to release tab from the radiator.
Splash guard on early M/Y:s.
The clamp for the negative battery cable on the sub-frame. (M/Y 1994 and up)
Removing attachment bolt AB B10
Remove attachment bolt for the wire duct/conduit on the sub-frame.
Loosen up the clamp for the exhaust pipes behind the catalyst.
Failing to loosen the clamp may result in leakage at the heater/pipe flange.
Note!
The clamp does not have to be removed.
Removing bolt attaching the universal joint AB B11


Note!
Mark U-joint in the relation to steering rack pinon shaft
Lock pin.
Remove the bolt attaching the universal joint to the steering rack, then push the joint upward off the steering rack.
Drain the oil out of the transmission.
Note!
Ensure the steering wheel does not turn so that the contact reel for the SRS is altered.
Lowering the sub-frame AB B12
Loosen the right side mounting bolts for the sub-frame 3 turns.
Do not use an impact wrench to loosen right side subframe bolts. Bolts may come out too tar.
Support the sub-frame with a transmission jack and remove the two left side attachment bolts.
Remove two bolts for the support bracket for the left rear sub-frame attachment (arrows).
Install tool 999 5517 and tighten to 20 Nm (15 lbs), turndown the flange nuts to 25 mm (1.0") from the bolt head.
Carefully lower the transmission jack to where the sub- frame rests on the flange nuts.
Remove the transmission jack.
Carefully turn the two flange nuts counter clockwise until the transmission cover can be removed without interfering w
Removing cover AB B13

Break loose the four 12 mm plugs for the pressure ports and the TORX plug on the cover. Do not remove the plugs.
Remove all bolts from the cover.
Carefully tap on the cover with a plastic hammer to loosen it from the case.
Then carefully pull and turn at the same time, the cover back and forth to remove it from the clutch drum making sure t
Secure drum AB B14
Important:
Ensure the drum is still secured and cannot move.
Check if the outer bearing race is still in the cover, one should see the needles in the trust bearing (arrow).
A new outer race will come with the new cover.
Carefully clean the contacting gasket surface on the case not damaging the surface. Do not use a razor blade.
Before installing the cover AB B15


Measure the distance between the gasket surface and the clutch drum as shown in the illustration. The measurement mu
In the measurement is more then 39 mm (1.590") one or more of the clutch or steel discs is out of position.
How to correct
Turn the drum back and fourth and tap carefully on the center pant of the drum with a rubber mallet. Several tries migh
Installing new O-rings AB B16
Note!
Secure the drum with a wire or similar so it cannot slide out.
Check if the outer bearing race is still in the cover, one will se the needles in the trust bearing. New race will come with
Clean the containing gasket surface on the case carefully, not damaging the surface. Do not use razor blade.
Install new O-rings (four supplied).
New cover AB B17


Caution!
Make sure no gasket material enters the oil channels. (arrows)
Apply a thin layer of liquid gasket P/N 1161409 on the gasket surface. Make sure gasket material is spread out around
Torque bolts crosswise:
-
M6: 10 Nm(7 lbs)
-
M8: 25 Nm(18 lbs)
Installing the cover AB B18
Make sure that no dowel pin came out with the old cover. If so it has to be transferred back to the transmission case.
The new trust bearing race using petroleum jelly.
Lubricate the seal rings and the grooves generously with Petroleum jelly. This will help keep the seal rings secured whi
Install the cover carefully so that the seal rings enter the drum without binding. The cover will seat against the case whe
Install all pressure port plugs and the TORX plug.
Torque bolts crosswise, M8 25Nm (18 lbs), M6 10 Nm (7 lbs).
Reattaching sub frame AB B19
Note!
New bolts must be used. Grease the bolt threads.
Carefully raise subframe with a transmission jack until it contacts the frame rail.

Remove the two special tools 999 5517.
Install the new M14 bolts and the rear support plate. Install the two support plate bolts loosely.
Torque subframe bolts (four) to 105 Nm (77.5 lbs) + 120.
Torque bolts for the support plate to 50 Nm (37 lbs)
Installing universal joint to steering gear AB B20
Note!
Make sure the markings on the U-joint and the pinon shaft correspond.
Install universal joint to steering gear. Tighten to 20 Nm (15 lbs).
Lock spring.
Installing attachment bolt AB B21

Re-tighten the clamp for the exhaust pipe behind the catalytic converter.

Install attachment bolt for the wire duct/conduit on the subframe.
Installing air guide AB B22
Install:
- Clamp for the negative battery cable.
- splash guard on early M/Y:s,
- air guide, two torx (27 screws).
Re-attach sway bar link AB B23
Re-attach sway bar link and torque the nut 50 Nm (37 lbs).
Install:
- wheel well liner with plastic nuts,
- left front wheel, torque 110 Nm (81 lbs)

Installing bolt and nut for torque arm AB B24

Install bolt and nut for torque arm/torque rod.
Note!
Use new screw and locknut.
Replacement part number lock nut P/N:
- M8 (on early version) p/n 948645-7
- M10 (on late version) p/n 971098-9
Note!
On later version the lock nut is installed.
Tighten to:
- M8: 18 Nm (13 lbs) + 120
- M10: 35 Nm (26 lbs) + 90
Installing air charge pipe/hose AB B25
Install:
- upper transmission oil cooler line on the radiator. Use a new lock clip.
- air charge air pipe/hose to the throttle body.
Cars with EGR AB B26

Install the hose(s) from the controller on the fan shroud bracket.
Installing air charge pipe (turbos only) AB B27
Install:
- the cover over the throttle bobbin (arrow),
- air charge pipe between the turbocharger and the intercooler (arrow).
Installing air cleaner house assembly AB B28

Vehicle speed sensor (VSS) torque screw 10 mm (6 lbs). Remove rag from inlet hose.
Install air cleaner house assembly with fresh air duct.
Install air mass sensor connector.
Turbos only:
Install the turbo charger valve (TC) to the air cleaner housing (only turbocharged engines).

Note!
Make sure the hoses for the TC valve are not pinched while the air cleaner housing is mounted in the bracket.
Filling up transmission AB B29
The transmission must be filled with DEXTRON III/MERCON transmission fluid, 3,5 liters (3.7 qt). Changing oil, Sec
Test drive and check function of the transmission and that no leakage is present after test drive.
Note!
It may be required to add/remove transmission fluid when the fluid has been warmed up after the test drive. Do not
AB C. Measuring Fluid Pressure

Special tools: 951 2782, 999 2531, 999 5074, 999 5114
Note!
Measuring fluid pressure
Measuring fluid pressure C1 and C2 AB C1
Warning!
The pressure must be checked with the engine idling only. Increasing RPM will damage the pressure gauge.
Remove the plug (Torx 55) and install special tool 951 2782 and 999 2531 (1) as per illustration.
Remove the plug and install special tool 999 5074 and 999 5114 (2) as per illustration.
Start the engine and move the gear selector into position N.
Measuring C1 AB C2
Apply the brake pedal.
Move the gear selector into position D.

The C1 gauge should read about 0.4 MPa (57 Psi) and the C2 gauge must read approximately 0 MPa (0 Psi).
Measuring C2 AB C3
Move the gear selector into position N, wait 3 seconds and then move it into position R.
The C2 gauge should approximately read 0.6 MPa (85 Psi) and the C1 gauge must read approximately 0 MPa (0 Psi).
If C2 pressure in step 2, and C1 pressure in step 3 showed other values than 0 MPa (0 Psi), the rear cover of the transm
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations
LOCATION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 4587
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 4588

TEMPERATURE
ARC WELDING
REPLACING
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Application and ID > Part and Serial Number

1 Volvo P/N
3 Part design
4 Serial number

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Application and ID > Part and Serial Number > Page 4591
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Application and ID > Page 4592
CAUTION:
- (TCM)
NOTE:
-
2. Removing the TCM

- Ignition OFF
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Application and ID > Page 4593

- Install new TCM.
- Ignition ON.

(AP)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins >
And Fluids
Differential Fluid - A/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical
Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 4599

AFFECTED VEHICLES
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins >
And Fluids > Page 4600
Differential Fluid - A/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Downshift Switch, A/T > Component Information > Service and Repair
1. Preparations
- Remove:

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Downshift Switch, A/T > Component Information > Service and Repair > Page 4604

3. Removal
4. Reinstallation
- Cars with SRS:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Downshift Switch, A/T > Component Information > Service and Repair > Page 4605

- Reinstall cover
8. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluid
Fluid - A/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain -
Lubricants And Fluids > Page 4610

AFFECTED VEHICLES
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluid
Fluid - A/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications

CAPACITY AW50-42LE
Refill After Servicing ...........................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4614
Fluid - A/T: Fluid Type Specifications
Transmission Fluid
Type .................................................................................................................................................... DEXRON II-E, DE

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4615
Fluid - A/T: Service and Repair
Replacing Transmission Fluid
Changing Oil
Note!
Use only automatic transmission fluid which fulfills both Dexron IIE and Ford Mercon standards. Avoid s
Conditions
The oil should be replaced only in the following instances:-

When the on-board diagnostic system (OBD system) has recoreded that the oil temperature is too high, diagnosti
- If the oil smells burnt and is discolored and no diagnostic trouble code (DTC) has been stored. For example due t
- On cars used in continuous taxi service and/or used to tow trailers extensively, should have the oil changes at 750
Warning! The oil may be very hot if the car has just been driven. Avoid skin contact.
Draining
- Remove the splash guard under engine (certain versions)

- Remove the oil plug. Drain the transmission oil.
Installing the oil pan plug
40 Nm. Install the oil pan plug with a new gasket.Torque Install splash guard (certain variants).
Preparing to flush the transmission
the battery
Remove-
- the battery shelf.
Remove the return hose on the control system cover.Install a plastic plug in the connection on the cover.Install a tran
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4616

Refilling
Apply the parking brake. Move the gear selector lever to position P. Add approximately 2 liters of oil.Start the engin
Further filling
7.6 0.25 litersFill with approximately 2 liters of oil.Apply the parking brake.Start the engine and let it idle.Move the
Erasing diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs)
After replacing the transmission, the adaptation and the "Transmission oil change" counter must be reset.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Cooler/Line Flushing Informati
Fluid Line/Hose: Technical Service BulletinsA/T - Cooler/Line Flushing Information
Retailer Technical Journal 19495Automatic transmission cooler/lines flushing

Date 09-11-2009
Reference: VIDA, VSTG, RTJ 16724
Note!
NOTE!
THIS RTJ SUPERSEDES THE PREVIOUS VERSION OF RTJ 19495 RELEASED 10-8-2008. A LABOR OPER
AFFECTED VEHICLES:
DESCRIPTION:
The purpose of this RTJ is to work as a guideline for technicians when an automatic transmission is being replaced. In
A faulty transmission often has debris in the ATF, the coolers, the lines, and throughout the transmission. This debris m
SERVICE:
Once a transmission is properly diagnosed to be faulty and needs to be replaced, it is important that the proper procedu
When an automatic transmission is replaced, follow VIDA to reset adaptive memory. Simply disconnecting the TCM (
On all vehicles, always flush the radiator, coolers, and lines before installing the new transmission. The guidelines and
There is a procedure for flushing coolers and lines found in a hyperlink in the VIDA transmission/gearbox installation p
The guidelines for flushing coolers on a GM 4T65 4-speed automatic are in VIDA/Information/Repair/Transmission, re
More details about these guidelines can be found below.
On a GM 4T65 (2003-2005 XC90 T6 and 1999-2005 580 6-cyl), if there is:
^
glycol in the transmission fluid (refer to RTJ 16724 for more information on checking for glycol contamination), th
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Cooler/Line
Flushing Information > Page 4621

^ Note!
metal in the transmission fluid, this would indicate an internal transmission problem. Metal in the ATF is nearly im
^ fine black sediment in the pan or on the pan magnet, this is normal. This can be flushed out according to VIDA. See
dirty oil or burnt oil, this would indicate friction component (band or clutch disc) breakdown and in order to be sure
*Note! All 2003-2005 XC90 T6 vehicles have an auxiliary automatic transmission fluid cooler.
Labor operation code 49115 should be used when the ATF cooling system is flushed, not replaced.
WARRANTY CLAIM INFORMATION

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Replacement of Compl
1. Removal
-
Remove:-
2. Installation
-
The shutter.
Install:-
- The panel.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Replacement of Compl
- Ignition off.
- Replace the bulb.

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications > Page 4631

[1]Volvo Number ............................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations
LOCATION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4636
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4637

TEMPERATURE
ARC WELDING
REPLACING
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Part and Serial N

1 Volvo P/N
3 Part design
4 Serial number

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Part and Serial N
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > Page 4641
CAUTION:
- (TCM)
NOTE:
-
2. Removing the TCM

- Ignition OFF
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID >
Page 4642

- Install new TCM.
- Ignition ON.

(AP)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Side Seal, Automatic Transaxle
Seals and Gaskets: Service and RepairDifferential Side Seal, Automatic Transaxle
Right Side
Special Tools
- Puller tool No. 999 5069, or equivalent
- Refer to special tool section for additional tool information.
Procedure
NOTE: To remove drive shaft, see steps 1 through 7 of Bevel Gear, Replacement. See: Transfer Case/Service an
1. Removing coupling sleeve
Remove circlip in coupling sleeve.Remove sleeve

Use drift tool No. 999 5656 and puller tool No. 999 5069, or equivalent.
NOTE: Ensure that the puller arms engage correctly in the groove in the sleeve.
2. Removing coupling sleeve sealing ring
Remove sealing ring from transmission Use extractor tool No. 999 5069 and drift tool No. 999 5656, or equivalen
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Side Seal, Automatic
Transaxle > Page 4647

3. Removing drive shaft sealing ring
Remove drive shaft sealing ring and coupling sleeve O-ring.Use a screwdriver.
4. Installing O-ring and sealing ring
Install a new coupling sleeve O-ring on the differential housingInstall a new drive shaft sealing ringLubricate sea
5. Installing sealing ring
Install coupling sleeve sealing ringLubricate seal with wheel bearing grease, part No. 1161241-3, or equivalent.U

6. Installing circlip and sleeve
Circlip in sleeve
Install:-
- Sleeve in transmission with the long splined section (2) toward the transmission.
Use a rubber mallet to knock in the sleeve.
NOTE: To install bevel gear and drive shaft, see steps 8 through 15 of Bevel Gear, Replacement. See: Transfer
Left Side
Special Tools:
- Lifting Beam tool No. 999 5006, or equivalent
- Lifting Hook tool No. 999 5460, or equivalent
- Disconnecting tool No. 999 5462, or equivalent
- Support tool No. 999 5563, or equivalent
1. Positioning lifting beam and lifting hook

- Position lifting beam 999 5006 directly above lifting hole in torque control arm.
Connect lifting hook 999 5460.Raise lifting hook to unload engine pads.
2. Lift up car and remove left front wheel
- Remove:
The bracket to the brake pipe and ABS line. Let bracket hang looseLink from anti-roll barControl arm/bal

Install protective socket 999 5562 on ball joint.
3. Install depressor on control arm

- Install depressor 999 5563 on control arm.
- Remove left engine mounting from transmission and sub-frame.
4. Detach drive shaft from transmission

- Use jimmy bar 999 5462 between transmission and inside of drive shaft.
- Fold out spring strut and remove drive shaft from transmission.
Let end of the drive shaft rest against subframe.
NOTE: Protect end of the drive shaft against dirt and mechanical damage.
5. Remove the seal ring

- Use a jimmy bar.
6. Install a new seal ring
- Smear some grease P/N 1161241-3, on the sealing ring lip.
- Use drift 999 5541 and bar 999 1801.
Place the side of the drift marked AW against the drive shaft seal.
- Tap in the seal ring until the drift is in contact with the transmission housing.

7. Install engine mounting to transmission and subframe
- 50 Nm (36.9 ft lb).Tighten screws to
8. Install drive shaft

- Press the drive shaft in firmly so that it locks on to the differential gear.
NOTE: Ensure that the drive shaft boot and the transmission sealing ring are not damaged
9. Remove control arm depressor

- Remove depressor 999 5563 on control arm.
- Install:
Control arm/ball joint to axle shaft.
50 Nm (36.9 ft lb)Remove socket 999 5562 from ball-joint.Use a new locknut, tighten to
Ensure that
Anti-roll barthe drive shaft lock ring sits in its locking groove. Check by pulling carefully on the drive shaf
link.
50 Nm (36.9 ft lb)Use a new locknut, tighten to
The bracket to the brake pipe and ABS line.
- Install wheel.
- Remove lifting beam and lifting hook.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Side Seal, Automatic Transaxle > Pa
Seals and Gaskets: Service and RepairPump Seal

SPECIAL TOOLS
- Extractor tool No. 999 5069, or equivalent
REMOVAL
1. Torque converter
- Pull the torque converter straight out of the transmission.
- Check the torque converter throat for damage.
2. Seal ring, oil pump-torque converter

- Use extractor Tool No. 999 5069, or equivalent.
INSTALLATION
3. New seal ring

NOTE: Drift 999 5117 modified as per Workshop Guide.

4. Torque converter
- Lubricate torque converter throat with ATF oil.
NOTE: Take care not to damage the oil pump during installation.

- Make sure torque converter is as far into the transmission as possible.
14 mm (0.55 inch).Check with a ruler.The distance between the cover and retaining tabs should be approx
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service and Repair
1. Preparations
- Remove:

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service and Repair >
Page 4657

3. Removal
4. Reinstallation
- Cars with SRS:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service and Repair >
Page 4658

- Reinstall cover
8. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
ECON MODE (ECONOMY)
SPORT MODE (SPORT)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
- Ignition off.
-
EB2 Installing
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information >

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > P

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications

Speed Sensor ..............................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 467
1. Remove:
- Battery
- ACL bracket.

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specificatio

Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................
4681


Volvo Number ..................................................................................................................................................................


1. Preparation
- Remove:
(ACL)

3. Remove:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information
> Specifications > Page 4684

4. Remove:

40 Nm.Tighten to:
- Remove sensor.

- 25 Nm.Tighten to:

9. Installation:


12. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
- Top up oil and test refer to Checking/Adjusting Oil Level. See: Testing and Inspection
13. Checking DTCs
- Check and erase DTCs. See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Dia
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Interlock: Diagram Information and Instructions

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4691

1/1 Battery

2/2 Fog lamp relay

Page 4692

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 4693

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 4694

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 4695


11A/1-9 Main fuses

Page 4696

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 4697



Page 4698

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 4699

C70 all

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4700
Shift Interlock: Electrical Diagrams
P-Shift Lock, Automatic Transmission

Wiring Diagram
Page 4701

Component Location
Component I.D. List

15/4 15I-rail
15/8 X-rail
P-Shift Lock, Automatic Transmission Function Diagram
Page 4702

Ignition on.
Gear selector locked in P-shift position.

Page 4703

Ignition on.
Stop (brake) lamp switch is closed and solenoid for P-shift lock is tripped.
Gear selector can now be moved from its P-shift position

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Diagrams > Page 4704
Shift Interlock: Description and Operation
PARK/NEUTRAL POSITION SWITCH
To avoid any chance of the gear selector inadvertently moving from the P position on the gear selector, cars in ce
Before it is possible to move the gear shift from the P (Park) position to any other gear position, the ignition must
When the ignition is switched on and the brake pedal is pressed at the same time, a solenoid (2) is activated in the
IGNITION SWITCH LOCK
In addition to this, there is a further interlock and safety function in certain markets - USA and Canada - (key inte
This means that the gear selector has to be in the Park position in order to remove the ignition key from the igniti
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Diagrams > Page 4705

SHIFT LOCK OVERRIDE
To allow the gear selector to be moved from the Park position when there is no battery voltage, or if there is a fau
For as long as the fault persists, the mechanical disconnect must be used together with the ignition key every time
There is a microswitch (6) in the electrical circuit between the stop (brake) light switch and the solenoid. The mic
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 4710

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 4711

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Shift Solenoid Inspection/Replacement

SPECIAL TOOLS:
PROCEDURE
NOTE:

3. Remove:
- Battery
- Battery shelf
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Shift Solenoid Inspection/

4. Install:
5. Remove:
- Left front wheel.
6. Oil, drain

7. Remove:

- Remove:
9. Remove:


13. Removal:
- Remove oil pipe.

14. Removal:
- Remove cover.
Use scraper.
Ensure
15. Preparation
- Remove:
Solenoid

- Solenoid S1
- Cable harness

17. Combinations
Illustration (A)
Illustration (B).
Illustration (A).

18. Solenoid SL
Illustration (C).
- Late versions
Illustration (D).
Illustration (C).

- Solenoid
10-15 STH:
- Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See: Valve Body/Servi
-
Replace complete control system as per step 2 of Control System Replacement. See: Valve Body/Service



- Install screws.
Tighten
- 10 NmTighten to:

10 NmTighten to:





12 Nm
Install oil pipe.




- Install:

50 NmTighten to:
50 NmTighten to:
30. Install:

25 NmTighten to:

32. Install:
- The front cover.

50 NmTighten to:
50 NmTighten to:

35. Install:
- Battery shelf
- Battery

38. Checking DTCs
-
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Shift Solenoid Inspection/Replacement > Page 4

SPECIAL TOOLS
1. Preparation
2. Preparation
- Remove:


- 0 ohms.Pin/Wire
Color gently
Pin No: 21
Pin No: 22
Pin No: 23
Pin No: 24
Pin No: 25


- Remove:
- Remove:





8. Install:
- Selector lever.
16 Nm.Tighten to:
10. Finishing work
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation
Shifter A/T: Description and Operation
The gear selector is mechanically connected to the transmission by a cable, which operates the gear selector valve in
A mode selector located on the gear selector makes it possible for the driver to switch between three different shiftin
ECON = Economy
SPORT = Sport
WINTER = Winter
The gear selector has 6 positions, with the following functions:
P Park position.
R Reverse.
N Neutral.
D Automatic shifting between all gears. (Not applicable when mode selector is in WINTER position).
3
In this position the 4th gear is blocked. The warning light on instrument panel lights. Automatic shifting occu
L In this position only the 1st and 2nd gears operate. The warning light on the instrument panel lights. Automatic
upshifting is inhibited. If the gear selector is moved to position L at a road speed exceeding approximately 25
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair
Selector Shaft: Service and Repair

SPECIAL TOOLS
REMOVAL
Removing Of Gear Position Sensor
1. Preparations
- Remove:
(ACL)
Battery Entire Air Cleaner Air intake manifold Battery shelf ACL bracket.
2. Removal
- Remove:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 4738

3. Replacement of control shaft seal ring.
- Use a small, rounded screwdriver to remove the old seal ring.
Take care not to damage shaft.
- Reinstall a new seal ring.
Apply ATF to the ring.Use tool No. 999 5476, or equivalent to tap the new ring into place.
INSTALLATION
Reinstallation And Adjustment Of Gear Position Sensor
4. Reinstallation
- Tighten nut.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 4739

5. Adjustment
- Adjust gear position sensor, refer to Powertrain Management.
6. Reinstallation, continue
-Install:
Dipstick pipe bracket.

Rod arm on control shaft.
16 Nm.Tighten to:
Transmission cable on rod arm with washer and lock clips.

- Install:
8. Checking DTCs
- Using
Airafilter
suitable scanBattery
bracket tool, check
shelfthat
ACL DTC's have with
complete been inlet
cleared.
pipe. Battery. Reconnect battery leads.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications
Shift Cable: Specifications

Shift Cable To Lever Assembly .................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4743
Shift Cable: Adjustments
1. Preparations
- Park car on level surface. Do not set the parking brake.
- Remove:
Air cleanerBatteryBattery tray
2. Remove:
- Locking clip and washer on rod arm
- Nuts and washers on cable bracket.
NOTE: No washers on later models.
- Transmission cable from rod arm
Transmission Cable Adjustment
3. Set gear lever to position R.
NOTE: Make sure the transmission cable can move freely in the engine compartment.
4. Push rod arm on transmission forward to position P
Do not
NOTE: - move the transmission cable.

- The transmission cable position must not be altered.
- Make sure you are in Park by trying to roll the car.

- Turn the rod arm to the next position (R).
- Apply grease part No. 1161241-3, or equivalent, sparingly to the rod arm pin.
NOTE: Do not change the position of the lever.
5. Carefully reinstall the cable on the studs and rod arm pin.
- Make sure that neither the transmission cable lever or rod arm change position!
- Secure with washers (early versions only) and nuts.
- 25 Nm.Tighten nuts in order lightly, then tighten to:
- Reinstall washers and locking clip on rod arm.
6. Check
- Lever in N position.
Push lever forward, do not touch lock button.Play should be felt.

- Lever in D position.
Push lever backward, do not touch lock button.Play should be felt.
Supplementary Work
7. Reinstall:
- Air cleaner
- Battery tray
- Battery.
- Reconnect cables.
Shift Cable: Service and Repair
1. Preparations
- Park car on level surface.
Do not set the parking brake.
- Remove:
Air cleanerBatteryBattery tray
2. Remove:
- Locking clip and washer on rod arm
- Nuts and washers on cable bracket.
NOTE: No washers on later models.
- Transmission cable from rod arm

Removal Of The Center Console
3. Remove:
- Cigar lighter panel (2 screws)
- Cover plate below parking brake lever.
- Cover plate in the center console storage box.

4. Detach connectors to center console.
- Remove screws (4) and remove the console.
5. Replacement of transmission cable

- Remove transmission cable from gear lever mechanism
- Use flat-nosed pliers to extract cotter pin on cable.
- Remove locking clip holding cable sleeve in lever mechanism.
6. Fold down carpet and remove side panel.

Remove the nuts to cable lead-in in the cowl panel.
- For cars with key interlock only:
Remove key interlock cable from transmission cable.
- Remove the cable
7. Reinstall transmission cable
NOTE:

- Be careful to avoid damaging the cable or sheath by excessive bending.
- Take care not to damage the gaiter.
- Fit cable into lever assembly.

- Reinstall:
Cable lead-in grommet in the cowl panel.
6 Nm.Tighten nuts to:
Cable sleeve into lever mechanism and lock with clip.Cable to lever with spindle
- For cars with key interlock only:
Connect the key interlock cable to the transmission cable.
- Reinstall side panel
- Fold carpet back into place.
8. Reinstall center console

- Screws (4)
- Connectors (Black, gray)
- Cover plate in the center console storage box.
- Cover plate below parking brake lever.
- Panel for cigar lighter
- Adjust and install the cable on the transmission as below.
Transmission Cable Adjustment

9. Set gear lever to position R.
NOTE: Make sure the transmission cable can move freely in the engine compartment.
10. Push rod arm on transmission forward to position P
Do not
NOTE: - move the transmission cable.
- The transmission cable position must not be altered.
- Make sure you are in Park by trying to roll the car.

- Turn the rod arm to the next position (R).
- Apply grease part No. 1161241-3, or equivalent, sparingly to the rod arm pin.
NOTE: Do not change the position of the lever.

11. Carefully reinstall the cable on the studs and rod arm pin.
- Make sure that neither the transmission cable lever or rod arm change position!
- Secure with washers (early versions only) and nuts.
- 25 Nm.Tighten nuts in order lightly, then tighten to:
- Reinstall washers and locking clip on rod arm.
12. Check
- Lever in N position.
Push lever forward, do not touch lock button.Play should be felt.

- Lever in D position.
Push lever backward, do not touch lock button.Play should be felt.
13. Supplementary work

- Reinstall:
Air cleaner Battery tray Battery.

- Reconnect cables.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Service and Repair
Throttle Valve Cable/Linkage: Service and Repair
Fig. 29 Throttle Cable Replacement
Fig. 29 Fig. 29
Fig. 29
Fig. 29
1. Remove throttle control lever (A), 2. Remove locking clip (B), , on cable tensioner.3. Unhook cable from throttle c
cable.
7. Reverse procedure to install.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 4758

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > TJ16724 > O
Contamination Information
Transmission Cooler: Customer InterestA/T - Coolant Contamination Information

Retailer Technical Journal 16724
Coolant contamination in automatic transmissions
Date: 10-8-2008
Reference: VIDA
Note!
NOTE!
THIS DOCUMENT SUPERSEDES THE PREVIOUS VERSION OF RTJ 16724 (TNN 43-48) DATED 4-18-2007
AFFECTED VEHICLES:
BACKGROUND:
The root cause for some automatic transmission failures is glycol contamination from the engine/transmission cooling s
A small leak from the cooling system into the transmission can cause driveability problems long before there are any v
SYMPTOMS OF COOLANT CONTAMINATION:
The most common symptom of coolant contamination is shudder; a high frequency vibration. ^
On AW55 transmissions, the shudder normally occurs while in torque converter slipping lock-up mode. It is most e
^ On the GM4T65 transmission, the shudder normally occurs during upshifts.
^ On all transmissions, other symptoms such as harsh shifts, slipping, flare, loss of drive, other DTCs, etc... are possib
The Volvo test kit, PN 30783360, will accurately detect even very low levels of glycol contamination in transmission o
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest:
> TJ16724 > Oct > 08 > A/T - Coolant Contamination Information > Page 4767

1. Start with a clean test tube. Wash it with a soap solution and the brush which is supplied in the kit.
Use the large pipette to put 5 ml (2 x 2.5 ml) of Volvo A (clear fluid) into the test tube.
2. Add 0.5 ml of the oil to be tested using the small pipette.
3. Add one packet of reagent B (white powder) to the test tube.

4. Screw on the cap & shake the tube until all the powder has dissolved.

5. Place the test tube in hot tap water for 5 minutes.
(A coffee cup full of tap water which has been microwaved for 2 minutes is suitable.)
6. Unscrew the cap and add one packet of reagent C (purple powder) to the test tube.

9. A clear (no color) result indicates no glycol contamination.
A purple result indicates glycol contamination.
SERVICE:
If the sample tests positive for glycol, the transmission and cooler will need to be replaced. The cooler hoses will need

In the event of needing to test for coolant contamination as part of a warranty repair, the labor and part description show
Note:
The following kit is also available as an alternative, but not via a Volvo part or tool number. It can be purchased dir
Nelco Company LLC, Glyt-Tek Test Kit1047 McKnight Rd S, Saint Paul, MN 55119Phone: 651.738.2014 Fax: 651.73
TESTING FOR GLYCOL CONTAMINATION WITH NELCO GLY-TEK KIT:
1. Let the vehicle sit for several minutes. Using a clean bottle, take a small sample of oil from the sump via the drain
2. Open one vial. Twist the cap while removing it. Do not use the one with the red cap (it is a sample already contai

3. Using a new syringe, add oil to the vial. The vial should now have about 50% oil, 50% clear liquid.
4. Cap the vial and shake it vigorously for 20 seconds.
5. Remove the cap and let the vial sit until the liquids separate.
6.
Remove the red caps from both ends of one glass tube. Note that for the remaining steps (7-12), care must be take

7.
Protect your eyes and hands from any small pieces of glass by wrapping the tube in a paper towel. While holding
8. While holding the tube horizontally, install the rubber bulb onto one end. Twist it while pushing it on.
9. While holding the tube horizontally, slowly squeeze the bulb to remove the majority of the liquid from the crysta
10. With the bulb squeezed, insert the open end of the tube into the bottom of the vial (through the oil, into the clear

11.
Slowly release the bulb to draw liquid into the tube. Stop when the liquid is just past the top felt plug and remove
12. Immediately lay the tube down flat and let it sit for exactly 15 minutes.
ANALYZING THE RESULTS:

After the tube has been laying flat for 15 minutes a brown band will have formed in the crystals above the bottom felt p
INFORMATION FOR NELCO GLY-TEK KIT

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins f
Sep > 09 > A/T - Cooler/Line Flushing Information
Transmission Cooler: All Technical Service BulletinsA/T - Cooler/Line Flushing Information

Date 09-11-2009
Note!
NOTE!
AFFECTED VEHICLES:
DESCRIPTION:
SERVICE:
^
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Cooler: > TJ19495 > Sep > 09 > A/T - Cooler/Line Flushing Information > Page 4779

^ Note!

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins f
Oct > 08 > A/T - Coolant Contamination Information
Transmission Cooler: All Technical Service BulletinsA/T - Coolant Contamination Information

Retailer Technical Journal 16724
Coolant contamination in automatic transmissions
Date: 10-8-2008
Reference: VIDA
Note!
NOTE!
THIS DOCUMENT SUPERSEDES THE PREVIOUS VERSION OF RTJ 16724 (TNN 43-48) DATED 4-18-2007
AFFECTED VEHICLES:
BACKGROUND:
The root cause for some automatic transmission failures is glycol contamination from the engine/transmission cooling s
A small leak from the cooling system into the transmission can cause driveability problems long before there are any v
SYMPTOMS OF COOLANT CONTAMINATION:
The most common symptom of coolant contamination is shudder; a high frequency vibration. ^
On AW55 transmissions, the shudder normally occurs while in torque converter slipping lock-up mode. It is most e
^ On the GM4T65 transmission, the shudder normally occurs during upshifts.
^ On all transmissions, other symptoms such as harsh shifts, slipping, flare, loss of drive, other DTCs, etc... are possib
The Volvo test kit, PN 30783360, will accurately detect even very low levels of glycol contamination in transmission o
Service Bulletins for Transmission Cooler: > TJ16724 > Oct > 08 > A/T - Coolant Contamination Information > Page 4784

1. Start with a clean test tube. Wash it with a soap solution and the brush which is supplied in the kit.
Use the large pipette to put 5 ml (2 x 2.5 ml) of Volvo A (clear fluid) into the test tube.
2. Add 0.5 ml of the oil to be tested using the small pipette.
3. Add one packet of reagent B (white powder) to the test tube.


(A coffee cup full of tap water which has been microwaved for 2 minutes is suitable.)
6. Unscrew the cap and add one packet of reagent C (purple powder) to the test tube.

9. A clear (no color) result indicates no glycol contamination.
A purple result indicates glycol contamination.
SERVICE:
If the sample tests positive for glycol, the transmission and cooler will need to be replaced. The cooler hoses will need

In the event of needing to test for coolant contamination as part of a warranty repair, the labor and part description show
Note:
The following kit is also available as an alternative, but not via a Volvo part or tool number. It can be purchased dir
Nelco Company LLC, Glyt-Tek Test Kit1047 McKnight Rd S, Saint Paul, MN 55119Phone: 651.738.2014 Fax: 651.73
TESTING FOR GLYCOL CONTAMINATION WITH NELCO GLY-TEK KIT:
1. Let the vehicle sit for several minutes. Using a clean bottle, take a small sample of oil from the sump via the drain
2. Open one vial. Twist the cap while removing it. Do not use the one with the red cap (it is a sample already contai

3. Using a new syringe, add oil to the vial. The vial should now have about 50% oil, 50% clear liquid.
4. Cap the vial and shake it vigorously for 20 seconds.
5. Remove the cap and let the vial sit until the liquids separate.
6.
Remove the red caps from both ends of one glass tube. Note that for the remaining steps (7-12), care must be take

7.
Protect your eyes and hands from any small pieces of glass by wrapping the tube in a paper towel. While holding
8. While holding the tube horizontally, install the rubber bulb onto one end. Twist it while pushing it on.
9. While holding the tube horizontally, slowly squeeze the bulb to remove the majority of the liquid from the crysta
10. With the bulb squeezed, insert the open end of the tube into the bottom of the vial (through the oil, into the clear

11.
Slowly release the bulb to draw liquid into the tube. Stop when the liquid is just past the top felt plug and remove
12. Immediately lay the tube down flat and let it sit for exactly 15 minutes.
ANALYZING THE RESULTS:

After the tube has been laying flat for 15 minutes a brown band will have formed in the crystals above the bottom felt p
INFORMATION FOR NELCO GLY-TEK KIT

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for T
> 09 > A/T - Cooler/Line Flushing Information
Transmission Cooler: All Technical Service BulletinsA/T - Cooler/Line Flushing Information

Date 09-11-2009
Note!
NOTE!
AFFECTED VEHICLES:
DESCRIPTION:
SERVICE:
^
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Cooler: > TJ19495 > Sep > 09 > A/T - Cooler/Line Flushing Information > Page 4796

^ Note!

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation
ECON MODE (ECONOMY)
SPORT MODE (SPORT)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4800
- Ignition off.
-
EB2 Installing
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4804

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications

Speed Sensor ..............................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4813
1. Remove:
- Battery
- ACL bracket.

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4814

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications

Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications >

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4820

Volvo Number ..................................................................................................................................................................


1. Preparation
- Remove:
(ACL)

3. Remove:

4. Remove:

40 Nm.Tighten to:
- Remove sensor.

- 25 Nm.Tighten to:

9. Installation:


12. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
- Top up oil and test refer to Checking/Adjusting Oil Level. See: Testing and Inspection
13. Checking DTCs
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Electrical Specifications
Valve Body: Electrical Specifications

RESISTANCE SPECIFICATIONS

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Electrical Specifications > Page 4829
Valve Body: Mechanical Specifications

Control System To Transmission ...............................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Open The Control System
Valve Body: Service and RepairOpen The Control System

SPECIAL TOOLS:
PROCEDURE
NOTE:

3. Remove:
- Battery
- Battery shelf
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Open The Control System > Page
4832

4. Install:
5. Remove:
- Left front wheel.
6. Oil, drain

7. Remove:
4833

- Remove:
9. Remove:
4834


13. Removal:
- Remove oil pipe.
4835

14. Removal:
- Remove cover.
Use scraper.
Ensure
15. Preparation
- Remove:
Solenoid
4836

- Solenoid S1
Solenoid SL is in two variants:
- Cable harness

17. Combinations
Illustration (A)
Illustration (B).
Illustration (A).
4837

18. Solenoid SL
Illustration (C).
- Late versions
Illustration (D).
Illustration (C).

- Solenoid
10-15 STH:
- Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See:
-
Replace complete control system as per step 2 of Control System Replacement. See: (Solenoid STH is cal
4838



- Install screws.
Tighten
- 10 NmTighten to:

10 NmTighten to:
4839




4840

12 Nm
Install oil pipe.

4841



- Install:

50 NmTighten to:
50 NmTighten to:
30. Install:
- 18 Nm +90Tighten early version with 8 mm screw to:

25 NmTighten to:
4842

32. Install:
- The front cover.
4843

50 NmTighten to:
50 NmTighten to:

35. Install:
- Battery shelf
- Battery
4844

38. Checking DTCs
-
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Open The Control System > Page 4845
Valve Body: Service and RepairControl System Replacement

SPECIAL TOOLS
1. Preparation
- Refer to steps 1 through 14 of Open The Control System. See:
2. Removal of control system

- Remove control system from transmission.
- Detach cable harness and connector from solenoids.
- Remove seven screws and two in cover.
- Remove seals (two) between control system and transmission (see illustration).
3. Finishing work
Refer to steps 22 through 38 of Open The Control System. See:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Open The Control System > Page 4846
Valve Body: Service and RepairSolenoid Wire Harness Inspection/Replacement

SPECIAL TOOLS
1. Preparation
- Refer to steps 1 through 14 of Open The Control System. See:
2. Preparation
- Remove:


- 0 ohms.Pin/Wire
Color gently
Pin No: 21
Pin No: 22
Pin No: 23
Pin No: 24
Pin No: 25
4847


- Remove:
- Remove:

4848


See steps 16 through 18 of Shift Solenoid Inspection/Replacement for late version. See: Actuators and Sol

4849

8. Install:
- Selector lever.
16 Nm.Tighten to:
10. Finishing work
Refer to steps 22 through 38 of Open The Control System. See:
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications

Use hydraulic fluid quality ...................................................................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications
Clutch Master Cylinder: Specifications
Clutch Master Cylinder ..............................................................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4858
Clutch Master Cylinder: Service and Repair
1. Remove:
- (ACL)Air Cleaner and intake pipe.
Screws
Timing holding
valve bracket(Turbo
from ACL. to ACL.
models only).-
- Cable tie to drain hose (move to one side).
2. Disconnect hose from brake fluid reservoir.

- Put absorbent paper under clutch master cylinder to protect paintwork.
- Collect brake fluid from reservoir and hose in a suitable container.
Disconnect
Disconnect pipesnap-on coupling
from clutch locks.
master cylinder.Late models (left hand drive) only:-
- Disconnect pipe from clutch master cylinder.
3. Remove clutch master cylinder

- Remove panel under dashboard.
Cars with SRS: Remove kneeguard also.
- Fold back carpet.
- Remove clip holding clutch master cylinder pushrod to clutch pedal.
- Remove nut and bolt securing clutch master cylinder to firewall.
- Remove clutch master cylinder.
4. Install new clutch master cylinder
- Transfer brake fluid supply hose to the new clutch master cylinder.
- Apply a little silicone grease to the clutch master cylinder pushrod lug.
- Install clutch master cylinder, nut and bolt.
25 Nm.Tighten to:
-
Install clip holding pushrod to clutch pedal.Cars with SRS: Install kneeguard.
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4859

20 Nm.Tighten to:
- Install panel under dashboard.
- Relay carpet.
5. Install:
- Clutch master cylinder pipe.
NOTE: Snap-on coupling pipes: fit new O-ring.
- Brake fluid reservoir hose.

- Drain hose and cable tie.
6. Fill up with fresh brake fluid and bleed system via clutch master cylinder bleed nipple.
NOTE: Use only genuine Volvo brake fluid, DOT+.
7. Install:
- Bracket retaining screws to ACL.
- ACL and intake pipe.
- Timing valve to ACL. (Turbo models only.)
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins
> Mar > 99 > Campaign - Decrease In Clutch Efficiency
Campaign - Decrease In Clutch Efficiency
Section4
Group41
No.0006
Year99
Month03
S70/V70/C70MY 1998 (partial)
Campaign No. 92 Clutch control cylinder
Background:
Some vehicles may experience a decrease in clutch efficiency, which could result in difficulty when changing gears. To
Parts:
Clutch control cylinder adapter kit 1 9181729
(contains quick coupling, seal andassembly fluid).
Brake fluid DOT4+ 1 1381183
Special Tools:
Hexagon socket 1 9512798
Fuel line removal tool 1 9995666

(see Special Tool Bulletin 100-A)
Procedure
Disconnect and remove
Remove:
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Clutch Slave Cylinder: > 4410006 > Mar > 99 > Campaign - Decrease In Clutch Efficiency > Page 4868

- battery,
- battery shelf.
Remove
Remove inlet hose (A).Turbo engines:Remove upper hose clamp and bend back charge air hose and charge air pipe (B)
Bleed hydraulic circuit
Place paper under the adapter to collect any brake fluid spillage.
Remove the protective cap from the bleeder nipple.Connect the collecting bottle hose (1).Open the nipple approximatel
Note:
Take care not to damage wiring harness (not pictured).
Remove
Turn the adapter so the lock clip is accessible.

Remove:
- the lock clip

- the elbow adapter.
Note:
Place a rag or paper under the adapter to avoid brake fluid spillage.
Remove
Remove and dispose of the quick coupling and seal.Use tool 999 5666.
Check to make sure the seal is not stuck in the adapter.
Remove
Remove the rubber boot.
Torque fitting

Torque clutch control cylinder fitting to 45 Nm (33 lb ft). Use hexagon socket 9512798 and a 16 mm (5/8") sleeve over
Install
- rubber boot for clutch fork.
Install
- the quick coupling on the fitting.
- new seal for quick coupling. Use assembly fluid.
Quick coupling, seal and assembly fluid are included in adapter kit p/n 9181729.
Install

- part-way: the elbow adapter to quick coupling lock clip (1).
- slide the elbow adapter on the quick coupling.
- push the lock clip on the rest of the way.
Turn the adapter so the bleeder nipple is upright.
Install and bleed system
- the hydraulic line on the elbow adapter.

- the lock clip on the adapter (2).
Connect the collecting bottle hose to the bleeder nipple (3).Pull up the clutch pedal from end position.Bleed the clutch
Install
- the battery shelf,
- the battery,
- the charge air pipe and hose (B) on turbo engines,
- the inlet hose (A)

Test drive car
Test drive the car to verify clutch operation is normal.
NOTE:
Test drive should be performed in compliance with all traffic regulations and posted speed limits.
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Recalls for Clutch Slave Cylind
- Decrease In Clutch Efficiency
Campaign - Decrease In Clutch Efficiency
Section4
Group41
No.0006
Year99
Month03
S70/V70/C70MY 1998 (partial)
Campaign No. 92 Clutch control cylinder
Background:
Some vehicles may experience a decrease in clutch efficiency, which could result in difficulty when changing gears. To
Parts:
Clutch control cylinder adapter kit 1 9181729
(contains quick coupling, seal andassembly fluid).
Brake fluid DOT4+ 1 1381183
Special Tools:
Hexagon socket 1 9512798
Fuel line removal tool 1 9995666

(see Special Tool Bulletin 100-A)
Procedure
Disconnect and remove
Remove:
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Recalls for
Clutch Slave Cylinder: > 4410006 > Mar > 99 > Campaign - Decrease In Clutch Efficiency > Page 4878

- battery,
- battery shelf.
Remove
Remove inlet hose (A).Turbo engines:Remove upper hose clamp and bend back charge air hose and charge air pipe (B)
Bleed hydraulic circuit
Place paper under the adapter to collect any brake fluid spillage.
Remove the protective cap from the bleeder nipple.Connect the collecting bottle hose (1).Open the nipple approximatel
Note:
Take care not to damage wiring harness (not pictured).
Remove
Turn the adapter so the lock clip is accessible.

Remove:
- the lock clip

- the elbow adapter.
Note:
Place a rag or paper under the adapter to avoid brake fluid spillage.
Remove
Remove and dispose of the quick coupling and seal.Use tool 999 5666.
Check to make sure the seal is not stuck in the adapter.
Remove
Remove the rubber boot.
Torque fitting

Torque clutch control cylinder fitting to 45 Nm (33 lb ft). Use hexagon socket 9512798 and a 16 mm (5/8") sleeve over
Install
- rubber boot for clutch fork.
Install
- the quick coupling on the fitting.
- new seal for quick coupling. Use assembly fluid.
Quick coupling, seal and assembly fluid are included in adapter kit p/n 9181729.
Install

- part-way: the elbow adapter to quick coupling lock clip (1).
- slide the elbow adapter on the quick coupling.
- push the lock clip on the rest of the way.
Turn the adapter so the bleeder nipple is upright.
Install and bleed system
- the hydraulic line on the elbow adapter.

- the lock clip on the adapter (2).
Connect the collecting bottle hose to the bleeder nipple (3).Pull up the clutch pedal from end position.Bleed the clutch
Install
- the battery shelf,
- the battery,
- the charge air pipe and hose (B) on turbo engines,
- the inlet hose (A)

Test drive car
Test drive the car to verify clutch operation is normal.
NOTE:
Test drive should be performed in compliance with all traffic regulations and posted speed limits.
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Clutch Pedal - Revised Auxiliary Spring
Clutch Pedal Assembly: Technical Service BulletinsClutch Pedal - Revised Auxiliary Spring
Section
4
Group
41
No.0004
Year
99
Month
07
S70/V70/C701998
Vehicles involved: Manual gearbox. Engine: B5234T
Clutch pedal, auxiliary spring
Background:
This Service Bulletin describes how to replace the existing, linear auxiliary spring with a progressive auxiliary spring.
This spring will provide smoother engagement of the clutch.
Material:
Progressive auxiliary spring 1 9480516-5

High pressure grease 1 1161246-2
Clutch pedal, replacing auxiliary spring
Removal of sound insulation

Remove sound insulation, 1 screw, Torx 20.
Replacement of spring
Caution!
Auxiliary spring is under pressure, use caution when removing/installing spring.
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Clutch Pedal - Revised Auxiliary Spring >
Page 4887

Warning!
Ensure to use eye protection.
Depress the clutch pedal.
Remove the spring assembly by pushing the upper guide socket down and turning it backwards.
Grease:
- contact surfaces between spring and spring seat

- guide for upper spring seat
- rod for lower spring seat
Use high pressure grease, part number 1161246-2.
Assemble the rod, seat and the new spring, as per illustration, part number 9480516-5, to the guide/rod.
Install the lower mount/rod to the clutch pedal. Depress clutch pedal and reinstall spring assembly to pedal.
Ensure operation of the clutch pedal and that no sound is heard when pedal is depressed.
Installing sound insulation

Install the sound insulation.
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Clutch Pedal - Revised Auxiliary Spring >
Page 4888

41904-2 Replacing clutch pedal auxiliary spring 0.1 hr
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Page 4889
Clutch Pedal Assembly: Service and Repair
1. Release clutch pedal

-
Remove panel under dashboard.Cars with SRS: Remove kneeguard also.
- Fold carpet back.
- Remove clip holding clutch master cylinder pushrod to clutch pedal.
2. Lift off pushrod from clutch pedal.
NOTE: Hold pedal down to prevent it pushing up against the cruise control contact if fitted.
- Now push clutch pedal down towards floor.

- Lift assist spring off of clutch pedal.
3. Remove pedal from pedal assembly.

- Remove clip, then pedal.
Grease
Check bushings
clutch with grease
pedal bushings. - 1161241-3.
- Install bushings on clutch pedal.
4. Fining new clutch pedal to pedal assembly.

- Install a new clip on the pedal spindle.
- Push pedal down and fit spring to pedal.
NOTE: Hold pedal down to prevent it pushing upwards against cruise control contact (if fitted).
5. Install:
- Clip holding clutch master cylinder pushrod to clutch pedal.
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Page 4890

Cars with SRS: Install kneeguard.
20 Nm.Tighten to:
- Panel below dashboard.
Put carpet back.
> Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications
Pressure Plate: Specifications
Clutch To Flywheel ....................................................................................................................................................
NOTE: First tighten carefully in rotation so clutch moves forward into locating pin and rests evenly against flyw
> Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair
Carrier Bearings: Service and Repair

NOTE: Special tools: 999 5566, 999 5661
Install Final Drive In Fixture

- Use fixture 999 5661,
> Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Page 4899

Mark Up Bearing Cap/housing
NOTE:
When disassembling; Mark up the differential bearing caps and the housing. Use a punch or power engraving too

Removing/installing Differential
- 0.35 mm (0.0137")The final drive housing can be expanded a maximum of .
- Use expander 999 5566. Install with two of the cover screws. Do not tighten.
- 0.25 - 0.35 (0.0098"-0.0137")Lightly tighten the screw, then tighten a maximum of 1 turn, this corresponds to .

Checking Runout
- Check flange axial runout.
NOTE: This check must always be carried out when replacing pinion seal/drive flange or when reconditioning th
- Install dial gauge with magnetic holder to fixture 999 5661

- 0.05 mm (0.0019")Axial runout must not exceed . If axial runout exceeds this value move the flange on the pinio
NOTE: Use a new nut every time.
NOTE: 200 Nm (147.6 ft.lb.) Do not exceed a tightening torque of . Check axial runout again.
-
Mark up the lowest point (where axial runout is greatest) on the edge of the flange. Use a colored pen. This mark
NOTE:
For Drive flange replacement refer to Drive/Propeller shaft section on balancing procedure. See: Drive/Propelle
> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > TNN46-08 >
From Angle Vent
Differential Case: Customer InterestDrivetrain - Oil Leak From Angle Vent

NO: 46-08
DATE: 3-10-2004
MODEL: All 5 Cylinder AWD Cars - V70 AWD XC, XC70, XC90, S60, V70, S80
M.YEAR: 1997-2004
SUBJECT: Oil Weepage from Angle Gear Vent
NOTE:
This TNN supercedes service bulletin 46-008 dated 4-9-2002. 46-008 has been deleted from VEN / VRC2. Please u
DESCRIPTION:
If oil weepage is found at the Angle Gear Vent, a new vent valve should be installed.
PARTS:
^ Filter, PN 30681138 (Quantity 1)

^ Brass Pipe, PN 8689527 (Quantity 1)
^ Metal Adhesive / Loctite 638, PN 1161722 (Quantity 0.1)
^ Gear Oil, PN 1161648 (Quantity 1)
SERVICE:
^ Remove the Angle Gear according to VADIS.

^ Remove the level plug and pour out the oil.
^ Pull out the brass vent pipe using cutting pliers.
^ Apply a small amount of metal adhesive to the outside of the new brass pipe.
^ Tap the pipe in, using a plastic hammer or rubber mallet. Install the filter on the pipe.
^ Position the angle gear so that it is standing as it would in the vehicle.

^
Fill the unit until the oil is level with the hole, then drain 0.1 Liters of oil. Install the level plug. Tighten to 35 Nm. I
> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case:
> TNN46-08 > Mar > 04 > Drivetrain - Oil Leak From Angle Vent > Page 4910

> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: >
Oil Leak From Angle Vent
Differential Case: All Technical Service BulletinsDrivetrain - Oil Leak From Angle Vent
NO: 46-08
DATE: 3-10-2004
MODEL: All 5 Cylinder AWD Cars - V70 AWD XC, XC70, XC90, S60, V70, S80
M.YEAR: 1997-2004
SUBJECT: Oil Weepage from Angle Gear Vent
NOTE:
This TNN supercedes service bulletin 46-008 dated 4-9-2002. 46-008 has been deleted from VEN / VRC2. Please u
DESCRIPTION:
If oil weepage is found at the Angle Gear Vent, a new vent valve should be installed.
PARTS:
^ Filter, PN 30681138 (Quantity 1)

^ Brass Pipe, PN 8689527 (Quantity 1)
^ Metal Adhesive / Loctite 638, PN 1161722 (Quantity 0.1)
^ Gear Oil, PN 1161648 (Quantity 1)
SERVICE:
^ Remove the Angle Gear according to VADIS.

^ Remove the level plug and pour out the oil.
^ Pull out the brass vent pipe using cutting pliers.
^ Apply a small amount of metal adhesive to the outside of the new brass pipe.
^ Tap the pipe in, using a plastic hammer or rubber mallet. Install the filter on the pipe.
^ Position the angle gear so that it is standing as it would in the vehicle.

^
Fill the unit until the oil is level with the hole, then drain 0.1 Liters of oil. Install the level plug. Tighten to 35 Nm. I
> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Differential Case: > TNN46-08 > Mar > 04 > Drivetrain - Oil Leak From Angle Vent > Page 4916

> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - Differential: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants
And Fluids > Page 4921

AFFECTED VEHICLES
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > P
Fluid - Differential: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid
Capacity ...............................................................................................................................................................................
Differential Fluid
Capacity ...............................................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4925
Fluid - Differential: Fluid Type Specifications
Differential Fluid
Type .....................................................................................................................................................................................
Differential Fluid
Type .....................................................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Component Information > Service and Repair
Output Shaft: Service and Repair

NOTE: Special tools: 999 5045, 999 5540, 999 5564, 999 5659, 999 5660
Removing Drive Shaft
Raise The Car
NOTE:
Follow instructions on positioning lift arms carefully according to Towing, changing wheels and rolling road/wheel sp
Remove:
- wheel
- ABS sensor. Tape sensor to track rod.
NOTE: Do not disconnect connector.
- Drive shaft nut, use a counterhold. 999 5540.

> Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Component Information > Service and Repair > Page 4929

Removing Brake Components
Remove:
- counterhold
- brake caliper, hang it up by a wire to avoid stretching the brake hose
- parking brake cable mountings

Removing Suspension Components
Remove:
- track rod-wheel bearing housing screw
- track rod from wheel bearing housing
- wheel bearing housing-lower control arm nut
- screw (tap out screw with a copper mallet).

Disconnecting Bushing Lug From Wheel Bearing Housing
- Remove upper control arm/wheel bearing housing nut.
- Tap bushing lug off the stub axle.
- Use a copper mallet.

Removing Wheel Bearing Housing
- Remove upper control arm bushing nut.
- Unhook wheel bearing housing from control arm and drive shaft. Hang up bearing housing in anti-roll bar.
- Use hook 999 5045.
NOTE: Take care not to bend parking brake cable or damage its sleeve.

- Remove drive shaft from final drive.
-
Lever or knock in a screwdriver between CV joint housing and final drive to release the snap ring. Remove drive

Replacing Drive Shaft Seal
- Remove seal.
- Use a jimmy bar.
- Check that no seal residue is left in the final drive.

Install New Seal
- Lubricate seal with wheel bearing grease, P/N 1161241-3.
- Press in seal with drift 999 5564.
- Tap in seal until drift bottoms on its stop in final drive
- housing.

Installing Drive Shaft
- Install drive shaft in final drive.
- Take care not to damage the seal.
- Press in drive shaft firmly so that the snap ring engages in its groove. Check by carefully pulling inner CV joint.

Installing Wheel Bearing Housing
- Align wheel bearing housing with drive shaft and upper control arm bushing.
- Install a new locknut loosely.

Installing Control Arm And Track Rod
- Press lower control arm up into normal position.
- See Use tensioner 999 5659.
-
Align wheel bearing housing with lower control arm bushing. Install screw with a new locknut. Hook track rod o
Tighten:
- 115 Nm (84.8 ft.lb.)upper control arm nut to
- 80 Nm (59.0 ft.lb.)lower control arm nut to
- 80 Nm (59.0 ft.lb.)track rod screw to
- Remove tools.

Installing Brake Components
Install:
- 60 Nm (44 ft.lb.)brake caliper. Use new screws. Tighten to
- 10 Nm (7.4 ft.lb.)ABS sensor. Lubricate mounting hole first. Tighten to
- parking brake cable clamps
- counterhold 999 5540. Lubricate drive shaft nut
- 120 Nm (88.5 ft.lb.)new drive shaft nut. Tighten to , angle-tighten to 600.
- Remove counterhold.
- Check oil level in final drive. Top up if necessary. P/N oil, 1161329-6.
- Install wheel according to Tightening wheel studs page 11.
> Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Differential Side Seal
Seals and Gaskets: Service and RepairDifferential Side Seal

Raise The Car
NOTE: Follow instructions on positioning lift arms carefully according to Towing, changing wheels and rolling road/
Remove:
- wheel
- ABS sensor. Tape sensor to track rod.
NOTE: Do not disconnect connector.
- Drive shaft nut, use a counterhold. 999 5540.

> Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Differential Side Seal > Page 4944

Removing Brake Components
Remove:
- counterhold
- brake caliper, hang it up by a wire to avoid stretching the brake hose
- parking brake cable mountings

Removing Suspension Components
Remove:
- track rod-wheel bearing housing screw
- track rod from wheel bearing housing
- wheel bearing housing-lower control arm nut
- screw (tap out screw with a copper mallet).

Disconnecting Bushing Lug From Wheel Bearing Housing
- Remove upper control arm/wheel bearing housing nut.
- Tap bushing lug off the stub axle.
- Use a copper mallet.

Removing Wheel Bearing Housing
- Remove upper control arm bushing nut.
- Unhook wheel bearing housing from control arm and drive shaft. Hang up bearing housing in anti-roll bar.
- Use hook 999 5045.
NOTE: Take care not to bend parking brake cable or damage its sleeve.

- Remove drive shaft from final drive.
-
Lever or knock in a screwdriver between CV joint housing and final drive to release the snap ring. Remove drive

Replacing Drive Shaft Seal
- Remove seal.
- Use a jimmy bar.
- Check that no seal residue is left in the final drive.

Install New Seal
- Press in seal with drift 999 5564.
- Tap in seal until drift bottoms on its stop in final drive
- housing.

Installing Drive Shaft
- Install drive shaft in final drive.
- Take care not to damage the seal.
- Press in drive shaft firmly so that the snap ring engages in its groove. Check by carefully pulling inner CV joint.

Installing Wheel Bearing Housing
- Align wheel bearing housing with drive shaft and upper control arm bushing.
- Install a new locknut loosely.

Installing Control Arm And Track Rod
- Press lower control arm up into normal position.
- See Use tensioner 999 5659.
-
Align wheel bearing housing with lower control arm bushing. Install screw with a new locknut. Hook track rod o
Tighten:
- 115 Nm (84.8 ft.lb.)upper control arm nut to
- 80 Nm (59.0 ft.lb.)lower control arm nut to
- 80 Nm (59.0 ft.lb.)track rod screw to
- Remove tools.

Installing Brake Components
Install:
- 60 Nm (44 ft.lb.)brake caliper. Use new screws. Tighten to
- 10 Nm (7.4 ft.lb.)ABS sensor. Lubricate mounting hole first. Tighten to
- parking brake cable clamps
- counterhold 999 5540. Lubricate drive shaft nut
- 120 Nm (88.5 ft.lb.)new drive shaft nut. Tighten to , angle-tighten to 600.
- Remove counterhold.
- Check oil level in final drive. Top up if necessary. P/N oil, 1161329-6.
- Install wheel according to Tightening wheel studs page 11.
Seals and Gaskets: Service and RepairPinion Seal
1. Mark position of propeller shaft drive flange in relation to rear axle drive flange
propeller shaft. Use socket 5244 for ordinary joint. Use counterhold 5426 for CV joint.
Remove:-
- drive flange retaining nut. Always use counterhold 5149 for ordinary joint and 5426 for CV joint.
- one bolt in weight
2. Mark position of drive flange in relation to pinion using light punch marks
3. Place container underneath axle to collect oil and drain oil.
4. Use puller 5304 and withdraw drive flange.

5. Use puller 5069 and withdraw seal.

6. Install new seal Lubricate seal. Use drift 2806.
7. Press on drive flange Use press tool 5156.
NOTE: Install flange as marked during removal.
180-200 Nm (133-148 ft. lbs.)8. Tighten drive flange to .
Use new, oiled nut.No axial clearance is permissible.
NOTE: 200 Nm must not be exceeded, otherwise pinion bearing may be overtightened, resulting in bearing fail
Check runout.
0.05 mm 0.0020 inch 0.08 mm 0.0031 inch () [ () for CV joint]
Install bolt in weight.

9. Install
50 Nmpropeller shaft as per marking
37 ft. lbs.
8 Nm (6 ft. lbs.)
30 5 Nm (22 4 ft. lbs.)
Use socket 5244 for ordinary propeller shaft. Use new bolts and nuts. Tighten alternately to ().Use counterhold 5
10. Fill final drive with oil of correct specification.
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > Customer Interest for Viscous Coupling:
Coupling - Rotating Sound
Viscous Coupling: Customer InterestViscous Coupling - Rotating Sound
BULLETIN NUMBER:4460004
DATE:February 1, 2000
MODELS:1998-1999 S70/V70 AWD, XC
TITLE:Viscous coupling housing/viscous coupling, rotating sound
SECTION4
GROUP46
NO.0004
YEAR00
MONTH02
BACKGROUND
A rotating sound may be heard from the viscous coupling/housing on some AWD/XC vehicles. The sound occurs most
This sound can be caused by movement of the outer bearing race in the torque tube housing. This service bulletin descr
AFFECTED VEHICLES
MATERIALS
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > Customer Interest for
Viscous Coupling: > 4460004 > Feb > 00 > Viscous Coupling - Rotating Sound > Page 4965

TOOLS
ROTATING SOUND FROM VISCOUS COUPLING HOUSING/VISCOUS COUPLING
Replacing the bearing, cleaning and bonding
To replace the bearing, see VADIS: Section 4, Removing, replacing and installing, 43 Gearbox,
Clean the mating surface of the bearing (viscous coupling housing side). Clean the corresponding surface in the viscous
Apply metal adhesive P/N 1161370 to the mating surface of the bearing (viscous coupling housing side) and to the corr
Caution! Allow 6 hours for the metal adhesive to cure properly and to reach maximum strength before delivering vehi
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > Customer Interest for Viscous Coupling:
Final Drive - Whining Noise
Viscous Coupling: Customer InterestRear Axle/Final Drive - Whining Noise
TITLE:Rear axle/final drive, whining noise
MODELS:All Wheel Drive (AWD) 1997-2000 850/S70/V70/V70 XC
SECTION4
GROUP46
NO.0001
YEAR00
MONTH02
REFERENCE:
This Service Bulletin replaces the previous Service Bulletin 46-0001 from January 2000, which should be discarded.
BACKGROUND
A whining noise may be heard from the rear axle (final drive) between 80 and 95 km/h (50-60 mph) on some AWD and
This Service Bulletin describes how to install a new type of counterweight on the viscous coupling housing mounting o
VEHICLES INVOLVED
MATERIALS
TOOLS:Drill
WHINING SOUND FROM REAR AXLE/FINAL DRIVE:
Viscous Coupling: > 4460001 > Feb > 00 > Rear Axle/Final Drive - Whining Noise > Page 4970

Preparations
Raise the car.
The vibration damper must be installed on the viscous coupling housing mounting on the underbody.
Removing the viscous coupling housing
Install a transmission jack as a support under the viscous coupling housing.
Remove the bolt for the viscous coupling housing mounting (see the illustration).
Lower the viscous coupling housing and propeller shaft. Clean any dirt and under-body sealant from the mounting.
Use Cleaner H, P/N 1161436-9.
3
Drilling holes
Drill a 4.5 mm (11/64") hole.
Note! Shorten the drill bit to approximately 12-15 mm (1/2") to obtain the correct angle for drilling.
Viscous Coupling: > 4460001 > Feb > 00 > Rear Axle/Final Drive - Whining Noise > Page 4971

Note! Refer to the illustration, and mark mount accordingly, to ensure correct center location for drilling.
Move the drill up.
Support the drill against the propeller shaft and the heat deflector plate.
Align the drill with the center of the mounting.
Drill.
Installing the counterweight
Remove the backing from the counterweight.
Press the counterweight into place on the mounting.
Install the screw.
Caution! Make sure the counterweight is positioned so it doesn't interfere with any other parts of the undercarriage.
Installing the viscous coupling housing

Lift up the viscous coupling housing using the jack.
Install a new bolt screw.
Tighten to 85 Nm (63 lb.ft).
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Visco
Viscous Coupling - Rotating Sound
Viscous Coupling: All Technical Service BulletinsViscous Coupling - Rotating Sound
MODELS:1998-1999 S70/V70 AWD, XC
TITLE:Viscous coupling housing/viscous coupling, rotating sound
SECTION4
GROUP46
NO.0004
YEAR00
MONTH02
BACKGROUND
A rotating sound may be heard from the viscous coupling/housing on some AWD/XC vehicles. The sound occurs most
This sound can be caused by movement of the outer bearing race in the torque tube housing. This service bulletin descr
AFFECTED VEHICLES
MATERIALS
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Viscous Coupling: > 4460004 > Feb > 00 > Viscous Coupling - Rotating Sound > Page 4977

TOOLS
ROTATING SOUND FROM VISCOUS COUPLING HOUSING/VISCOUS COUPLING
Replacing the bearing, cleaning and bonding
To replace the bearing, see VADIS: Section 4, Removing, replacing and installing, 43 Gearbox,
Clean the mating surface of the bearing (viscous coupling housing side). Clean the corresponding surface in the viscous
Apply metal adhesive P/N 1161370 to the mating surface of the bearing (viscous coupling housing side) and to the corr
Caution! Allow 6 hours for the metal adhesive to cure properly and to reach maximum strength before delivering vehi
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Visco
Rear Axle/Final Drive - Whining Noise
Viscous Coupling: All Technical Service BulletinsRear Axle/Final Drive - Whining Noise
TITLE:Rear axle/final drive, whining noise
MODELS:All Wheel Drive (AWD) 1997-2000 850/S70/V70/V70 XC
SECTION4
GROUP46
NO.0001
YEAR00
MONTH02
REFERENCE:
This Service Bulletin replaces the previous Service Bulletin 46-0001 from January 2000, which should be discarded.
BACKGROUND
A whining noise may be heard from the rear axle (final drive) between 80 and 95 km/h (50-60 mph) on some AWD and
This Service Bulletin describes how to install a new type of counterweight on the viscous coupling housing mounting o
VEHICLES INVOLVED
MATERIALS
TOOLS:Drill
WHINING SOUND FROM REAR AXLE/FINAL DRIVE:
Bulletins for Viscous Coupling: > 4460001 > Feb > 00 > Rear Axle/Final Drive - Whining Noise > Page 4982

Preparations
Raise the car.
The vibration damper must be installed on the viscous coupling housing mounting on the underbody.
Removing the viscous coupling housing
Install a transmission jack as a support under the viscous coupling housing.
Remove the bolt for the viscous coupling housing mounting (see the illustration).
Lower the viscous coupling housing and propeller shaft. Clean any dirt and under-body sealant from the mounting.
Use Cleaner H, P/N 1161436-9.
3
Drilling holes
Drill a 4.5 mm (11/64") hole.
Note! Shorten the drill bit to approximately 12-15 mm (1/2") to obtain the correct angle for drilling.
Bulletins for Viscous Coupling: > 4460001 > Feb > 00 > Rear Axle/Final Drive - Whining Noise > Page 4983

Note! Refer to the illustration, and mark mount accordingly, to ensure correct center location for drilling.
Move the drill up.
Support the drill against the propeller shaft and the heat deflector plate.
Align the drill with the center of the mounting.
Drill.
Installing the counterweight
Remove the backing from the counterweight.
Press the counterweight into place on the mounting.
Install the screw.
Caution! Make sure the counterweight is positioned so it doesn't interfere with any other parts of the undercarriage.
Installing the viscous coupling housing

Lift up the viscous coupling housing using the jack.
Install a new bolt screw.
Tighten to 85 Nm (63 lb.ft).
> Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Technical Service Bulletins > Page 4984
Viscous Coupling: Service and Repair

NOTE: Check that the parking brake is not set and that no gear is engaged.
NOTE: Special tools: 999 5972, 999 5010, 999 5089, 999 5212, 999 5304, 999 5504, 999 5561, 999 5652, 999 5653,
Removing Torque Tube
Raise The Car
Removing propeller shaft
NOTE:
Follow instructions on positioning lift arms carefully according to Towing, changing wheels and rolling road/wheel sp
Mark Propeller Shaft CV Joint In Relation To Viscous Coupling Flange.
NOTE:
Carefully note the length and position of screws on the propeller shaft CV joint. The propeller shaft may have been ba
- Remove propeller shaft screws. Use counterhold 9995561
- Move propeller shaft to one side and support

- Position a mobile jack, 998 5972, lightly under the torque tube
- Remove the screw holding torque tube to car body.
- Lower the torque tube so that the final drive housing is resting on the lower section of the rear axle member.
- Remove mobile jack

Marking Flange
- Mark flange in relation to the end of the viscous coupling shaft.
- Remove drive flange. Use counterhold 999 5652. Pull the flange off the shaft.
- Use a separator if the flange is stuck 999 5304.

- Remove four screws holding torque tube to final drive. Pull off torque tube, turning it to release it from the fuel ta
- Keep the washer from the viscous coupling shaft.
- If the bearing in the torque tube is not being replaced, continue with removing viscous coupling.
- Replacing bearing in torque tube.

Pressing Out Bearing
- Use drift 999 5010 as a support for torque tube and press tool 999 5212.

Pressing In Bearing
- Use drift 999 5858. Press in bearing to its stop in torque tube.
NOTE: For installation of torque tube, continue with installing viscous coupling.
Replacing Rear Pinion Seal And Viscous Coupling


Removing Viscous Coupling
- Remove viscous coupling from final drive Mark the position of the viscous coupling flange in relation to the fina
NOTE: If replacing the viscous coupling it is not necessary to mark up the flange.
-
If replacing just the viscous coupling, continue with Measuring flange, viscous coupling and Balancing procedure
- Then continue with installing torque tube.

Marking Flange
- Mark flange in relation to the end of the pinion
- Remove flange nut. Use counterhold 999 5652.

Removing Flange
- Use a separator if it is stuck 999 5304.
- Put a container under the car to collect oil draining from the final drive.
Checking Flange
- Check flange seal face carefully. Replace flange if necessary.

Removing Pinion Seal
- Use separator 999 5069.

Check
- Check that no seal residue remains.

Installing Seal
- Lubricate sealing ring lip with Volvo wheel bearing grease P/N 1161241-3.
- Install seal on drift 999 5653 (on the side of the tool marked 1031-1165).
- Press seal into its seating. Use press tool 999 5504.

Installing Flange To Pinion
Install Drive Flange

- If reinstalling the old flange, install according to markings.
- Use press tool 999 5504. Use a new, lubricated nut. There must be no axial play.
NOTE:
If installing a new flange, measure according to Measuring flange, viscous coupling and Balancing procedure. R
- 180-200 Nm (132.8-147.6 ft.lb.)Tighten to . Use counterhold 999 5652.
NOTE: 200 Nm (147.5 ft.lb.) Do not exceed a tightening torque of . The forces on the pinion bearing may beco
- If reinstalling the old flange, continue with installing viscous coupling.


Installing Viscous Coupling
- Check that the flange and viscous coupling mating surfaces are absolutely clean.
- Align viscous coupling as marked.
- 50 Nm (37 ft.lb.Use new screws. Tighten crosswise in stages until the viscous coupling flange is in full contact. T
- If reinstalling the old viscous coupling, continue with installing torque tube.
NOTE
; If installing a new viscous coupling, measure according to Measuring flange, viscous coupling and Balancing pr

Installing Torque Tube
- 50 Nm (37 ft.lb.)Install torque tube. Lightly tighten the four screws crosswise, then tighten to
NOTE:
Check that the mating faces on the final drive housing and torque tube are clean and that the washer is in place o

Installing Flange To Viscous Coupling
- 180 Nm (132.8 ft.lb.)Install flange to viscous coupling shaft as marked Use a new nut. Tighten to . Use counterh
NOTE: If the old flange has been installed as above, continue with installing propeller shaft.

Checking Runout
Check axial runout on the flange and locating pin
NOTE: Only needs to be carried out if the flange has been replaced.
NOTE: Ensure that the measuring faces are absolutely clean.
- Secure plate 999 5971 in the torque tube and magnetic holder with dial gauge on plate.
- 0.05 mm (0.00197")Check locating pin radial runout, maximum value .
- 0.05 mm (0.00197")Check flange axial runout, maximum value .
- If values are exceeded move the flange a quarter turn at a time.
NOTE: Always use a new nut.
- Check runout again until the correct values are obtained.

- Remove measuring equipment and plate 999 5971.

Installing Propeller Shaft
Install Propeller Shaft To Flange
NOTE: Install propeller shaft as marked. Use new screws of the same length. Reinstall screws in the same posit
- Check that viscous coupling and propeller shaft flange mating surfaces are clean.
- 8 Nm (5.9 ft.lb.) 30 Nm (22.1 ft.lb.)Tighten screws crosswise to . Then tighten crosswise to . Use counterhold 99
- Start tightening with the same screw both times.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Front
Axle Shaft: SpecificationsFront
Driveshaft Hub Nut ....................................................................................................................................................

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Front > Page 5008
Axle Shaft: SpecificationsRear

Shaft to Final Drive:
Method 1:
1st Pass ..................................................................................................................................................................

Method 2 .....................................................................................................................................................................
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5009
Axle Shaft: Description and Operation
GENERAL
The completely new design of the drive (axle) shafts is the most significant innovation. The shafts are in two section
OUTER SHAFT
The outer shaft (1) and outer universal joint (2) are supported in bearings in the wheel bearing housing (3).The whee
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front
Axle Shaft: Service and RepairFront
Removal
Special Tools
- Prying tool No. 999 5462, or equivalent
NOTE:
- This section on driveshafts includes cars with both manual and automatic transmission.
- Unless stated otherwise in the text or illustrations, the Procedures are the same for both manual and automatic mo
- The illustrations normally show driveshafts for manual models.
- The Procedure is the same for both LH and RH driveshafts unless stated otherwise.
Procedure
1. Remove:
- Front wheel.
- ABS sensor from steering swivel member.
NOTE: Do not undo connector.
2. Undo brake pipe bracket and ABS lead.

- Unhook bracket
Remove and letcenter
driveshaft it hangnut.
free.
- Remove the split pin from the hub center nut.
- Use counterhold tool No. 999 5461 (4 wheel bolts) or tool No. 999 5540 (5 wheel bolts), or equivalent, and re
Disconnect driveshaft end from hub
Tap shaft end in approx. 10-15 mm, using a plastic or copper mallet.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 5012

3. Remove:
- Link arm from anti-roll bar.
- Nuts holding link arm/ball joint together.
Unhook link arm from ball joint.
Be careful with ball joint bellows (gaiter).
Remove
Only splashguard
If removing from under
RH driveshaft: - engine (earlier models only).
4. Remove driveshaft from hub.

Twist and remove MacPherson strut.
Tap on driveshaft end with plastic or copper mallet and remove driveshaft from hub.
Clean spline joint (hub-driveshaft) of metal glue.
5. RH driveshaft:
- Remove bearing cap from driveshaft support bearing.
- Remove driveshaft from gearbox.
NOTE: Take care not to damage seal in transmission or driveshaft boot (gaiter).

6. LH driveshaft:
- Remove driveshaft from transmission.
Use prying tool No. 999 5462, or equivalent, to apply leverage between transmission and inside of drivesh
NOTE: Take care not to damage driveshaft seal or boot (gaiter).

Installation
Special Tools
- Counterhold Tool No. 999 5461, or equivalent
- Counterhold Tool No. 999 5540, or equivalent
- Torque Sleeve Tool No. 115 8147-7, or equivalent
Universal Tool
NOTE: The Procedure is the same for both LH and RH driveshafts unless stated otherwise.
Preparation
- Check that ABS sensor and sensor wheel are free of dirt.
Procedure
1. Install driveshaft to transmission.
NOTE: Take care not to damage driveshaft seal or boots (gaiter).
RHInstall bearing cap.

Driveshaft:-
25 Nm.Tighten to:
- Install splashguard under engine (earlier models only).

2 . LH driveshaft:
Check that ABS sensor wheel on driveshaft is free of dirt.Push driveshaft in correctly so its circlip engages in dif
Check by carefully pushing in inboard driveshaft joint.
Install driveshaft in hub:
NOTE: Apply metal glue 1161370-0 to driveshaft splines as shown in illustration.
Twist and remove MacPherson strut and fit driveshaft into hub.
Use a socket wrench to hold link arm down.
Install a new driveshaft nut, hand-tight.
NOTE: Oil nut threads and flange.
3. Install
- Link arm onto ball joint. Use new nuts.
NOTE: Check that mating surfaces on ball joint and link arm are clean and free of grease.
18 Nm + 120.
Tighten from inside and out to Use protractor 951 2050.Apply rustproofing agent to area between ball joint, link
Use rustproofing agent part No. 1161432-8, or equivalent.
- 50 Nm.Link arm to anti-roll bar with new nuts and tighten to

4. Tighten driveshaft center nut.
120 Nm + 60.
Use counterhold tool No. 999 5461 (4 wheel bolts) or tool No. 999 5540 (5 wheel bolts) and protractor tool No. 9
5. Install:
- Brake pipe/ABS lead bracket.
NOTE: Check that ABS sensor seat is absolutely clean first
- 10 Nm.First clean ABS sensor with a soft brush; then fit it to wheel shaft and tighten to:
6. Install front wheel.
Check that brake disc and pad contact surfaces are clean. Lubricate hub center locating pin in front of pad with ru
110 Nm.Install bolts, but do not tighten.Then tighten in pairs to: .

When tightening using a socket wrench, use torque sleeve tool No. 1158147-7, or equivalent.
Axle Shaft: Service and RepairRear
REPLACEMENT
1. Jack up car and remove wheel.2. Remove large nut holding drive (axle) shaft to wheel bearing housing.
3. Remove bolts and nuts securing top and bottom halves of rear axle member.
4. Remove:
- bolts holding drive (axle) shaft to final drive
- drive (axle) shaft.
5. Reverse procedure to install.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front
Constant Velocity Joint: Service and RepairFront
Special Tools
- Pliers tool no. 981 4215, or equivalent
Preparation
- Removing/installing driveshafts, see sections:
Axle Shaft Assembly, Constant Velocity Type, Removal steps 1 through 6. See: Axle Shaft/Service and Repa
- The Procedure is the same for both LH and RH driveshafts.
NOTE:
- To make removal of driveshaft joints easier, insert a drift as shown.
- The rounding off on the underside (R) prevents the drift from hooking into the driveshaft circlip slot.
- The somewhat acute angle (ca 60) gives the drift more contact with the inner race.
Procedures
1. Exposing outboard CV joint

- Remove clips from boot (gaiter).
- Remove boot from CV joint.
- Clean CV joint free of grease.
- Put driveshaft in a vice with the gap in the circlip at the top.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front >
Page 5021

2. Remove CV joint from shaft
- Open the circlip to free it from the groove and insert a drift between the circlip lugs as above.
- Tap the inner race a little way along the shaft to hold the circlip open.
- Using a brass drift, tap CV joint off the shaft.
NOTE: Tap inner race only to avoid damaging cage or outer race.
- Remove circlip from CV joint.
3. Remove clips from inboard boot (gaiter) if changing boot.

- Remove boot from driveshaft.
Cleaning and checking outboard CV joints, see steps 4 through 7.
Cleaning inboard CV joints
NOTE: All inboard CV joints (manual and automatic) must be cleaned assembled and blown clean before greas
Cleaning/checking outboard CV joints
NOTE: Outboard CV joints can be cleaned in assembled form. For inspection/check Procedures see steps 4 thro
4. Mark the relative positions of the outer race, cage and inner race in the CV joint with an electric scriber.
Page 5022

5. Remove balls
-
Tilt inner race and cage and remove balls clockwise, one by one.Use an electric scriber to mark where you sta
- Put the balls in order so they can be put back in the same position later.
6. Remove cage and inner ring from shaft.

- Rotate inner race 90 relative to cage.
- Remove inner race.
- Remove circlip from inner race.
7. Clean all CV joint components thoroughly.

If any part shows signs of cracking or scoring, replace entire CV assembly
NOTE: Slight scoring or pitting in races is acceptable.

8. Installing inner race in cage.
- Line up markings and put the first ball in.
NOTE: Carefully note positions of balls.
Page 5023

- Turn inner race and cage.
- Put balls back in their original positions, one by one.
9. Grease CV joint thoroughly.
Insert a new circlip in the joint's inner race.Grease should also be applied to the back of the joint through the open
Part No. 1161428-6 (80g) (non-turbo models), or equivalentPart No. 1161429-4 (120g) (turbo models), or equ
10. Install new boot on driveshaft.

- Fix the driveshaft in a vice.
Check
Install CV that
Jointinner race sits square inside the joint.
on shaft.-
TapCheck that circlip

Joint onto is sitting
shaft using properly
a plastic in its groove.
mallet.-
11. Apply remaining grease to inner race and cage.
NOTE: Take care not to get any grease on the parts of the boot (gaiter) which come into contact with CV joints o
Use
Wipe offpliers tool No.
any excess 981 4215,
grease or equivalent.
with methylated (mineral) spirits.Slide boot (gaiter) over CV joint and check that it is
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front > Page 5024
Constant Velocity Joint: Service and RepairRear
REPLACEMENT
1. Jack up car and remove wheel2. Remove large nut holding drive (axle) shaft to wheel bearing housing.
3. Remove bolts and nuts securing top and bottom halves of rear axle member.
4. Remove:
- bolts holding drive (axle) shaft to final drive
- drive (axle) shaft.
5. Remove outer cover from drive (axle) shaft joint Tap off cover carefully with hammer and drift.
Page 5025

6. Carefully tap off inner cover Remove inner clip. Push gaiter over drive (axle) shaft.
7. Remove:
- grease, until circlip is visible
- circlip
8. Press joint off shaft Use drift.
Remove gaiter from drive (axle) shaft and wash shaft clean.When replacing gaiters only: Remove original gasket
9. Install/mount:
- new gaiter and inner cover
- universal
Page 5026

10. Press joint onto drive (axle) shaft Use drift 2731 and universal puller as counterhold.
Install new circlip.
11. Remove protective paper from new gasket. Locate gasket in recess in joint
12. Pack joint and outer cover with grease

Use grease supplied with kit.
13. Press home cover14. Press new grease into joint and bellows15. Coat inner cover with sealing agent. Press home c
17. Install clips and tighten with pincers.
Page 5027

18. Install:
- drive (axle) shaft
- 30 Nm (22 ft. lbs.)
65-75 Nm (48-55 ft. lbs.)bolts securing shaft to final drive. Use new, oiled bolts. Tighten to and angle-tighten
19. Insert two M12 bolts or two 12 mm drifts in rear axle member centering holes
NOTE: This is essential to ensure that wheel alignment is correct after assembly.
70 Nm (52 ft. lbs.) 30 degrees20. Tighten bolts securing upper and lower halves of rear axle member. Tighten to and
21. Install:
- large nut holding drive (axle) shaft to wheel bearing housing. Use new, oiled nut.
- 85 Nm (63 ft. lbs.)wheel and tighten nuts to .
140 Nm (103 ft. lbs.) 60 degrees22. Lower car. Apply hand brake23. Tighten drive (axle) shaft nut to and, then angle
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair
Constant Velocity Joint Boot: Service and Repair
Special Tools
- Pliers tool no. 981 4215, or equivalent
Preparation
- Removing/installing driveshafts, see sections:
- The Procedure is the same for both LH and RH driveshafts.
NOTE:
- To make removal of driveshaft joints easier, insert a drift as shown.
- The rounding off on the underside (R) prevents the drift from hooking into the driveshaft circlip slot.
- The somewhat acute angle (ca 60) gives the drift more contact with the inner race.
Procedures
1. Exposing outboard CV joint

- Remove clips from boot (gaiter).
- Remove boot from CV joint.
- Clean CV joint free of grease.
- Put driveshaft in a vice with the gap in the circlip at the top.
2. Remove CV joint from shaft
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair >
Page 5031

- Open the circlip to free it from the groove and insert a drift between the circlip lugs as above.
- Tap the inner race a little way along the shaft to hold the circlip open.
- Using a brass drift, tap CV joint off the shaft.
- Remove circlip from CV joint.
3. Remove clips from inboard boot (gaiter) if changing boot.

- Remove boot from driveshaft.
Cleaning and checking outboard CV joints, see steps 4 through 7.
Cleaning inboard CV joints
NOTE: All inboard CV joints (manual and automatic) must be cleaned assembled and blown clean before greas
Cleaning/checking outboard CV joints
NOTE: Outboard CV joints can be cleaned in assembled form. For inspection/check Procedures see steps 4 thro
4. Mark the relative positions of the outer race, cage and inner race in the CV joint with an electric scriber.
5. Remove balls
-
Tilt inner race and cage and remove balls clockwise, one by one.Use an electric scriber to mark where you sta
- Put the balls in order so they can be put back in the same position later.
Page 5032

6. Remove cage and inner ring from shaft.
- Rotate inner race 90 relative to cage.
- Remove inner race.
- Remove circlip from inner race.
7. Clean all CV joint components thoroughly.

If any part shows signs of cracking or scoring, replace entire CV assembly
NOTE: Slight scoring or pitting in races is acceptable.
8. Installing inner race in cage.

- Line up markings and put the first ball in.
NOTE: Carefully note positions of balls.
- Turn inner race and cage.

- Put balls back in their original positions, one by one.
9. Grease CV joint thoroughly.
Page 5033

Insert a new circlip in the joint's inner race.Grease should also be applied to the back of the joint through the open
Part No. 1161428-6 (80g) (non-turbo models), or equivalentPart No. 1161429-4 (120g) (turbo models), or equ
10. Install new boot on driveshaft.

- Fix the driveshaft in a vice.
Check
Install CV that
Jointinner race sits square inside the joint.
on shaft.-
TapCheck that circlip

Joint onto is sitting
shaft using properly
a plastic in its groove.
mallet.-
11. Apply remaining grease to inner race and cage.
NOTE: Take care not to get any grease on the parts of the boot (gaiter) which come into contact with CV joints o
Use
Wipe offpliers tool No.
any excess 981 4215,
grease or equivalent.
with methylated (mineral) spirits.Slide boot (gaiter) over CV joint and check that it is
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Support - Half Shaft/Short Shaft > Component Information > Service and Repair
Support - Half Shaft/Short Shaft: Service and Repair
Special Tools
- Standard shaft tool No. 999 1801, or equivalent
- Ring tool No. 999 2853, or equivalent
- Press ring tool No. 999 5491, or equivalent
Universal Tool
- Pliers tool No. 981 4215, Or Equivalent
Preparation
- Removing/replacing driveshafts, see:
NOTE:
-
Unless stated otherwise, the Procedure for replacing the support bearing and cleaning the inboard universal joint
- The inboard universal joint can only be dismantled in automatic models.
Procedure
Driveshaft, manual models,
1. Exposing inboard universal joint

- Remove clips from inboard boot (gaiter).
- Slide boot (gaiter) off inboard universal joint.
2. Cleaning off grease from universal joint.
Mount driveshaft In vice with gap In circlip pointing upwards.
> Page 5037

3. Remove universal joint from driveshaft
-
Open circlip to free it from groove and insert a drift between the circlip lugs, refer to Constant Velocity Joint
- Tap the inner race a few mm along the shaft to hold the circlip open.
- Using a brass drip, tap inboard universal joint off the shaft.
4. Clean universal joint thoroughly.
Clean joint in assembled form, as it will not come apart.To replace support bearing, refer to steps 18 and 19.
5. Install a new circlip on universal joint.

Grease universal joint.
Use grease pack part No. 1161429-4 (120g), or equivalent.
Check that boot (gaiter) is undamaged, or fit new boot onto outboard shaft.
6. Assembling inboard and outboard driveshafts:
Fix Check that inner In

outer driveshaft race is sitting squarely in universal joint.
vice.-
> Page 5038

Tap shaft into joint.
- Check that circlip is seated in its groove.
7. Pack the remaining grease into joint.
NOTE: Take care not to get any grease on the part of the boot (gaiter) in contact with the joint and shaft.
- Clean off any excess grease using methylated (mineral) spirits.
Use
Slide pliers
boot tool No.
(gaiter) onto981
the 4215, or equivalent.
joint and check it is correctly positioned on the driveshaft.Fit new clips.-
Driveshaft, automatic transmission AW 50-42
8. Expose inboard universal joint

- Remove clips from inboard boot (gaiter).
- Slide boot (gaiter) off inboard universal joint.
Non-turbo models:
9. Dismantling universal joint
- Mark driveshaft position relative to joint casing.
- Bend casing plate tabs back slightly and remove shaft from joint casing.
Turbo models:
> Page 5039

10. Dismantling universal joint
- Mark driveshaft position relative to joint casing.
- Turn back collar of joint casing tab.
NOTE: Turn back properly so spider and needle bearings come well clear of joint casing.
- Remove shaft from joint casing.

- Remove needle bearings from spider.
Mark position relative to spider.
11. Clean joint casing thoroughly
Do not dismantle needle bearings.Clean off thoroughly with a clean lint-free cloth.Replacing support bearings, se
12. Only if replacing boot (gaiter):

Mark spider relative to driveshaft markings. Remove circlip.
Remove spider off
from shaft.-
- Push spider shaft.
Removemodels:Use
Non-turbo boot (gaiter) from
drift shaft.
tool 999 5118 and drift tool 999 5318, or equivalents, as support under spider.Turbo
> Page 5040

13. Install:
- New boot (gaiter) on driveshaft.
- Spider, lining up as above.
NOTE: Spider's position relative to shaft (non-turbo models only).
TapUse Drift
spider tool until
down No. 999 5519, the
it reaches or equivalent.
stop.-
Install circlip, making sure it engages in its groove.
Assembling inboard and outboard driveshafts
14. Non-turbo models:
Pack grease into joints.Use grease pack part No. 1161430-2 (190 g), or equivalent.
15. Turbo models:

Grease spider pins, use grease pack part No. 1161430-2 (190g), or equivalent.
-Install
Packneedle
grease
bearings
into joint,
on spider.-
use grease pack part No. 1161430-2 (190g), or equivalent.
> Page 5041

16. Fit spider onto joint, lining marks up.
Tap plate flaps back properly.Turbo models:
NOTE: Tap joint tabs back carefully: avoid sharp edges or angles.
Pack remaining grease into joint.
NOTE: Check that no grease gets onto boot (gaiter) where it touches driveshaft or joint.
- Wipe off excess grease with methylated (mineral) spirits.
17. Slide boot (gaiter) over joint.
Check that it is correctly positioned on driveshaft.Install new cups.Use pliers tool No. 981 4215, or equivalent.
Replacing support bearing, manual automatic models

18. Remove circlip and support bearing from shaft.
- Use ring tool No. 999 2853, or equivalent.
Support tool and shaft as in picture.
> Page 5042

19. Install new bearing and circlip.
Use press ring tool No. 999 5491, or equivalent, as support against circlip.Put standard shaft tool No. 999 1801, o
Manual models: step 6.Automatic models: step 14.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection
Special tools:
999 5418999 5507
Preparations



> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5046

- 0.020 mm (0.00079")Note test gauge run-out. Hub lateral run-out must not exceed .
- 0.020 mm (0.00079")Replace hub if maximum lateral run-out exceeds .
Finishing
-
8 Nm (6 ft. lbs.)Install brake disc on hub, lining up marks.Tighten locating pin and bolt to .
- Go to Brake disc front, replacement or Brake disc rear, replacement.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications
Axle Nut: Specifications

Driveshaft Nut, Rear
Stage 1 ..............................................................................................................................................................................
Driveshaft Nut, Front
Stage 1 ..............................................................................................................................................................................
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Page 5051
Axle Nut: Service and Repair
Warning The use of protective equipment such as safety goggles is recommended.
If a drive shaft nut that requires staking needs to be re-tightened or removed, a new nut must be installed. Tighten the
Procedure for locking hub:

Clean splines and groove in shaft thoroughly. Remove all oil, anti-rust agent and dirt.
3 - 4 mm (3/16" - 1/4")
Apply wide bead of metal adhesive, P/N 1161370-0 Apply bead around shaft covering approximately 1/3 of splined
Note! Apply adhesive around complete shaft just before installing hub.
120 Nm (89 ft. lbs) + 60

Install hub and new nut.Tighten nut to as specified in service manual.Lock the nut (stake the nut) by tapping outer fl
Note!
From chassis no:s. 854: 219646,855: 121429 a new drive shaft nut has been introduced on all versions of the 850, w
- The nut is reusable

- There is no locking groove in the drive shaft.
- The threads on the shaft end have increased from M20 to M22.
- New self-locking nut with M22 thread.
Note! The nut must be oiled before use.
120 Nm (89 ft. lbs) + 60.The new nut must be tightened to the same torque and protractor angle as previously.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain - Revised Drivesha
Drive/Propeller Shaft: Technical Service BulletinsDrivetrain - Revised Driveshaft Removal/Installation
Retailer Technical Journal 19917Updated procedure, propeller shaft, removal/installation
Date 12-05-2008
Reference: VIDA
Note! If using a printed copy of this Retailer Technical Journal, first check for the latest online version.
This RTJ supersedes TNN 46-10 released 4-27-2007. The procedure for joint replacement is now in VIDA. Changes ha
AFFECTED VEHICLES:
SERVICE:When loosening the propeller shaft from the bevel gear, final drive or when replacing the propeller shaft, it i
Note:
When handling a propeller shaft out of the vehicle, it is important to support it so that the boot on the center joint is no
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain -
Revised Driveshaft Removal/Installation > Page 5057

There is a protrusion inside the joint that can damage the rubber boot if the propeller shaft is bent to its maximum when
If the entire propeller shaft is to be removed, the rubber boot must be protected.
Cut a 35 mm (1 3/8") piece of discarded coolant hose or similar. Cut the hose to length. Insert the hose in the joint and
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain -
Revised Driveshaft Removal/Installation > Page 5058

Important! The propeller shaft must not be raised without protecting the rubber boot
If a part of the propeller shaft is to be loosened, use a jack to support the part until the propeller shaft is suspended. If th
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5059
Drive/Propeller Shaft: Service Precautions

NOTE: This article contains updated information called out in TSB TJ19917.
Retailer Technical Journal 19917Updated procedure, propeller shaft, removal/installationDate 12-05-2008
Volvo Cars of North America, LLC Technical SupportReference: VIDA
Note! If using a printed copy of this Retailer Technical Journal, first check for the latest online version.
This RTJ supersedes TNN 46-10 released 4-27-2007. The procedure for joint replacement is now in VIDA. Changes
AFFECTED VEHICLES:
SERVICE:
When loosening the propeller shaft from the bevel gear, final drive or when replacing the propeller shaft, it is import
Note:
Whenishandling
There a propeller
a protrusion inside shaft out that
the joint of the
canvehicle,
damageit the
is important to support
rubber boot it so thatshaft
if the propeller the boot ontothe
is bent itscenter joint wh
maximum is
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5060

If the entire propeller shaft is to be removed, the rubber boot must be protected.
Cut a 35 mm (1 3/8") piece of discarded coolant hose or similar. Cut the hose to length. Insert the hose in the joint an
Important! The propeller shaft must not be raised without protecting the rubber boot
If a part of the propeller shaft is to be loosened, use a jack to support the part until the propeller shaft is suspended. If
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Installing Propellar Shaft, All-Wheel D
Drive/Propeller Shaft: Service and RepairInstalling Propellar Shaft, All-Wheel Drive (AWD)
Installing propeller shaft, All-wheel drive (AWD)
Background
In general the propeller shaft should be installed in a straight line to avoid vibrations. This is especially important wh
The propeller shaft CV joints must be handled carefully and not treated roughly. CV joints should be held as straight
Tools:
Jemmy bar 1158092-5
Installing the SIPS member

When tighten the SIPS member it should be placed as far to the left of the car as possible before tightening.
25 Nm (18.4 ft.lbs)Use the jemmy bar and use the exhaust pipe as a counterhold when the SIPS member screws are
Drive/Propeller Shaft: Service and RepairPropellar Shaft CV Joint, Replacement
Propeller shaft CV joint, replacement
Removal
Marking the rear propeller shaft

- Mark the position of the propeller shaft flange in relation to the torque rod's flange.
Note! Carefully note the length and position of screws on the propeller shaft CV joint.
- Remove the propeller shaft screws. Use counterhold 999 5743 .
Marking the front propeller shaft

- Mark the position of the propeller shaft flange in relation to the bevel gear flange.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Installing Propellar
Shaft, All-Wheel Drive (AWD) > Page 5064

- Remove the propeller shaft screws. Use: 999 5743.
Removing components
- Remove:

- Remove the two screws (2) holding the propeller shaft to the SIPS member
- the screws (1) for the SIPS member one at a time. Screw them in again 4 turns
- the propeller shaft. Place the propeller shaft in a vise. Use pieces of wood in the jaws.
- The propeller shaft must be replaced if it is damaged.
Removing the front cover


- Tap the front cover loose from the propeller shaft CV joint. Remove the snap ring.
Removing the propeller shaft CV joint


- Pull the propeller shaft CV joint from the axle. Use: 999 5427
Note! Never load the propeller shaft CV joint axially by pulling or tapping the joint's outer ring. The joint's bearing r
- Remove the clamp and the old boot with cover from the axle. Clean the axle end.
Lubricating the propeller shaft CV joint


- Lubricate the propeller shaft CV joint thoroughly. Apply grease to the front cover towards the boot and to the mid
Installation
Installing the propeller shaft CV joint


- Install the boot and gasket on the propeller shaft.
- Tap the joint into its seating on the propeller shaft. Use: 999 5345
- Install the new snap ring. Ensure that the snap ring is in the groove.
Securing the gasket


-
Ensure that the sealing surface in the propeller shaft CV joint's rear edge is not greased. Secure the gasket at the f
Installing the cover


- Press the front and rear cover into place. Use: 999 5427 .
Installing the boot


-
Press the boot into the cut-out on the propeller shaft. Install the clamp with the raised areas towards the boot. Tig
Installing components

-
the propeller shaft
Install:-
- 25 Nmthe screws (2). Tighten to
- 25 Nmthe screws (1). Tighten to .
Installing the rear propeller shaft

- Check that the viscous coupling and propeller shaft flange mating surfaces are clean.
-
8 Nm 30 NmInstall the propeller shaft as marked. Use new screws of the same length. Place the screws in the sam

- Use: 999 5743 Start the tightening with the same screw both times.
Installing the front propeller shaft

- Check that the bevel gear and propeller shaft flange mating surfaces are clean.
- Install the propeller shaft as marked. Use new screws. Tighten the screws crosswise. First tighten to 8 Nm. Then

- Use: 999 5743 Start the tightening with the same screw both times.
Drive/Propeller Shaft: Service and RepairFront Propellar Joint, Replacing
Front propeller joint, replacing
Special tools:
999 5427 999 5743
RemovalRemoving the rear joint from the propeller shaft
Mark the position of the propeller shaft flange in relation to the flange on the torque tube.
Note! Carefully note the length and position of screws on the propeller shaft constant velocity joint. Also see Specifi
Remove the propeller shaft screws. Use counterhold 999 5743
Note! Wrong counterhold illustrated.
Removing the front joint on the propeller shaft

Remove the propeller shaft screws. Use counterhold 999 5743

Note! Wrong counterhold illustrated
Remove:

- the 2 screws (2) holding the propeller shaft to the SIPS member
- the 4 screws (1) for the SIPS member one at a time. Screw them in again 4 turns
- the propeller shaft.
Place the propeller shaft in a vice. Use pieces of wood.
Note! The propeller shaft must be replaced if it is damaged.
Removing the propeller joint


- Tap off the front cover using a screwdriver and a hammer.
- Wipe off the grease.

- Remove the snap ring.
- Remove the clamp (1) from the rubber boot.


- Remove the propeller joint from the propeller shaft. Use puller 999 5427 or knock it off using a plastic mallet.
Note! The propeller shaft must be replaced if it is damaged.

- Wipe any grease and dirt off the propeller shaft and splines.
InstallationInstalling the propeller joint

- Squeeze grease into the joint on the surface (2).
Note! There must not be any grease on the mating surface (1).
- Apply a thin layer of liquid gasket to the mating surfaces (1) on both the joint and the rear cover.
- Install the rear cover on the propeller shaft. Ensure that the holes are aligned.
-
the propeller joint on the propeller shaft. Knock it into place using a rubber mallet. Use a socket as a space
Install:-

- the snap ring. Check that it is in the groove.
- Squeeze the remaining grease into the propeller joint (2). The entire contents of the tube must be used.

Note! There must not be any grease on the mating surface (1).
- Install the gasket and the front cover by hand. Ensure that the holes are aligned.
- Press the cover onto the propeller joint, using 2 washers, 4 screws and 4 nuts. Tighten crosswise until the cover b
- Remove the screws, nuts and washers.

- Press the air out of the rubber bellow. Ensure that the rubber boot is positioned correctly on the propeller shaft.

- Install the new clamp (1).
Installing the propeller shaft


-
the propeller shaft in the car
Install:-
- 25 Nmthe 2 screws (2). Tighten to .
- 25 NmTighten the 2 screws (1). Tighten to .
- Check that the viscous coupling and propeller shaft flange mating surfaces are clean.
- Install the propeller shaft as marked.
- Use new screws of the same length. Reinstall the screws in the same positions.

- 8 Nm 30 NmFirst tighten the screws crosswise. Tighten to . Then re-tighten crosswise. Tighten to . Use counterh

- Check that the bevel gear and propeller shaft flange mating surfaces are clean.
- Use new screws.

- 8 Nm 30 NmFirst tighten the screws crosswise. Tighten to . Then re-tighten crosswise. Tighten to . Use counterh

> Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications

Carrier Plate
Tighten to .........................................................................................................................................................................
> Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
FLYWHEEL
Stage 1 ..............................................................................................................................................................................
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Repla
1. Removal
-
Remove:-
2. Installation
-
The shutter.
Install:-
- The panel.
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Repla
- Ignition off.
- Replace the bulb.

> Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Tran
Fluids
Differential Fluid - M/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service
Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 5108

AFFECTED VEHICLES
> Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Tran
Fluids > Page 5109
Differential Fluid - M/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications
Drain Plug: Specifications
Drain Plug ...................................................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications
Fill Plug: Specifications
Fill Plug ......................................................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - M/T: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain -
Lubricants And Fluids > Page 5120

AFFECTED VEHICLES
> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids >
Fluid - M/T: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants

NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
Oil Fill Specifications
Capacity ...............................................................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 5124
Fluid - M/T: Fluid Type Specifications
Transmission Specifications
Volvo Synthetic Transmission Oil .......................................................................................................................................

> Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Specifications
Input Shaft: Specifications
Throwout Bearing Guide Sleeve ................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair
Output Shaft: Service and Repair

NOTE: To remove drive shaft, refer to Replacing Bevel Gear See: Transfer Case/Service and Repair
Removing coupling sleeve

- Remove circlip In coupling sleeve. Remove sleeve Use drift 999 5656 and puller 999 5089.
NOTE: Ensure that the puller arms engage correctly in the groove in the sleeve.
> Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Page 5131

Removing coupling sleeve sealing ring
- Remove sealing ring from transmission.
- Use extractor 999 5069 and drift 999 5656.

Removing Drive Shaft Sealing Ring
- Remove drive shaft sealing ring and coupling sleeve O-ring.
- Use a screwdriver.

Installing O-ring and sealing ring
- Install a new coupling sleeve O-ring on the differential housing.
- Install a new drive shaft sealing ring Lubricate seal with wheel bearing grease, P/N 1161241-3.
- Use drift 999 5654.

Installing Sealing Ring
- Install coupling sleeve sealing ring.
- Use drift 999 5657.
- Tap in seal until drift bottoms on its stop against transmission.

Installing Circlip And Sleeve
Install:
- circlip in sleeve
- sleeve in transmission with the long splined section (2) toward the transmission. Use a rubber mallet to knock in
NOTE: To install bevel gear and drive shaft, See: Transfer Case/Service and Repair
> Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transaxle Side Seals, M/T
Seals and Gaskets: Service and RepairTransaxle Side Seals, M/T
Special Tools
- Prying tool No. 999 5462, or equivalent
NOTE: The Procedure is the same for both sides unless stated otherwise.
Procedure
1. Removing front wheel.
Let bracket
Disconnect hang
brake free.
pipe and ABS lead bracket. -
Disconnect link arm from anti-roll bar.
Remove nuts holding link arm/ball joint and unhook link arm from ball joint.Take care not to damage ball joint b
2. LH side:
- Disconnect driveshaft from transmission, using prying tool tool No. 999 5462, or equivalent, between transmi
Rest
Bend driveshaft strut
MacPherson end on subframe.
back and remove driveshaft from transmission.-
3. RH side:
Let driveshaft
Remove endunder
splashguard rest onengine.
pipe running
(Earliertomodels
steering gear.
only.)Remove driveshaft support bearing cover.Pull out drive
> Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transaxle Side Seals, M/T > Page
5140

4. Remove driveshaft seal.
- Use a lever.
5. Installing new driveshaft seal.

- Grease seal lip lightly.
- Use drift tool No. 999 5541 and shaft tool No. 999 1801, or equivalent.
NOTE: Do not use old style drift (tool No. 999 5478).
Put the side of the drift marked "M56" against the driveshaft seal.
RHPut the side of the drift marked "M56" against the driveshaft seal, and turn as shown in picture on right.
side-
Tap driveshaft in gently until drift Is touching transmission casing.
LH side:-
5141

6. Installing driveshafts.
NOTE: Take care not to damage driveshaft seals or boot (gaiter).

-RHInstall
driveshaft:-
bearing cap. under
splashguard Tighten
engine.
to 25 (Earlier
Nm (18 models).
ft. Lb.).
LH driveshaft:Push driveshaft in properly so it locks into the circlip in the differential slot.
Make sure driveshaft circlip engages in slot.Check by pushing in driveshaft inboard universal joint careful
5142

7. Install:
- Link arm to ball joint. Use new nuts.
NOTE: Check that mating surfaces on ball joint and link arm are clean and free of grease.
18 Nm+120.
Tighten nuts Inside and out to: Use protractor tool No. 951 2050, or equivalent.Apply rustproofing agent to the ar
Use rustproofing agent part No. 1161432-8, or equivalent.
- 50 Nm.Link arm to anti-roll bar (use new nuts) and tighten to:
8. Install:
- Brake pipe and ABS lead bracket.
Check transmission on level and top up as necessary.
- 35 Nm.Tighten to:
5143

9. Install:
- Wheel.
110 Nm.Check that brake disc and pad contact surfaces are clean.Grease hub center in front of pads with r
When tightening with socket wrench, use torque sleeve 1158147-7.
> Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transaxle Side Seals, M/T > Page 5144
Seals and Gaskets: Service and RepairInput Shaft Seal
Special Tools
- Extractor tool No. 999 5489, or equivalent
Preparations
- Before replacing gearbox input shaft seal, follow:
Steps 1 through 26 of transmission removal. See: Service and RepairStep 2 of clutch replacement. See: Clutch
1. Remove throwout (release) bearing sleeve.

- Remove the three screws holding the sleeve.
2. Tap in extractor tool No. 999 5489, or equivalent.
NOTE: Jackscrew in extractor must be unscrewed.
- Check that extractor grips input shaft seal. Remove Input shaft seal.
3. Install new input shaft seal.
- Grease input shaft seal lip.
- Use drift tool No. 999 5490, or equivalent
- Tap seal in until drift touches transmission cover.
4. Install throwout (release) bearing sleeve.
- Apply a little locking fluid to the bolts.
5145

- 10 Nm.Install the three bolts and tighten to:
Now follow:
Steps 1 through 25 of transmission installation. See: Service and RepairStep 7 of clutch replacement. See: Clu
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications
Shifter M/T: Specifications
Cross Member ............................................................................................................................................................
Shift Lever ..................................................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Knob and Boot (Gaiter)
Shifter M/T: Service and RepairShift Knob and Boot (Gaiter)
1. Remove shift lever knob
CutRemove
away theinner
outersleeve
knob using
sleevepincers to expose circlip.
with a knife-
- Remove knob.
2. Remove shift lever boot (gaiter)

- Remove cover panel from underneath parking brake lever
-
Remove shift lever boot (gaiter) from tunnel bracket by pushing on rear bellows fastening from underneath vi
- Pull boot (gaiter) off lever.
3. Install shift lever boot (gaiter)
Push ring
Locating stubdown until itring
on bellows reaches
mustthe
fit lower lockinggroove
into locating groove.on shift lever.-
-- Install
Install shift
coverlever
panelbellows in tunnel
underneath bracket:
parking brakepress
lever.hooks in front home first, then snap fittings on side and rear
Install shift lever knob.Match locating lug on shift lever knob to guide groove on shift lever and push down to loc
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Knob and Boot (Gaiter) > Page 5151
Shifter M/T: Service and RepairShift Lever
Special Tools
- underlay ring No. 999 2852, or equivalent
Preparation
- Remove shift refer to steps 4, 6 and 7 of Selector Cable, M/T replacement. See: Shift Linkage/Shift Cable/Servic
Procedure
1. Remove:
- Link plate clip
- Link plate and bushings
- Ball and socket joint from shift lever link plate.
(If only replacing bushings or link plate, see step 5).
2. Replacing shift lever and shift lever ball and socket joint:
Fix shift lever casing in a vice.Remove shift lever knob and boot (gaiter) from lever (steps 1 and 2 of Shift Knob
To remove shift lever ball and socket joint from shift lever casing, ease up socket locking tabs.
LiftReplace
ball andball andjoint
socket socket
andjoint
shiftand/or
lever shin
fromlever
shift as necessary.
lever casing.-
3. Fitting socket to shift lever
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Knob and Boot (Gaiter) > Page 5152

Stand socket in hot water for a while. Press socket onto shift lever ball, lubricate using grease part No. 1161236-3
4. Put shift lever housing on bench
Usethat
Check driftO-ring
tool No. 999 2412 and
in aluminium underlay
bracket ring
seat is tool No 999
undamaged and2852,
lyingorflat
equivalents.
against the bottom.Fit ball and socket jo
Tap ball and socket joint into place in shift lever housing.
5. Lubricating link plate bushings and ball and socket joints with grease part No. 1161236-3, or equivalent.
Link plate bushings onto shift lever housing.

- Ball and socket joint to shift link rod
- Link plate to shin lever housing.
At the same time, guide link plate onto shin lever link rod and fit washer and clip.
6. Fit shift lever housing
See steps 10 through 14 of Selector Cable, M/T replacement. See: Shift Linkage/Shift Cable/Service and Repair
Lubricate
NOTE: - selector cable ball and socket joints with grease part No. 1161236-3, or equivalent.
- If shift lever knob and boot (gaiter) have been removed, install these when shift lever housing and tunnel cons
For Installation, see step 3 of Shift Knob and Boot Replacement. See: Shift Knob and Boot (Gaiter)
Install:-
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications
Shift Cable: Specifications
Cable Bracket Assembly To Transmission ................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Selector Cables
Shift Cable: Service and RepairSelector Cables
Special Tools
- Fitting tool No. 999 5511, or equivalent
Removal
1. Remove:
- Battery negative cable.
- (ACL)Air Cleaner and intake pipe.
Turbo models only: Disconnect timing valve from ACL.
2. Remove:
- Clip and washers from levers.
- Clips from cable bracket.
- Selector cables from cable bracket.
NOTE: The selector cable runs in engine compartment.

3. Remove:
- Cigarette lighter panel/storage compartment (two bolts at back).
- Some models: DLC from panel.
- Cover from under handbrake lever.
- Storage compartment lid.
Press shift
Disconnect lever
shift bellows
lever (gaiter)
bellows rear
(gaiter) fastener
from tunnelfrom underneath through the gap under the parking brake lever.
console.-
> Page 5159

4. Remove:
- Tunnel console.
Undo connectors (the car in the picture has two).
- Screws at the front and the back of the tunnel console.
- The tunnel console.
5. Remove the selector cable lead-through from the firewall.

- Remove panel and fold back carpet to gain access to cable lead-through in the firewall.
- Undo the two bolts holding the lead-through and undo the lead-through from the bolts in the bodywork.
- Remove the screw holding the console to the tunnel (earlier models).
- Pull air duct apart.
6. Remove the shift lever and four screws.
NOTE: Remove the cross member side reinforcement members.

7. Disconnect selector cable socket joint from shift lever linkage.
> Page 5160

Use fitting tool 999 5511.
Remove clip holding selector cables to the shift lever.Remove the shift lever.
8. Pull cables out through center console one by one and remove complete cable assembly from car.
Installation
NOTE:
- Take care not to damage cables or sheathing by bending them too sharply.
- Be careful with cable bellows (gaiter).
- Check that shift lever housing rubber bushings and spacers are In good condition.
9. Feed new selector cables through firewall

Make sure they are on the right side of the steering wheel column.
NOTE: The LH link plate on the shift lever housing and selector cable which goes on the left are marked in yell
- Push cables as far down into the sheathing as possible and feed them under the air duct and through the tunne
- Check that the cable marked yellow runs easily into its sheathing.
The other will not run in so easily, because there is more grease in the sheathing.
10. Install:
- Clip holding selector cables to shift lever.
- Ball and socket joints to shift lever arms, using fitting tool No. 999 5511, or equivalent.
11. Install:
- Shift lever to bodywork Note 1993 models onwards:
- Fit cross-member to side reinforcement members.
- Fit four bolts to shift lever.
> Page 5161

25 Nm.Tighten four shift lever bolts to
- 25 Nm.Tighten cross-member bolts to
12. Install:
- Bolt to tunnel console (earlier models).
- Connect air duct.
- Two lead-through nuts.
- Panel and put carpet back in place.
13. Install:
- Tunnel console via screws at front and back of console.
- Connect connectors (the car in the picture has two).
14. Install:
- Cigarette lighter panel/storage compartment via the two screws at the back.
- Some models: fit DLC to panel.
- Cover under parking brake lever.
- Storage compartment lid.
- Shift lever bellows (gaiter) to tunnel console.
Do up the front fasteners first, then the rear ones.
> Page 5162

15. Check that dampers on transmission cable bracket are in good condition.
Selector cables on cable bracket using clips.

Install:-
NOTE: The link plate and outermost selector cable have yellow markings.
- Lubricate selector arm pins with grease P/N 1161241-3.

- Selector cables to selector levers with washers and clips.
16. Install:
- ACL
- Timing valve on ACL (turbo models only).
- Hoses and connectors.
- Battery negative cable.
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Selector Cables > Page 5163
Shift Cable: Service and RepairSelector Cable Bushings and Dampers
(ACL)1. Remove Air Cleaner .
Turbo models only: Disconnect timing valve from ACL.
2. Remove clips and washers from levers
Press the old bushings out of the ring terminals.Only If replacing damper units on cable bracket:Remove clips fro
3. Install the new bushings in the ring terminals.
NOTE: Make sure bushings/openings are positioned as illustrated.

> Page 5164

4. Install the new damper units on the cable bracket as illustrated.
5. Install:
- 25 Nm.Cable bracket assembly on transmission, tighten to:
- Selector cables to bracket by clips.
NOTE: The outer mounting and associated selector cable are both marked yellow.
- Lubricate selector arm pins with grease part No. 1161241-3, or equivalent.
- Selector cables to selector levers
- The two washers and two clips
6. Install ACL.
- Install hoses and connectors
- Timing valve to ACL (turbo models only).
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations
LOCATION
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5170
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5171

TEMPERATURE
ARC WELDING
REPLACING
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Application and ID > P

1 Volvo P/N
3 Part design
4 Serial number

CAUTION:
- (TCM)
NOTE:
-
2. Removing the TCM

- Ignition OFF
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information >
Application and ID > Page 5176

- Install new TCM.
- Ignition ON.

(AP)
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Service and Repai
1. Preparations
- Remove:

> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information >
Service and Repair > Page 5182

3. Removal
4. Reinstallation
- Cars with SRS:
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information >
Service and Repair > Page 5183

- Reinstall cover
8. Checking DTCs
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Descripti
ECON MODE (ECONOMY)
SPORT MODE (SPORT)
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Descripti
- Ignition off.
-
EB2 Installing
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information >
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information >

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifica

Speed Sensor ..............................................................................................................................................................
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifica
1. Remove:
- Battery
- ACL bracket.

> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Informati
Specifications

Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................


Volvo Number ..................................................................................................................................................................


1. Preparation
- Remove:
(ACL)

3. Remove:
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T >

4. Remove:

40 Nm.Tighten to:
- Remove sensor.

- 25 Nm.Tighten to:

9. Installation:


12. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
- Top up oil and test refer to Checking/Adjusting Oil Level. See: Automatic Transmission/Transaxle/Testing an
13. Checking DTCs
> Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Dri
Differential Fluid - Transfer Case: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins >
Transmission/Drivetrain - Lubricants And Fluids > Page 5218

AFFECTED VEHICLES
> Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Dri
Page 5219
Differential Fluid - Transfer Case: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Viscous Coupling, Transfer Case > Component Information > Service Precautions
Viscous Coupling: Service Precautions
Towing
CAUTION:
All-wheel drive cars must not be towed with only one pair of wheels off the ground. If the car is towed in the wrong
Rolling Road Test
When testing brakes or on a rolling road or wheel spinner or balancing wheels the other wheels must rotate freely, se
> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids
Fluid - Transfer Case: Technical Service BulletinsTransmission/Drivetrain - Lubricants And Fluids
Note!
NOTE!
> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And
Fluids > Page 5227

AFFECTED VEHICLES
> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Transmission/Drivetrain - Lubricants And Fluids > Page 52
Fluid - Transfer Case: Technical Service BulletinsA/T, M/T, AWD - Approved Lubricants
NO: 40-04
DATE: 10-13-2005
SUBJECT:

> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications

Bevel Gear 1155 Volume .....................................................................................................................................................
> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5231
Fluid - Transfer Case: Fluid Type Specifications

Bevel Gear 1155
Grade ....................................................................................................................................................................................
> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5232
Fluid - Transfer Case: Service and Repair
Filling Bevel Gear Fluid
NOTE:
If bevel gear has been removed, position the bevel gear so that it is standing on the oil pan (as it is loctated in the car)
Remove level plug.
P/N 1161648Fill with oil () until the oil runs out of the level plug hole.
CAUTION!
0.2 LThen drain of oil
Install the level plug.
35 NmTighten level plug: ....................................................................................................................................................

> Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Sealing Ring Crown Wheel Shaft Left Hand Side, Replacing
Seals and Gaskets: Service and RepairSealing Ring Crown Wheel Shaft Left Hand Side, Replacing
Sealing ring crown wheel shaft lefthand side, replacing
Special tools:
999 7086999 7087
Note! As the illustrations in this service information are used for different model years and / or models, some variatio
essential information is always correct.
Preparatory work
- Remove the bevel gear.
Removing the sealing ring

- Position the bevel gear on a workbench. Support the gear using a wooden block.
- Use extractor 999 7086. Knock the seal towards the housing using the extractor sleeve.
- Remove the seal using the impact driver handle of the extractor.
- Check thoroughly that no seal residue remains.
> Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Sealing Ring Crown Wheel Shaft Left Hand
Side, Replacing > Page 5237

Draining the bevel gear oil
- Position the bevel gear over a container.
- Remove the level plug. Allow the oil to run out through the bearing.
- Wipe away spilt oil from the sealing ring seat on the bevel gear. Use a lint-free rag.
Installation
- Installing the sealing ring

- Install sleeve 7087-1 in the end of the shaft.
- Lubricate the lip of the new sealing ring. Use grease 116 1241-3 (80g). Position the seal on the sleeve.

- Tap the seal into the bevel gear. Use drift 999 7087 . Ensure that the tool goes towards the bevel gear housing.
- Check that sleeve 7087-1 is removed with the tool.
Finishing
- Install the bevel gear.
- Fill the bevel gear with new oil.
> Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Sealing Ring Crown Wheel Shaft Left Hand Side, Replacing
Seals and Gaskets: Service and RepairReplacing the Pinion Seal For the Bevel Gear
NOTE: Check that the parking brake is not set and that no gear is engaged.
NOTE: Special tools: 998 7693, 999 5069, 999 5304, 999 5504, 999 5561, 999 5652, 999 5653
Marking Propeller Shaft - Flange

- Mark propeller shaft CV joint in relation to bevel gear flange.
- Remove propeller shaft screws
- Use counterhold 999 5561. Modify counterhold according to Workshop Guide.

Removing Propeller Shaft Bracket And Cross-member Screws
- Remove two propeller shaft center bearing bracket screws from member (removed in illustration).
- Remove left member screws. Remove right screws (removed in illustration).
- Push the propeller shaft to the right, tie it at the front and let it rest on the member.

Removing Bevel Gear Flange Nuts
- Mark flange In relation to the end of the pinion. Remove nut
- Use counterhold 999 5652.

Removing Pinion Flange And Spacer Sleeve
Remove:
- flange. Use puller 999 5304.
- pinion spacer sleeve. Use puller 998 7693 or universal puller
- Use container to collect oil spillage

Removing Seal
- Use puller 999 5069.
NOTE: Check that no seal residue is left. Check that sealing face on pinion spacer sleeve is OK.

Installing Seal
- Lubricate sealing ring lip with wheel bearing grease, P/N 1161241-3. Install seal on drift 999 5653 on the side of
- Press in seal
- Use press tool 999 5504.

Installing Pinion Spacer Sleeve And Flange
- Install pinion spacer sleeve and flange as marked If necessary use press tool 999 5504.

Installing New Nut For Flange
- Install a new lubricated nut, there must be no axial play.
- 180-200 Nm (132.8-147.6 ft.lb.)Tighten to . Use counterhold 999 5652.
NOTE: 200 Nm (147.6 ft.lb.) Do not exceed a tightening torque of . The forces on the pinion bearing may becom

Installing Propeller Shaft To Bevel Gear
- Install propeller shaft according to marking on bevel gear flange
- Use new screws.
- 8 Nm (5.9 ft.lb.) 30 Nm (22.1 ft.lb.)
Tighten screws crosswise to . Then crosswise to . Start tightening with the same screw both times. Usecounterhol

Installing Center Bearing Member And Center Bearing Bracket
Install:
- 25 Nm (18.5 ft.lb.)Center bearing member on car body. Tighten to .
- 25 Nm (18.5 ft.lb.)Center bearing bracket on cross member. Tighten to .
- Check oil level in bevel gear Top up if necessary.
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A
Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A

[1]Volvo Number ............................................................................................................................................................
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Componen
Electrical Specifications

Resistance .........................................................................................................................................................................
Electrical Specifications > Page 5261

5262

Volvo Number ..................................................................................................................................................................

Shift Solenoid Inspection/Replacement

SPECIAL TOOLS:
PROCEDURE
NOTE:

3. Remove:
- Battery
- Battery shelf
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/
T > Component Information > Service and Repair > Shift Solenoid Inspection/Replacement > Page 5265

4. Install:
5. Remove:
- Left front wheel.
6. Oil, drain

7. Remove:

- Remove:
9. Remove:


13. Removal:
- Remove oil pipe.

14. Removal:
- Remove cover.
Use scraper.
Ensure
15. Preparation
- Remove:
Solenoid

- Solenoid S1
- Cable harness

17. Combinations
Illustration (A)
Illustration (B).
Illustration (A).

18. Solenoid SL
Illustration (C).
- Late versions
Illustration (D).
Illustration (C).

- Solenoid
10-15 STH:
-
Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. See: Automatic Transm
-
Replace complete control system as per step 2 of Control System Replacement. See: Automatic Transmiss

Body/Service and Repair(Solenoid STH is calibrated together with the control system).


- Install screws.
Tighten
- 10 NmTighten to:

10 NmTighten to:





12 Nm
Install oil pipe.




- Install:

50 NmTighten to:
50 NmTighten to:
30. Install:

25 NmTighten to:

32. Install:
- The front cover.

50 NmTighten to:
50 NmTighten to:

35. Install:
- Battery shelf
- Battery

- See Checking/Adjusting Oil Level. See: Automatic Transmission/Transaxle/Testing and Inspection
38. Checking DTCs
-
Use a suitable scan tool to check for and erase any Diagnostic Trouble Codes (DTCs). See: Testing and Inspe

SPECIAL TOOLS
1. Preparation
- Refer to steps 1 through 14 of Open The Control System. See: Automatic Transmission/Transaxle/Valve Bod
2. Preparation
- Remove:


- 0 ohms.Pin/Wire
Color gently
Pin No: 21
Pin No: 22
Pin No: 23
Pin No: 24
Pin No: 25


- Remove:
- Remove:





8. Install:
- Selector lever.
16 Nm.Tighten to:
10. Finishing work
Refer to steps 22 through 38 of Open The Control System. See: Automatic Transmission/Transaxle/Valve
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Soleno
Specifications

Resistance .........................................................................................................................................................................
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Soleno

Volvo Number ..................................................................................................................................................................

> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Informat
Replacement of Complete Unit
1. Removal
-
Remove:-
2. Installation
-
The shutter.
Install:-
- The panel.
> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Informat
Replacement of Complete Unit > Page 5292
- Ignition off.
- Replace the bulb.

> Transmission and Drivetrain > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Info
LOCATION

TEMPERATURE
ARC WELDING
REPLACING
and Serial Number

1 Volvo P/N
3 Part design
4 Serial number

and Serial Number > Page 5302
5303
CAUTION:
- (TCM)
NOTE:
-
2. Removing the TCM

- Ignition OFF
> Transmission and Drivetrain > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T >
Component Information > Application and ID > Page 5304

- Install new TCM.
- Ignition ON.

(AP)
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component
1. Preparations
- Remove:

> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T
> Component Information > Service and Repair > Page 5310

3. Removal
4. Reinstallation
- Cars with SRS:
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T
> Component Information > Service and Repair > Page 5311

- Reinstall cover
8. Checking DTCs
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Co
and Operation
ECON MODE (ECONOMY)
SPORT MODE (SPORT)
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Co
and Operation > Page 5315
- Ignition off.
-
EB2 Installing
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor,
Adjustments
SPECIAL TOOLS
PROCEDURE
1. Preparations
- Remove:
2. Adjustment
- Remove:
- Transmission
No.999from rodor
5475, armSelector
equivalent,lever
on control shaft.
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position

3. Adjustment
- Remove:

- Install:
16 Nm.

5. Install:
- Battery shelf
- Battery
6. Checking DTCs
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor,

1. Preparations
- Remove:
(ACL)
2. Removal
- Remove:

3. Disassembling
5. Reassembling

6. Reinstallation
- Tighten nut.
7. Adjustment

16 Nm.Tighten to:


- Install:

10. Checking DTCs
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Co

Speed Sensor ..............................................................................................................................................................
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Co
> Page 5328
1. Remove:
- Battery
- ACL bracket.

> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed
Sensor, A/T > Component Information > Specifications > Page 5329

- Remove sensor

6. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
7. Checking DTCs
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Sw
Specifications > Electrical Specifications

Resistance at:
0C ...............................................................................................................................................................................
20C .............................................................................................................................................................................
40C .............................................................................................................................................................................
80C .............................................................................................................................................................................
100C ...........................................................................................................................................................................
150C ...........................................................................................................................................................................
Specifications > Electrical Specifications > Page 5334


Volvo Number ..................................................................................................................................................................


1. Preparation
- Remove:
(ACL)

3. Remove:
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission
Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5337

4. Remove:

40 Nm.Tighten to:
- Remove sensor.

- 25 Nm.Tighten to:

9. Installation:


12. Reinstall:
- ACL bracket.
- Battery shelf
- Battery
- Top up oil and test refer to Checking/Adjusting Oil Level. See: Automatic Transmission/Transaxle/Testing an
13. Checking DTCs
- Check and erase DTCs. See: Testing and Inspection/Initial Inspection and Diagnostic Overview
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions
ABS Light: Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions >
Page 5346

1/1 Battery

2/2 Fog lamp relay

Page 5347

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 5348

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 5349

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 5350


11A/1-9 Main fuses

Page 5351

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 5352



Page 5353

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 5354

C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Page 5355
ABS Light: Description and Operation
ABS warning light
This is located on the instrument panel (dashboard) and is activated if the ABS system control module detects a fault
Warning: ABS and EBD are not available while Volvo Diagnostics is activated. Take great care when test dri
When the control module DTM is disengaged, the warning light comes on for approximately 2 seconds and then goe
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Specifications

SPECIFICATIONS
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Specifications > Page 5359
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Page 5373
Preparations
Disconnect
front endfrom
of carEBD
Protective

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Page 5374

TheO-ring
- Captive washer
-
Check
seal^

-
Finishing
-
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Diagrams > Diagram Information and Instructions
Diagnostic Connector - ABS: Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Electrical Specifications

SPECIFICATIONS
Power supply ....................................................................................................................................................................
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Electrical Specifications > Pag

Mounting bolts .................................................................................................................................................................
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructio

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 5404

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, Replace
[MMMM1]
Preparations
[MMMM2]
Remove:
[MMMM3]

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Control

[MMMM4]
Connect:
[MMMM5]
Function check
Warning!
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, Replace
[NNNNA1]


> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Diagram Information
Hydraulic Control Assembly - Antilock Brakes: Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams >

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Diagram Information
Hydraulic Control Assembly - Antilock Brakes: Exploded Views
Part 1 Of 2

ABS-control unit Hydraulic modulator - AWD, V70, V70XC, XC70
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Page 5426
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Hydraulic unit
The hydraulic unit (1) is integrated with the control module and is located in the engine compartment. The hydraulic
The control module controls, via the inlet and outlet valves and the hydraulic pump, the pressure to the different brak
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Page
5427

Cars fitted with TRACS have a different hydraulic unit. The difference is that:
^
The brake pipe (1) between the master cylinder primary circuit and the hydraulic unit is larger in diameter. This g
^
The valve block has an extra inlet valve (2) (TRACS inlet valve) which closes the connection between the hydrau
^
The valve block has an extra hydraulic valve (3) (TRACS valve) which closes the connection between the master
^
he valve block has an overflow valve (4). If the hydraulic pump supplies more brake fluid than is normally requir
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Page 5428
Hydraulic Control Assembly - Antilock Brakes: Service and Repair

OOOO. Hydraulic modulator, replacement
Note! Do not open the master cylinder under any circumstances. It takes special equipment and facilities to reass
[OOOO1]
Preparations
- Ignition off- Put rags under the hydraulic unit to protect painted surfaces against brake fluid spillage.- Depress brak
[OOOO2]
In cars with turbo
Remove:
- Intake pipe between filter casing and turbo unit
[OOOO3]
Locking brake pedal in position

- Jack car up- Remove cap from bleed nipple by LH front wheel.- Connect hose from drain bottle.- Open bleed nippl
[OOOO4]
Removing bracket and hydraulic unit
Remove:
- Brake pipe between hydraulic unit and master cylinder.- Undo brake pipe to wheel brakes.
5429

Seal off the brake pipe and connections on the hydraulic unit and master cylinder to prevent dirt getting into the syste
- Undo the connection to the control module by first pressing in the catches on the back of the cover (facing wheel ho
Remove:
- Bracket mounting bolts and lift bracket up.- Lift bracket up and undo vacuum hose.
[OOOO5]
In cars with TRACS:
- Lift bracket up slightly and move it forward.- Disconnect non-return valve and vacuum hose from brake servo.
[OOOO6]
Removing hydraulic unit from bracket

Note!
Hydraulic unit must be replaced as a complete unit. Hydraulic unit must not be opened under any circums
5430

- Disconnect pump motor connection from control module.- Remove bracket and control module from hydraulic unit
[OOOO7]
Checking hydraulic unit
Check that the hydraulic unit is of the correct type, depending on whether the car is fitted with TRACS. The differen
Note! The hydraulic unit must not be opened under any circumstances. Special equipment is needed for re-assem
[OOOO8]
Installing hydraulic unit
Note! The hydraulic unit is full of brake fluid. It is important not to remove the protective plugs until the brake p

1.8 NmCheck and install the control module to the hydraulic unit as per . See: Electronic Brake ControlModule/Serv
8 Nm
8 Nm- Install the new hydraulic unit on the bracket and tighten the mounting bolts. Tighten to .- Hold down the vacu
[OOOO9]
In cars with TRACS

5431

Insert vacuum hose between bracket and hydraulic unit. Check that non-return valve and rubber seals are intact and i
[OOOO10]
Installing hydraulic unit continued
14 Nm (10.3 ft lb)
- Connect connector to control module and pump motor.- Remove protective plugs and connect brake pipe to hydrau
[OOOO11]
In cars with turbo
Install:
- Intake pipe between air filter casing and turbo.
[OOOO12]
Finishing work
AAAA. Bleeding brakes with bleeding unit- Bleed braking system as per . See: Brake Bleeding/Service and Repa
Clean up any brake fluid spillage with lukewarm water and car-wash shampoo.
[OOOO13]
Function check
5432

- Read out any DTCs which are posted in the control module and replace them.- Switch off Volvo ST. Check that AB
Warning!
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructio
Traction Control Indicator Lamp: Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Diagrams > Page 5446
Traction Control Indicator Lamp: Description and Operation
Traction Control Not Working
This indicator is located in the instrument panel and comes on if TRACS is disengaged via the switch, if there is a fa
2 seconds 2 seconds
When the ignition is switched on or the engine starts, the control module switches the warning light on. The light the
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Description and Operation
TRACS switch
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Description and Operation > Page 5450
- Ignition off.
-
EB2 Installing
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram Information and Instruction

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS Wheel Sensor - Installat
No.109
Date:FEBRUARY, 1998

9995694-8 U.S. $43.65 $50.85
(EG-139-98-06)
9995694-8 CANADA $61.11 $71.19

(EG-339-98-06)

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5468

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 5480
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [KKKK]
[KKKKA1]
Preparations
- Ignition off.
- Remove wheel.
[KKKKA2]
Removing sensor

- Remove connector.
[KKKKA3]
Installing sensor
[KKKKA4]

[KKKKA5]
Installing wheel
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [
KKKK] > Page 5483

- Install wheel.
[KKKKA6]
Operational checks
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [KKKK] > Page 5
[LLLLA1]
Preparations
4-door cars:
5-door cars:
[LLLLA2]
KKKK] > Page 5485

[LLLLA3]
[LLLLA4]

[LLLLA5]
KKKK] > Page 5486

[LLLLA6]
Finishing
[LLLLA7]
Operational checks
KKKK] > Page 5487


- Wheel sensor
-
KKKK] > Page 5489

Strip insulation
KKKK] > Page 5490

Strip cable pairs
Twist cable ends

KKKK] > Page 5491


KKKK] > Page 5492


Foldheat-shrink
tubing is
asintended
illustrated
to(arrow).
provide Carefully
good electrical
pull the
insulation.Hold
heat-shrink tubing
a putty
over
knife
thebehind
soldered
thecable
heat-shrink
splices.tub
KKKK] > Page 5493

Checking ABS system
Ignition
After repairsoff.
KKKK] > Page 5494

Special tools:
999 5242
Remove:
Clean:
Install/reconnect:
KKKK] > Page 5496

> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA]
[AAAA1]
Note!
[AAAA2]
Preparations
Remove:
- Filler Gap.
[AAAA3]

> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA] > Page 5501

[AAAA4]
Remove:
Remove:
[AAAA5]


Remove:
[AAAA6]
Check
200 N
40 mm (1.6 in)
40mm (1.6 in)
[BBBB1]
[BBBB2]
Preparations
Ignition off.
- Jack car up.
Remove:
[BBBB3]


[BBBB4]
Check
200 N
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications

Brake pedal, knee guard ...................................................................................................................................................
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5508
Brake Pedal Assy: Description and Operation
OPERATION
The brake light switch is located by the brake pedal. It is activated by the brake pedal arm and switches the car's b
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5509
Brake Pedal Assy: Service and Repair
VVV. Brake pedal, replacement of bushes
VVVA. Brake pedal, replacing bushings
[VVVA1]
Removal
- Remove sound insulation.

- In cars with SRS, remove knee-guard.
- Disconnect brake pedal from support bracket by removing locking spring.
- Remove locking washer, bushings and brake pedal.
[VVVA2]
Installing
- Grease new bushings with grease 116 1241-3.

- Install new bushings.
- Install brake pedal and a new locking washer.
- Connect brake pedal to support bracket by locking spring.
- 20 Nm (15 ft lbs)In cars with SRS, install knee-guard, tighten to .
- Install sound insulation.
> Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions
Brake Warning Indicator: Diagram Information and Instructions

> Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5514

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Page 5523
Brake Warning Indicator: Description and Operation
Brake circuit warning light
The warning light is located on the instrument panel (dashboard) and comes on if the brake fluid in the brake fluid le
When the ignition is switched on, the warning light comes on whatever the position of the brake fluid level sensor. O
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel
Brake Caliper: Description and OperationBrake Caliper and Brake Discs on Front Wheel
Brake caliper and brake discs on front wheel
Front wheel brakes have ventilated brake discs (1) and sliding brake caliper (2) with special brake blocks (3) making
The brake caliper has two main components: the caliper and the caliper mounting. The caliper slides in the caliper m
Braking force from the brake pads is absorbed by the caliper mounting, which transmits the force to the spindle. The
The pressure on the piston is transmitted directly to the nearest brake pad and via the caliper to the other brake pad. T
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel > Page 5529
Brake Caliper: Description and OperationBrake Caliber and Brake Discs, Rear Wheel
Brake caliber and brake discs, rear wheel
The rear wheel brakes have solid brake discs (4) and fixed brake calipers (5). The brake disc hub (6) also acts as the
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper, Servicing
Brake Caliper: Service and RepairBrake Caliper, Servicing
Front Brake Caliper, Repair [OOO]

OOO. Front brake caliper, repair
OOOA. Brake caliper front, overhaul
Special tools: 115 8147, 981 4071
[OOOA1]
Preparations
- Remove wheel.
[OOOA2]
Draining brake fluid
- Clean brake caliper carefully.- Remove protective cap from bleed nipple and open nipple.- Lock pedal in depressed
[OOOA3]
Removing brake caliper and brake pads

7 mm (0.276")- Undo brake hose (1/2 turn).- Remove retaining spring (3) carefully to avoid deforming it.- Remove
[OOOA4]
- Remove brake caliper carefully from mounting to avoid damaging brake hose.- Remove brake pads.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper, Servicing > Page 5532

[OOOA5]
Removing brake hose
- Unscrew brake caliper from brake hose.- Drain remaining brake fluid.
[OOOA6]
Dismantling brake caliper
Warning! Take care to avoid getting fingers caught when piston is pushed out.
- Put a block of wood in front of piston. Push piston out carefully using compressed air.
[OOOA7]
- Remove dirt guard (3).- Remove 0-ring (4). Use weatherstrip tool 981 4071 or similar so as not to damage edges of
[OOOA8]
Cleaning and inspection

- Clean components in turpentine. Check for wear, damage, cracks and rust. Replace components if necessary.- Alwa
[000A9]
Assembling brake caliper

- Blow ducts clean with compressed air.- Coat cylinder lining, piston (2) and new 0-ring (4) with brake fluid.- Install
[OOOA10]
9 Nm (7 ft lb)- Install dirt guard in groove inside cylinder and push piston in carefully.- Check that dirt guard slots in
[OOOA11]
Finishing

Front Wheel Brake Linings, Replacement [MMM]- Install rubber bushings in brake caliper.- Screw brake caliper
Rear Brake Caliper, Repair [PPP]

PPP. Rear brake caliper, repair
PPPA. Brake caliper rear, overhaul
Special tools: 115 8147, 981 4071,999 2809,999 2917
[PPPA1]
Preparations
- Remove wheel
[PPPA2]
Removing brake caliper

- Clean brake caliper carefully.- Remove protective cap from bleed nipple and open nipple.

[PPPA5]- Lock pedal in depressed position using a pedal jack.- Collect emerging brake fluid.- If brake pads are rem
[PPPA3]
Removing brake pads
3 mm (0.12")
- Knock out split pins with a mandrel.- Remove retaining spring.
[PPPA4]
- Remove brake pads and shims. Use puller 999 2917 if brake pads will not come out easily.
[PPPA5]

- Remove brake pipe from brake caliper.- Remove brake caliper mounting bolts (1) and let caliper down.- Drain rem
[PPPA6]

Warning! Take care not to get fingers caught when piston is pushed out.
- Remove dirt guard (3).- Put a block of wood in front of pistons (4) and press out carefully with compressed air.- Re
[PPPA7]
- Use weatherstrip tool 981 4071 or similar to remove O-rings (5).- Remove bleed nipple (7).
Note! Do not separate the two halves. This requires special pressure testing equipment and special assembly flui
[PPPA8]
- Clean components with turpentine. Check for wear, damage, cracks and rust. Replace components it necessary.- Al
[PPPA9]

5 Nm (4 ft lb)- Coat pistons, cylinder lining and 0-rings with brake fluid.- Install 0-rings (5) in cylinder grooves.- Ins
[PPPA1O]
Installing brake caliper

60 Nm (45 ft lb)
14 Nm (10 ft lb)- Install brake caliper. Use new bolts and tighten to .- Install brake pipe on caliper, tighten to .
[PPPA11]
Finishing
Rear Wheel Brake Linings, Replacement [NNN]Refer to:

Brake Caliper: Service and RepairBrake Caliper, Replacing
Front
Replacing the front brake calipers
Removal
Collect the brake fluid

Remove the wheel.
Secure the pedal in the depressed position. Use a pedal jack.Clean the brake caliper thoroughly.Remove the protectiv
Remove the securing spring and locating pins
Slacken off the brake hose (4) from the brake caliper half a turn.
Remove:
the securing spring (3) carefully so that it does not deform
-- the protective caps (1) from the two locating pins (2)
- the locating pins, use a hex socket 7 mm.
Remove the brake caliper and brake pads

the brake
Remove: - caliper from the holder
- the brake hose from the brake caliper. Drain the remaining brake fluid
- the brake pads.
Note: Do not depress the brake pedal while the brake pads are removed.
Installation
Install the brake pads and brake caliper
Install:
the brake hose (4) in the brake caliper. Do not tighten the hose yet
-- the brake pads
- the brake caliper.
Install the locating pins (2) in the brake caliper
30 Nm
18 NmCheck the rubber sleeves of the locating pins. Replace if necessary. Lubricate the locating pins using grease, P
Check the brake hose Ensure that the brake hose is not twisted. If necessary alter the hose at the other end (brake pi
Note: If the brake hose is twisted it may rub against the tire, rim or wheel arch. This could cause the circuit to fail.
Note: Use only Volvo Genuine parts brake fluid (Volvo DOT 4+).

the function
Check: - of the brakes after bleeding. Check that there is no leakage
- the brake fluid level. Depress the brake pedal a few times. Check the level of the brake fluid reservoir. Top up if
Install the wheel

Installing wheels
Rear
Replacing the rear brake calipers
Removal

Replacing the front brake calipers.

Slacken off the brake hose (4) half a turn.
Remove:

the brake
- the brake hose from the caliper

- the brake pads.
Drain any remaining brake fluid.
Installation
Install:
-- the brake pads
30 Nm
Check the brake hose
Ensure that the brake hose is not twisted. If necessary alter the hose at the other end (brake pipe end).

Install the wheel

Installing wheels.
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front
Brake Pad: SpecificationsFront
Brake pads front, replacement
Minimum thickness
3.0 mm (0.12")Replacement point ..................................................................................................................................

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 5546
Brake Pad: SpecificationsRear
Brake pads rear, replacement
Minimum thickness
2.0 mmReplacement point ...............................................................................................................................................

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Front, Replacement
Brake Pad: Service and RepairBrake Pads Front, Replacement
51: Replacing components, AW42 AWD
Brake pads front, replacement
Special tools:
115 8147
Minimum thickness
3.0 mm (0.12")Replacement point =
Preparations
- Remove wheel.
- Remove retaining spring (3) carefully to avoid deforming it.

- Remove protective caps (1) from the two locating pins (2).
- 7 mm (0.276")Remove both locating pins, using hexagonal socket.
- Remove brake caliper carefully from mounting so as not to damage brake hose.
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Front, Replacement > Page 5549

- Remove brake pads.
- Suspend brake caliper from a steel wire in front spring to avoid damaging hose.
Note! Do not depress brake pedal while brake pads are removed.
Cleaning and checking

- Clean brake pad contact surfaces in brake caliper and on caliper mounting.
- Check piston dirt guard.
- If dirt guard looks worn, replace it as a precautionary measure.
- If dirt guard is damaged, overhaul brake caliper as per Brake caliper front, overhaul.
Note! If dirt guard is damaged, dirt may have penetrated into the cylinder and so the brake caliper needs to be overhaul
Checking brake disc

- Check brake disc friction surface.
- If brake disc shows signs of being skew, check its lateral run-out as per Measuring lateral run-out on brake disc.
- If brake disc shows signs of major wear, variations in thickness etc., replace it as per Brake disc front, replaceme
Note! 23.0 mm (0.9") 23.8 mmDisc thickness = replacement point = . Minimum recommended disc thickness when in
(0.94").
Installation of itemsInstallation of locating pins

- Check locating pin rubber bushings. Replace as necessary
- Grease locating pins with Volvo silicon grease (PN 116 1325-4) and insert them in rubber bushings (4). Pin shou
Installation of brake caliper and brake pads

- Push piston back in cylinder on brake caliper.
- Check that dirt guard is positioned correctly.
- Install new brake pads and install brake caliper.
- 30 Nm (22 ft.lb)Tighten locating pins to and install protective caps.
- Install retaining spring (3).
Finishing and checking

- If brake hose was not unscrewed, go to Checking brake fluid level.
- 18 Nm (13 ft.lb)If brake hose was unscrewed, tighten brake hose onto brake caliper to
Note! Make sure that hose is not twisted. There is a white line running along the hose which shows if the hose is twiste
necessary.
- Top up and bleed braking system as per Bleeding brakes. Then continue as below.
- Check that there are no leaks and that brakes are working properly.
Checking brake fluid level

- Push brake pedal down a few times.
- Check level in brake fluid reservoir. Top up brake fluid if necessary.
Installation of wheel
- Make sure that brake discs and rin contact surfaces are clean.
- Install wheel

- 110 Nm (80 ft.lb)Tighten bolts handtight. Then tighten them crosswise to If using airgun, use torque socket 115
Note! Tightening bolts crosswise to a specific torque setting is important in preventing stresses in the brake disc.
Brake Pad: Service and RepairBrake Pads Rear, Replacement
51: Replacing components, AW42 AWD
Brake pads rear, replacement

- Lift up the rear suspension.
- Remove the wheels.
- Remove the screw in the lower sliding bolt.
- Counterhold with a 15 mm wrench.
- Fold up the piston housing and hang with a steel wire.

- Remove the brake pads

Note! Do not depress the brake pedal while the linings are removed.
- Clean the lining's contact surfaces in the yoke.

- Check the dirt protection for the brake piston.
- If dirt has penetrated the cylinder on account of damaged dirt protection, the brake yoke must be renovated in acc
- Press back the piston fully:

- Use a Polygrip.
- Use one of the old brake linings as a block against the piston.
- If the piston runs sluggishly this may be due to corrosion.
- This is recognised by the piston not springing back when pressed in.
- The yoke must then be renovated according to.
Note!
When pressing in the level in the brake fluid reservoir can rise resulting in brake fluid spraying out. Check the rubberpr
Checking brake discs

- If the brake discs are heavily worn, deformed or the thickness varies they should be replaced according to.
Thickness brake disc

Install new linings.
- Turn the piston housing.
- Turn carefully so that the dirt protection is not damaged.
- Tighten the screw on the lower sliding bolt.
- 34 NmThe torque must be .
Note! Use new screws.
Check the brake fluid level.

- Check the level of the brake fluid reservoir.
- Depress the brake pedal repeatedly.
- Mount the wheels.
- Install the wheels. See Installing wheels.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc
Brake Rotor/Disc: SpecificationsBrake Rotor/Disc
Front
Front brake disc, replacement
23.0 mm (0.9")
23.8 mm (0.94")
280 mm 0.040 mmMin. disc thickness = replacement point ..........................................................................................
Rear Brake Rotor Dimensions

Rear Brake Rotor Dimensions
All brake rotors have a discard dimension cast into them. This is a wear dimension and not a refinish dimension. An
Alternative 2 AWD Outer Diameter 283.0 mm

Alternative 2 is aplicable to All Wheel Drive (AWD)
vehicles built up to and including week 49 of 1998. The
brake rotor is manufactured by Lucus.
Thickness New 10.0 mm
Minimum Thickness 8.0 mm
Max Thickness Variation 0.008 mm
Maximum Runout Loose Disc 0.040 mm
Mounted on Hub 0.060 mm
Alternative 3 AWD Outer Diameter 288.0 mm

Alternative 3 is aplicable to All Wheel Drive (AWD)
vehicles built from and including week 50 of 1998. The
brake rotor is manufactured by Teves.
Thickness New 12.0 mm
Minimum Thickness 10.0 mm
Max Thickness Variation Loose Disc 0.035 mm
Mounted on Hub 0.040 mm

> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 5559
Brake Rotor/Disc: Specifications
Attaching Bolts: Front 10 Nm
Rear 25 Nm
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel
Brake Rotor/Disc: Description and OperationBrake Caliper and Brake Discs on Front Wheel
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel > Page 556
Brake Rotor/Disc: Description and OperationBrake Caliber and Brake Discs, Rear Wheel
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Measuring Lateral Wheel Hub Movement [SSS]
Brake Rotor/Disc: Testing and InspectionMeasuring Lateral Wheel Hub Movement [SSS]
SSS. Measuring lateral wheel hub movement
SSSA. Measuring lateral run-out in hub
Special tools: 999 5418, 999 5507
[SSSA1]
Preparations
[QQQA2 - QQQA4 or RRRA2 - RRRA5]- Get measurement tool set 999 5418.- Remove brake caliper and brake p
Note Mark brake disc up against hub so disc can return to its old position when installing.
[SSSA2]
[SSSA3]

- Install measurement equipment as per illustration. Illustration shows testing front.- Front: Use M8 bolts, washers an
Note! Make sure that bracket is not lying against driveshaft gaiter, (front only).
- Rear: Use the bolts included in the measurement tool set when installing measurement tool bracket to the rear brake
[SSSA4]
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Measuring Lateral Wheel Hub Movement [SSS
] > Page 5565

- Put the test gauge point against the hub flange as in the illustration.- Rotate hub gently. Use a wheel wrench as an a
Note! Illustration shows testing front.
0.02 mm (0.00079")
0.020 mm (0.00079")- Note test gauge run-out. Hub lateral run-out must not exceed .- Replace hub if maximum late
Front: Replace hubRear:Replace hub
[SSSA5]
Finishing
8 Nm (6 ft lb)- Install brake disc on hub, lining up marks. Tighten locating pin and bolt to .
Front Brake Disc, Replacement [QQQA7 - QQQA8] Rear Brake Disc, Replacement [RRRA8 - RRRA9]- Go to
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Measuring Lateral Wheel Hub Movement [SSS] > Page 5566
Brake Rotor/Disc: Testing and InspectionMeasuring Brake Disc Lateral Movement [TTT]
TTT. Measuring brake disc lateral movement
TTTA. Measuring lateral run-out on brake disc
Special tools: 115 8147, 999 5418, 999 5442, 999 5507
[TTTA1]
Preparations
- Get measurement tool set 999 5418, 999 5418.
Front:Remove brake caliper from caliper mounting as per [MMMA1-MMMA4] See: Brake Pad/Service and Repair
[TTTA2]
Installing clamp ring

Hubs with four wheel bolts: Install clamp ring 999 5442 on hub with wheel nuts.
Hubs with five wheel bolts:
110 Nm (80 ft lb)- Install clamp ring 999 5419 from measurement tool set 999 5418 on hub with wheel nuts.- Make
[TTTA3]
Installing test equipment
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Measuring Lateral Wheel Hub Movement [SSS
] > Page 5567

Front:
Rear:
0.040 mm (0.0016") 0.080 mm (0.0031")Install measurement tool set bracket. Attach bracket to caliper mounting w
QQQA. Brake disc front, replacement RRRA. Brake disc rear, replacement- Remove test equipment.- If brake d
Note! Illustration shows testing front.
[TTTA4]
Finishing
Rear Wheel Brake Linings, Replacement [NNNA7 - NNNA12]Go to . See: Brake Pad/Service and Repair
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Disc, Replacement [QQQ]
Brake Rotor/Disc: Service and RepairFront Brake Disc, Replacement [QQQ]

QQQ. Front brake disc, replacement
QQQA. Brake disc front, replacement
[QQQA1]
Preparations
- Remove wheel.
[QQQA2]
7 mm (0.276")- Remove retaining spring (3) carefully so as not to deform it.- Remove protective caps (1) from the t
[QQQA3]
- Remove brake caliper carefully from mounting so as not to damage brake hose.- Remove brake pads.- Hang brake
Note! Do not depress brake pedal while brake pad is removed.
[QQQA4]
Removing brake disc
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Disc, Replacement [QQQ] > Page
5570

- Remove both caliper mounting bolts and remove mounting.- Remove locating pins (and bolt on earlier models).- R
[QQQA5]
Note! Cleaning is important to prevent lateral run-out in brake disc.
SSSA. Measuring lateral run-out in hub- Make sure that hub flange is clean. Remove rust with a steel blade and st
[QQQA6]
Installing brake disc
Note! Handle new brake disc with care. Careless handling can cause damage (e.g. twisting).
8 Nm (6 ft lb)- Install new brake disc. Tighten locating pins (and bolt) to .
[QQQA7]
100 Nm (75 ft lb)- Install caliper mounting with new mounting bolts. Tighten both mounting bolts to
[QQQA8]
Finishing
Front Wheel Brake Linings, Replacement [MMMA7-MMMA13]- Go to . See: Brake Pad/Service and Repair
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Disc, Replacement [QQQ] > Page 5571
Brake Rotor/Disc: Service and RepairRear Brake Disc, Replacement [RRR]

RRR. Rear brake disc, replacement
RRRA. Brake disc rear, replacement
Special tools: 115 8147,999 2917
[RRRA1]
Preparations
- Remove wheel.
[RRRA2]
Removing brake pads
3 mm (0.12")
- Push out split pins with a mandrel.- Remove retaining spring.
[RRRA3]
[RRRA4]

5572

- Remove both caliper mounting bolts and remove brake pipe from clips. If removing LH brake caliper, you will also
[RRRA5]
Removing brake disc
- Undo parking brake adjusting screw until brake disc can be removed. Access the adjusting screw by turning the bra
[RRRA6]
Note! Cleaning is important to avoid lateral run out in the brake disc.
SSSA. Measuring lateral run-out in hub- Make sure that hub flange is clean. Remove rust with a steel blade and st
[RRRA7]
Installing brake disc

5573

Note! Take care when handling the new brake disc. Careless handling can cause damage (e.g. warping).
8 Nm (6 ft. lb)- Install new brake disc on hub.- Install locating pin and tighten to .
[RRRA8]
60 Nm (45 ft.lb)
- Install brake caliper with new bolts. Tighten to .- Install brake pipe in clips.- Install three way connector mounting b
[RRRA9]
Finishing
Rear Wheel Brake Linings, Replacement [NNNA7-NNNA12]- Go to . See: Brake Pad/Service and Repair
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA]
[AAAA1]
Note!
[AAAA2]
Preparations
Remove:
- Filler Gap.
[AAAA3]

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA] >
Page 5579

[AAAA4]
Remove:
Remove:
[AAAA5]

Page 5580

Remove:
[AAAA6]
Check
200 N
40 mm (1.6 in)
40mm (1.6 in)
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brakes With Bleeding Unit [AAAA] > Page 5581
[BBBB1]
[BBBB2]
Preparations
Ignition off.
- Jack car up.
Remove:
[BBBB3]

Page 5582

[BBBB4]
Check
200 N
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel
Brake Caliper: Description and OperationBrake Caliper and Brake Discs on Front Wheel
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Brake Caliper and Brake Discs on Front Wheel > Page
Brake Caliper: Description and OperationBrake Caliber and Brake Discs, Rear Wheel
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper, Servicing
Brake Caliper: Service and RepairBrake Caliper, Servicing
Front Brake Caliper, Repair [OOO]

OOO. Front brake caliper, repair
OOOA. Brake caliper front, overhaul
Special tools: 115 8147, 981 4071
[OOOA1]
Preparations
- Remove wheel.
[OOOA2]
Draining brake fluid
- Clean brake caliper carefully.- Remove protective cap from bleed nipple and open nipple.- Lock pedal in depressed
[OOOA3]

7 mm (0.276")- Undo brake hose (1/2 turn).- Remove retaining spring (3) carefully to avoid deforming it.- Remove
[OOOA4]
- Remove brake caliper carefully from mounting to avoid damaging brake hose.- Remove brake pads.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper, Servicing > Page 5590

[OOOA5]
Removing brake hose
- Unscrew brake caliper from brake hose.- Drain remaining brake fluid.
[OOOA6]
Warning! Take care to avoid getting fingers caught when piston is pushed out.
- Put a block of wood in front of piston. Push piston out carefully using compressed air.
[OOOA7]
- Remove dirt guard (3).- Remove 0-ring (4). Use weatherstrip tool 981 4071 or similar so as not to damage edges of
[OOOA8]

- Clean components in turpentine. Check for wear, damage, cracks and rust. Replace components if necessary.- Alwa
[000A9]

- Blow ducts clean with compressed air.- Coat cylinder lining, piston (2) and new 0-ring (4) with brake fluid.- Install
[OOOA10]
9 Nm (7 ft lb)- Install dirt guard in groove inside cylinder and push piston in carefully.- Check that dirt guard slots in
[OOOA11]
Finishing

Front Wheel Brake Linings, Replacement [MMM]- Install rubber bushings in brake caliper.- Screw brake caliper
Rear Brake Caliper, Repair [PPP]

PPP. Rear brake caliper, repair
PPPA. Brake caliper rear, overhaul
Special tools: 115 8147, 981 4071,999 2809,999 2917
[PPPA1]
Preparations
- Remove wheel
[PPPA2]

- Clean brake caliper carefully.- Remove protective cap from bleed nipple and open nipple.

[PPPA5]- Lock pedal in depressed position using a pedal jack.- Collect emerging brake fluid.- If brake pads are rem
[PPPA3]
Removing brake pads
3 mm (0.12")
- Knock out split pins with a mandrel.- Remove retaining spring.
[PPPA4]
[PPPA5]

- Remove brake pipe from brake caliper.- Remove brake caliper mounting bolts (1) and let caliper down.- Drain rem
[PPPA6]

Warning! Take care not to get fingers caught when piston is pushed out.
- Remove dirt guard (3).- Put a block of wood in front of pistons (4) and press out carefully with compressed air.- Re
[PPPA7]
- Use weatherstrip tool 981 4071 or similar to remove O-rings (5).- Remove bleed nipple (7).
Note! Do not separate the two halves. This requires special pressure testing equipment and special assembly flui
[PPPA8]
- Clean components with turpentine. Check for wear, damage, cracks and rust. Replace components it necessary.- Al
[PPPA9]

5 Nm (4 ft lb)- Coat pistons, cylinder lining and 0-rings with brake fluid.- Install 0-rings (5) in cylinder grooves.- Ins
[PPPA1O]
Installing brake caliper

60 Nm (45 ft lb)
14 Nm (10 ft lb)- Install brake caliper. Use new bolts and tighten to .- Install brake pipe on caliper, tighten to .
[PPPA11]
Finishing
Rear Wheel Brake Linings, Replacement [NNN]Refer to:

Brake Caliper: Service and RepairBrake Caliper, Replacing
Front
Replacing the front brake calipers
Removal

Remove the wheel.
Secure the pedal in the depressed position. Use a pedal jack.Clean the brake caliper thoroughly.Remove the protectiv
Slacken off the brake hose (4) from the brake caliper half a turn.
Remove:

the brake
- the brake hose from the brake caliper. Drain the remaining brake fluid
- the brake pads.
Installation
Install:
-- the brake pads
30 Nm
Check the brake hose Ensure that the brake hose is not twisted. If necessary alter the hose at the other end (brake pi
Note: Use only Volvo Genuine parts brake fluid (Volvo DOT 4+).

the function
Check: - of the brakes after bleeding. Check that there is no leakage
- the brake fluid level. Depress the brake pedal a few times. Check the level of the brake fluid reservoir. Top up if
Install the wheel

Installing wheels
Rear
Replacing the rear brake calipers
Removal


Slacken off the brake hose (4) half a turn.
Remove:

the brake
- the brake hose from the caliper

- the brake pads.
Drain any remaining brake fluid.
Installation
Install:
-- the brake pads
30 Nm
Check the brake hose
Ensure that the brake hose is not twisted. If necessary alter the hose at the other end (brake pipe end).

Install the wheel

Installing wheels.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications
Brake Fluid: SpecificationsFluid type

Fluid type
Fluid Type DOT 4 +

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5603
Brake Fluid: Testing and Inspection

REPLACEMENT GUIDELINES
Replacing brake fluid is recommended every 48000 km (30 000 miles), or every other year. In cars where the bra
BACKGROUND
The reason that brake fluid should be changed is that brake fluid is hygroscopic: that is, it absorbs water molecule
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service and Repair > Brake Fluid, Replacement With Bleeding Unit [CCCC]
Brake Fluid: Service and RepairBrake Fluid, Replacement With Bleeding Unit [CCCC]
CCCC. Brake fluid, replacement with bleeding unit
Special tools: 115 8147, 999 2809
[CCCC1]
48,000 km (30,000 miles)

[CCCC2]
Background
Note! Use only Volvo original brake fluid marked DOT 4+. Never re-use brake fluid.Always keep brake fluid in
[CCCC3]
Preparations
Ignition off
0.2 - 0.3 MPa (29-42.7 psi)- Jack car up and remove wheels.- Clean around brake fluid reservoir cap.- Remove fillin
[CCCC4]
- connect bleeding unit to brake fluid reservoir.
Follow manufacturers' instructions for connecting and using bleeding unit.
[CCCC5]
Replacing brake fluid LH front

Remove:
- Protective cap from bleed nipple on front LH brake caliper.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service and Repair > Brake Fluid, Replacement With Bleeding Unit [
CCCC] > Page 5606

Connect drain bottle hose. Open nipple approx. one turn.
2 - 3 dl (0.2 - 0.3 US qt)
- Push brake caliper piston to bottom of caliper using a bolt clamp. Leave bolt clamp in the pushed-in position.- Pres
[CCCC6]
Replacing brake fluid RH, front
[CCCC3 - CCCC5]- Repeat steps , on the front RH brake caliper. Then continue as per instructions below.
[CCCC7]
Remove:
- Brake pad from brake caliper as per KB , Service manual, TP 5001011.
[CCCC8]
- Remove protective cap from bleed nipple.- Connect drain bottle hose.- Open nipple approx. one turn.- Push brake c
[CCCC9]
Installing rear brake pad
- Install brake pad as per KB , Service manual, TP 5001011.- Depress brake pedal a few times.
[CCCC10]
- Repeat steps CCCC6 - CCCC8, on RH rear brake caliper.
CCCC] > Page 5607

[CCCC11]
Removing bleeding unit
Remove:
- Bleeding unit connection from brake fluid reservoir.
[CCCC12]
Finishing work
[CCCC13]
Installing wheels
Install:
110 Nm (81.2 ft lb)- Wheel.- Nuts hand tight. Then tighten them in a star pattern to . It tightening with a nut wrench
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service and Repair > Brake Fluid, Replacement With Bleeding Unit [CCCC] > Page 5
Brake Fluid: Service and RepairBrake Fluid, Replacement Without Bleeding Unit [DDDD]
DDDD. Brake fluid, replacement without bleeding unit
Special tools: 115 8147, 999 2809
[DDDD1]
48,000 km (30,000 miles)

[DDDD2]
Background
Note!
[DDDD3]
Preparations
- Ignition off.- Jack car up and remove wheels.- Clean around brake fluid reservoir cap. Get a drain bottle and hose to
[DDDD4]
Replacing brake fluid, front
2 - 3 dl (0.2 - 0.3 US qt)
[DDDD5]
CCCC] > Page 5609

Replacing brake fluid RH front
[DDDD2 - DDDD4]- Repeat steps , on the front RH brake caliper.
[DDDD6]
- Remove brake pad brake caliper.
[DDDD7]
2 - 3 dl
Remove:
- Remove tools from brake caliper.
[DDDD8]
Install brake pad.
- Depress brake pedal a few times.
[DDDD9]
Repeat steps
CCCC] > Page 5610

[DDDD10]
Finishing work
Clean off any brake fluid spillage with lukewarm water and car-wash shampoo.
[DDDD11]
Installing wheels
110 Nm- Grease hub center rim guide with anti-rust agent 116 1038-3.- Re-fit wheel.- Tighten nuts hand tight. Then
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Specifications

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions

> Page 5616

1/1 Battery

2/2 Fog lamp relay

> Page 5617

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
> Page 5618

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

> Page 5619

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

> Page 5620


11A/1-9 Main fuses

> Page 5621

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

> Page 5622



> Page 5623

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

> Page 5624

C70 all

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5625
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5626

- Unscrew cover.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Rear Brake Hose - Revised
Brake Hose/Line: Technical Service BulletinsRear Brake Hose - Revised
Section5
Group52
No.0005
Year99
Month06
850/S70/V701997-
Vehicles involved: AWD
Brake hose AWD, new spare part
Background:
As a running change in production a new type of brake hoses has been introduced. If for any reason the rear brake hose
If one of the brake hoses needs to be replaced, the other side must be replaced as well.
Materials:
Rear brake hose AWD 2 9475298

Brake hose bracket 2 9475299
Brake hose AWD, new version
Replacing the brake hose AWD
Preparations
Note!
Ensure proper collection of brake fluid from calipers.
Remove the rear wheels.
Remove protective cap from the bleed nipple and open the nipple.
Lock the pedal in its depressed position with a pedal jack/stopper.

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Rear Brake Hose - Revised > Page
5631

2
Replacing the brake hose
Remove the brake hose.
Install the bracket and the new brake hose as illustrated.
Repeat step on other side of car.
The tightening torque for the brake hoses must be 18 Nm (37 ft.lbs).
Rust-proof the metal components on the brake hose at the brake caliper. Spray rust proofing agent in between the brake
Bleeding of brakes, Bleeding brake system without a bleeding unit Service Manual Section 5(50, 52, 55, 59), Brakes (i
Wipe off any brake fluid spill.
Reinstall rear wheels torque to 100 Nm (78 Ft.lbs)
Ensure the brakes are functioning normally.
Operation No. Labor Description Time Allowance
51001-2 Bleeding the brake system 2 rear wheels 0.1 hr

52205-2 Replacing the rear brake hose x1 0.2 hr
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose
Brake Hose/Line: SpecificationsBrake Hose

Brake Hoses .....................................................................................................................................................................
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 5634
Brake Hose/Line: SpecificationsBrake Line

Flange Nut ........................................................................................................................................................................
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5635
Part 2 Of 2
Brake Hose/Line: Description and Operation
Brake pipes
4.75 mm (3/8 inch)

6.35 mm (1/4 inch)
The brake pipes have an external diameter of approximately . If the braking system is fitted with TRACS, the brake p
Brake Hose/Line: Service and Repair

UUU. Brake pipes and hoses, replacement
UUUA. Brake pipe and hoses, replacement
[UUUA1]
Removal
- Remove brake pipe and hoses.
Note! Check that brake pipe and hoses are not damaged by plastic mounting to the left on the rear axle when the
[UUUA2]
Installing brake pipe
14 Nm (10 ft lb)- Install pipe. It may need bending to the right shape.- Blow pipe through clean with compressed air
[UUUA3]
Installing brake hoses
18 Nm (13 ft lb)- Install hoses. Hoses must not be twisted when in position. Hoses have white lines running along th
[UUUA4]
Bleeding
Bleeding brakes- Bleed braking system as per: . See: Brake Bleeding/Service and Repair
[UUUA5]
Cleaning
Always carry out the following cleaning procedure after overhauling the braking system or installing new parts to rem
- Clean brake pipe by flushing out with clean brake fluid or turpentine.

- Blow pipe clean with dry, filtered compressed air.
NOTE:
Always carry out the following cleaning procedure after overhauling the braking system or installing new parts to remo
1. Clean brake pipe by flushing out with clean brake fluid or turpentine.2. Blow pipe clean with dry, filtered compres
> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Diagram Information and Instructions
Hydraulic Control Assembly - Antilock Brakes: Diagram Information and Instructions

> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Diagram Information and Instructions
Hydraulic Control Assembly - Antilock Brakes: Exploded Views
Part 1 Of 2

ABS-control unit Hydraulic modulator - AWD, V70, V70XC, XC70
> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Page 5654
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Hydraulic unit
The hydraulic unit (1) is integrated with the control module and is located in the engine compartment. The hydraulic
The control module controls, via the inlet and outlet valves and the hydraulic pump, the pressure to the different brak

Cars fitted with TRACS have a different hydraulic unit. The difference is that:
^
The brake pipe (1) between the master cylinder primary circuit and the hydraulic unit is larger in diameter. This g
^
The valve block has an extra inlet valve (2) (TRACS inlet valve) which closes the connection between the hydrau
^
The valve block has an extra hydraulic valve (3) (TRACS valve) which closes the connection between the master
^
he valve block has an overflow valve (4). If the hydraulic pump supplies more brake fluid than is normally requir
Hydraulic Control Assembly - Antilock Brakes: Service and Repair

OOOO. Hydraulic modulator, replacement
Note! Do not open the master cylinder under any circumstances. It takes special equipment and facilities to reass
[OOOO1]
Preparations
- Ignition off- Put rags under the hydraulic unit to protect painted surfaces against brake fluid spillage.- Depress brak
[OOOO2]
In cars with turbo
Remove:
- Intake pipe between filter casing and turbo unit
[OOOO3]
Locking brake pedal in position

- Jack car up- Remove cap from bleed nipple by LH front wheel.- Connect hose from drain bottle.- Open bleed nippl
[OOOO4]
Removing bracket and hydraulic unit
Remove:
- Brake pipe between hydraulic unit and master cylinder.- Undo brake pipe to wheel brakes.

Seal off the brake pipe and connections on the hydraulic unit and master cylinder to prevent dirt getting into the syste
- Undo the connection to the control module by first pressing in the catches on the back of the cover (facing wheel ho
Remove:
- Bracket mounting bolts and lift bracket up.- Lift bracket up and undo vacuum hose.
[OOOO5]
In cars with TRACS:
- Lift bracket up slightly and move it forward.- Disconnect non-return valve and vacuum hose from brake servo.
[OOOO6]
Removing hydraulic unit from bracket

Note!
Hydraulic unit must be replaced as a complete unit. Hydraulic unit must not be opened under any circums

- Disconnect pump motor connection from control module.- Remove bracket and control module from hydraulic unit
[OOOO7]
Checking hydraulic unit
Check that the hydraulic unit is of the correct type, depending on whether the car is fitted with TRACS. The differen
Note! The hydraulic unit must not be opened under any circumstances. Special equipment is needed for re-assem
[OOOO8]
Installing hydraulic unit
Note! The hydraulic unit is full of brake fluid. It is important not to remove the protective plugs until the brake p

1.8 NmCheck and install the control module to the hydraulic unit as per . See: Antilock Brakes / Traction ControlSy
8 Nm
8 Nm- Install the new hydraulic unit on the bracket and tighten the mounting bolts. Tighten to .- Hold down the vacu
[OOOO9]
In cars with TRACS


Insert vacuum hose between bracket and hydraulic unit. Check that non-return valve and rubber seals are intact and i
[OOOO10]
Installing hydraulic unit continued
14 Nm (10.3 ft lb)
- Connect connector to control module and pump motor.- Remove protective plugs and connect brake pipe to hydrau
[OOOO11]
In cars with turbo
Install:
- Intake pipe between air filter casing and turbo.
[OOOO12]
Finishing work
AAAA. Bleeding brakes with bleeding unit- Bleed braking system as per . See: Brake Bleeding/Service and Repa
Clean up any brake fluid spillage with lukewarm water and car-wash shampoo.
[OOOO13]
Function check

- Read out any DTCs which are posted in the control module and replace them.- Switch off Volvo ST. Check that AB
Warning!
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications
Brake Master Cylinder: Specifications

GENERAL SPECIFICATIONS
Cylinder Diameter:
Primary .......................................................................................................................................................................
Servo Cylinder:
Size .............................................................................................................................................................................
Attachment Nuts ...............................................................................................................................................................

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Master Cylinder
Brake Master Cylinder: Description and OperationMaster Cylinder
Master cylinder
The master cylinder is designed as a tandem cylinder. It has two pistons, a primary piston (for the primary circuit) an
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Master Cylinder > Page 5666
Brake Master Cylinder: Description and OperationBrake Fluid Reservoir and Level Sensor
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Replacing and Cleaning Brake Fluid Reservoir
Brake Master Cylinder: Service and RepairReplacing and Cleaning Brake Fluid Reservoir
Replacing and cleaning brake fluid reservoir
Preparations
Clean around brake fluid reservoir cap, connections between reservoir and master cylinder and any hose connections
Removing brake fluid reservoir
Ignition off.
- Disconnect connector from brake fluid level sensor.

- Drain brake fluid reservoir.
Remove:
- Bolt from underside of brake fluid reservoir.

- Brake fluid reservoir from master cylinder.
- Block hose to clutch cylinder with hose pliers.
- Disconnect hose from brake fluid reservoir and plug connections to prevent dirt entering system.

-
Inspect brake fluid reservoir, level sensor, nonreturn valves and seals.Use new seals if necessary.Clean carefully
Installing brake fluid reservoir
Grease
Check that O-rings anddirt
there is no anyinhoses with brake fluid or glycerine.
the connections.-
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Replacing and Cleaning Brake Fluid
Reservoir > Page 5669

Note: Do not use cleaning solution for greasing hoses. Use brake fluid or glycerine.
Install:
- Brake fluid reservoir from directly above.

-
3.5 NmBolt on underside of brake fluid reservoir.Tighten to .
Fill brake fluid reservoir with new brake fluid.In cars with manual transmission:Connect hose to brake fluid reser
Finishing

-
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Replacing and Cleaning Brake Fluid Reservoir > Page
Brake Master Cylinder: Service and RepairReplacing the Master Cylinder
Replacing the master cylinder
Preparations
Clean around brake fluid reservoir cap, by pipe connections, and, if necessary, by hose connection between reservoir
Caution:
Release non-return valve in air hydraulic brake power assist unit (brake servo) or pump brake peda
Put rags under master cylinder to prevent brake fluid spillage on paintwork surfaces.
Note: Do not open the master cylinder under any circumstances. It takes special equipment and facilities to reass
Removing master cylinder
Ignition off.
Remove:
- (Not for VADIS use) Brake fluid reservoir, replacement and cleaning
Brake fluid reservoir as per Brake fluid reservoir, replacement andcleaning.
Disconnect:
- Connector to EBD sensor from master cylinder.

- Brake pipe from master cylinder.
Plug brake pipe to prevent dirt entering braking system.

Remove:
- Mounting nuts.
- Master cylinder.
Installation, master cylinder
Check:
- That there is no dirt in the master cylinder connections and that the packing box is intact.
Install:
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Replacing and Cleaning Brake Fluid
Reservoir > Page 5671

- 25 Nm (18.4 ft. lbs.)Master cylinder and EBD pressure sensor. Use new nuts. Tighten to .
Remove:
-
14 Nm (10.3 ft. lbs.)Plugs from brake pipe and connect brake pipe.Tighten to .
Connect:
- Connector to EBD sensor.

- Brake fluid reservoir, as per (Not for VADIS use) Brake fluid reservoir, replacement and cleaning Brake fluid res
Finishing
- Bleed braking system as per (Not for VADIS use) Bleeding brakes with bleeding unit. Bleeding brakes.Then con
-
Bleed clutch on cars with manual transmission.Clean off any brake fluid spillages with lukewarm water and car-w
Pressure-testing the braking system

Once the system has been bled, it must be pressure-tested. Depress the brake pedal as if braking sharply, nearly enou
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair
Parking Brake Cable: Service and Repair
Brake cable (later version), replacement
Note: There are two types of cable cover.
Older version:
^ cable cover with loose guide sleeve towards end piece.
Later version:
^
cable cover with fixed plastic guide sleeve towards end piece.The removal and installation procedures are differe
Preparations
Removing center console
- Remove cigarette lighter panel (2 bolts). If DLC is fitted, remove this from panel first.
- Put parking brake on and put gearshift in neutral.
- Remove the two cover panels, one under the Handbrake lever and the other under the armrest.
- Remove the four console bolts.
- Undo the connectors at the front of the console.
CarsLift rear end ofgearshift:Undo
console first and press itgaiter
forwards
fromuntil theconsole
parkingby
brake lever on
comes freerear
of the console cross-m
with manual gearshift tunnel pressing gaiter's snap fastening from
- Now lift front edge and remove console.
Removing cable
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 5676

- Remove rear wheel.
- Remove cable clip mounting bolt located in front of rear wheel arch.
- Remove cable clip and rivet on carrier arm.
- Undo cable from carrier arm end piece by bending cable cover guide sleeve up and down moderately.
- Remove cable rear end from grip on expander.
- Remove cable.
Installing cable
- Insert new cable through floor from outside.

- Install cable front end in parking brake mechanism.
- Check that O-ring on cable cover guide sleeve is OK.
- Install cable end in grip on expander.
- Pinch grip on expander around cable with a pair of pliers.
- Press guide sleeve home in carrier arm end piece.
- Install cable to carrier arm with a new clip and rivet.
- Install mounting bolt in front of rear wheel arch.
Installing center console
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 5677

- Install center console in reverse order to that in which it was removed.
CarAttach gearshift
with manual gaiter by hooks at front of tunnel console.
gearshift:-
- Press snap fasteners on sides and at back together.
> Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications
Parking Brake Drum: Specifications
Diameter 178 mm
Radial Runout (Max) 0.15 mm
Out of Round (Max) 0.15 mm

> Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications
Parking Brake Lever: Specifications

GENERAL SPECIFICATIONS
Full Braking Affect:
After Adjusting ...........................................................................................................................................................

> Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever, Overhauling
Parking Brake Lever: Service and RepairParking Brake Lever, Overhauling
Parking brake lever, overhaulingPreparations

Removing center console
- Remove cigarette lighter panel (2 bolts).

- Tighten parking brake and put gearshift in neutral.
- Remove the two cover panels, one under the parking brake lever and the other under the armrest.
- Remove the four console bolts.
- Undo the connectors on the front of the console.
- Lift the rear end of the bracket first and push it forwards until the parking brake lever comes free in front of the c
- Now lift front and remove bracket.
- Remove connector from parking brake contact.
- Remove contact mounting bolt and contact itself.
- Remove parking brake lever mounting bolts (3).
- Remove brake cables and remove complete lever unit.
> Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever, Overhauling > Page
5686

Installing center console
- Install center console in reverse order to which it was removed.
Finishing
- Install battery negative lead.

- Adjust parking brake as per Parking brake.
> Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever, Overhauling > Page 5687
Parking Brake Lever: Service and RepairHandle, Parking Brake Lever, Replacing
Handle, parking brake lever, replacing
Remove the handle
Lift the handle slightly. Use a sharp knife. Pry the handle apart so that the lugs are released. The lugs are at the front
Install the handle
Press the handle into place until the lugs in the handle lock onto the lever. Press the knob onto the lever.
Check that it is secure

Check by pulling the handle forward.
> Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair
Parking Brake Shoe: Service and Repair
Brake shoes, replacement
PREPARATIONS
- Remove cover panel under center console armrest.

- Undo parking brake adjusting bolt by parking brake lever until cable goes slack.
- Remove rear wheel.
-
Remove both caliper mounting bolts and remove brake pipe from its mountings. If removing the LH brake calipe
- Remove brake caliper.
- Hang brake caliper from a steel wire in the spring to avoid damaging brake pipe.
Removing brake disc
-
Undo parking brake adjusting bolt until brake disc can be removed. Adjusting bolt can be accessed by turning the
- Remove locating pin and mark brake disc against hub so that disc lines up properly when reinstalling.
- Remove brake disc.
Removing brake shoes

> Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5691

- Lower brake shoe return spring.
- Press brake shoes apart and remove from hub.
CLEANING AND CHECKING
- Check that no grease leaks out of the hub.

- Check that brake arms and cables are not worn and not rubbing anywhere.
- Clean the surfaces of the brake drum where the brake shoes make contact.
- Check that the adjusting bolts turn easily on their threads. Grease with heat-resistant grease if necessary.
- Apply a thin layer of heat-resistant graphite grease to the sliding surfaces.
- Check that hub flange is clean.
- Remove rust with a steel blade and steel brush.
- Brush any dirt off of wheel sensor and pulse wheel with a soft brush.
Installing brake shoes

- Brake shoes on hub and install upper return spring.
- Check that adjusting bolts are turned correctly as per illustration. Illustration is looking from outside.
Installing brake disc and brake caliper
> Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5692

Note: Be careful when handling the new brake disc. Careless handling can cause damge (e.g. warping)
- Install brake disc on hub in line with mark on hub.

- 8 Nm (6 ft lbs)Install locating pin and tighten to
- 60 Nm (45 ft lbs)Install brake caliper with new bolts. Tighten to
- Install brake pipe in brackets.
- Install three-way connector mounting bolt, (LH brake caliper only).
- Adjust parking brake.
> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Diagrams > Diagram Information and Instructions
Parking Brake Warning Lamp: Diagram Information and Instructions

> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Diagrams > Diagram Information and Instructions >
Page 5697

1/1 Battery

2/2 Fog lamp relay

Page 5698

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 5699

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 5700

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 5701


11A/1-9 Main fuses

Page 5702

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 5703



Page 5704

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 5705

C70 all

> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Diagrams > Page 5706
Parking Brake Warning Lamp: Description and Operation
Parking brake warning light
The warning light is located on the instrument panel (dashboard) and comes on when the parking brake lever is pulle
> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions

> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 5711

1/1 Battery

2/2 Fog lamp relay

Page 5712

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 5713

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 5714

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 5715


11A/1-9 Main fuses

Page 5716

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 5717



Page 5718

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 5719

C70 all

> Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 5720

Remove:-
Disconnect
brake connector:-
Removeparking
brake switch:-
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Engine - Installing Clamp on Vacuum Hose
Vacuum Brake Booster: Technical Service BulletinsEngine - Installing Clamp on Vacuum Hose
850/S70/V701992-
Section
5
Group
52
No0001
Year
98
Month
09
Reference: TP 5002202, Section 5 (50, 52, 55, 59) Brakes (incl. ABS and TRACS); 850 1996-
Installing clamp on vacuum hose
Background:
This service bulletin describes the installation of a hose clamp under the air cleaner box
Materials:
Hose See parts catalog 3524376-5

Clamp 1 978390-3
Installing clamp on vacuum hose (brake booster)
Installing clamp on vacuum hose between brake booster and intake manifold
Installing clamp 1
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Engine - Installing Clamp on
Vacuum Hose > Page 5726

Install the clamp as shown in illustration
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 5727
Vacuum Brake Booster: Specifications

Mounting Nut ...................................................................................................................................................................
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster Overload Relay
Vacuum Brake Booster: Description and OperationPower Brake Booster Overload Relay
DESCRIPTION
The power brake booster overload relay is located between the brake pedal and the master cylinder.
OPERATION
The power brake booster overload relay is of the vacuum-assisted type and enhances the force the driver exerts o
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster Overload Relay > Page 5730
Vacuum Brake Booster: Description and OperationAir Hydraulic Brake Power Assist Unit (Brake Servo)
Air hydraulic brake power assist unit (brake servo)
The air hydraulic brake power assist unit (brake servo) is of the vacuum-assisted type, and enhances the force the dri
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5731
Vacuum Brake Booster: Testing and Inspection
Vacuum system, checking
Preparation
Disconnect the negative battery lead
Preparations for checking the check valve
Remove:
- the mounting screws for the torque rod

- the screw and nut for the engine mounting in the torque rod
- the torque rod.
Check the vacuum hose
Check:
- the vacuum hose connections at the manifold and the check valve
- that the vacuum hose is not crimped or rubbing anywhere
- that the vacuum hose inner weave has not broken and blocked the through flow. Disconnect the hose. Start the en
Check the check valve

Check the function of the check valve. Start the engine. Remove the check valve from the power brake booster. Chec
Note: Replace a defective check valve.
Check the function after replacing the check valve
Depress the brake pedal several times to so that it has no travel.Hold the pedal down. Start the engine. The pedal sho
Replacing the vacuum hose
See Brake pipe Master cylinder / ABS unit-replacing.
Remove the check valve from the power brake booster. Remove the vacuum hose
Pull out the check valve. Remove the hose from the intake manifold. Pull the hose forwards between the bracket for
Install the vacuum hose
Install:

- the hose with the check valve behind the bracket for the ABS hydraulic modulator
- the check valve in the power brake booster
- the hose to the intake manifold.
Install the torque rod
Install:
- 50 Nmthe torque rod. Tighten the mounting screws. Tighten to

- 80 Nmthe screw and a new nut for the engine mounting. Tighten to .
Check the power brake booster

Check if there is a vacuum to the power brake booster. Do this by removing the hose from the check valve.Depress t

Release the brake. switch off the engine. Wait 1 minute. Then depress the pedal. The pedal should still feel soft but s
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Brake Booster, Replacing
Vacuum Brake Booster: Service and RepairBrake Booster, Replacing
Left-Hand Drive Cars
Replacing the power brake booster, left-hand drive cars
Preparations
Ignition off.Place a rag under the ABS hydraulic modulator as protection against brake fluid spillage
Removing the power brake booster
The main
Remove: - cylinder. See Replacing the master cylinder. Then continue as follows
-
The bracket with the ABS hydraulic modulator.See Replacing the hydraulic unit.
Release
Then theaccording
continue cable above the power brake
to instructions booster.
below-
The soundproofing
Remove: - under the steering wheel
- The locking spring holding the support bracket to the brake pedal
- The four nuts securing the power brake booster to the inside of the firewall.
The power
Remove: - brake booster. Take care with the O-ring between the power brake booster and the firewall.
Installing new power brake booster
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Brake Booster, Replacing > Page 5737

Transfer the cable clips and the seal to the new power brake booster. If necessary replace the seal.
Install: -
The power brake booster with the connector for the relief valve (1) at four o'clock.Connect the push rod to the bra
The retaining
Install: - clip
- 25 NmThe four new mounting nuts. Tighten to .
The main
Install: - cylinder.
- The bracket with the ABS hydraulic modulator. Then continue according to instructions below.
Finishing work
It isRemove and
important install
that the stop
the stop lamplamp switch.
switch is set after the brake pedal lever has been disconnected from the power brake
- Install the sound insulation under the steering wheel.
Right-Hand Drive Cars
Replacing the power brake booster, right-hand drive cars
Special tools:
999 5517, 5518998 5972951 2050
Preparations
- Ignition off.
Put rags under the hydraulic unit to protect painted surfaces against brake fluid spillage.
Disconnect:

- Positive and negative leads from battery.
- Positive leads from battery shelf.
- Sparkplug leads from coil.
- Sparkplug leads from mountings on air filter casing.
- Ground braids from back of valve cover.
- Connectors from brake fluid reservoir cap, EBD pressure sensor, AC pressostat and anti-theft alarm horn.
- Cable from mountings on air hydraulic brake power assist unit (brake servo).
- Non-return valve and vacuum hose from air hydraulic brake power assist unit (brake power).
Remove:
Bolt from torque member/torque arm.
-- Air inlet hose from air filter casing.
In cars with automatic transmission Disconnect upper oil radiator hose from radiator. Use expanding circlip pliers on
In cars with turbo Disconnect turbo air pipe from hose connection by upper intercooler connection. Disconnect uppe
Drain brake fluid reservoir
Block hose to clutch cylinder with hose pliers. Disconnect hose from brake fluid reservoir. All cars Disconnect brake
Remove: -
Master cylinder from air hydraulic brake power assist unit (brake servo). Lift master cylinder up carefully to avoi
Removing master cylinderIn cars with manual transmission -
Note: Fix master cylinder in a horizontal position to prevent air entering braking system.
Removing sound insulation
Remove:
Sound insulation on driver's side.
-
In cars with SRS:

Remove:
- Knee-guard. Turn steering wheel so that steering wheel shaft bolt and nut are in best position for removal.
Note:
In cars with SRS: Remove ignition key and turn steering wheel until it locks. Do not move steering wheel or fron
Removing locking lug, bolt, nut and gaiter.
Remove: -
Locking lug, nut and bolt from steering wheel shaft joint.Remove lower steering wheel shaft from joint.Push stee
- Circlip and gaiter.Take care to prevent dirt entering gaiter bearing. Protect the joint's bearing surface as well.
Working with car jacked up

Jack car up.

Remove:
Both front protective cover bolts. Push cover forward so that guide on rear edge comes clear. Undo cover at front
-
Working with car jacked up, continued
Remove:
- Cable pipe mounting bolt from subframe. Unhook pipe from frame.
- Bolt from negative lead clip on frame member.
In cars with turbo:

- Disconnect turbo air pipe from hose connection by lower intercooler connection.
Installation tools

Use 999 5517 (bright) (2 x for LH side) and 999 5518 (yellow) (2 x for RH side).Position jack998 5972 under LH sid
Front and
Remove: - rear frame bolts.
Install: -
Tool 999 551 7, the front one with the bolt washer.Tighten tools as far as they will go. Then tighten the tool nuts.
Remove: -
Support bracket bolts by rear lever arm bolt.Move jack to RH side and repeat as above.
Lowering subframe
Start by lowering front of frame to half the tool's bolt length.Now do the same with the rear of the frame.Now lower
Check while lowering that the turbo air pipe by the lower intercooler connection does not get caught in the radiat
In cars with turbo:-
Note: It is important to lower the frame in the correct order, otherwise the steering wheel shaft joint will catch in
Removing air hydraulic brake power assist unit (brake servo)

Circlip- from air hydraulic brake power assist unit (brake servo) pushrod.
Remove:
- The four nuts holding the air hydraulic brake power assist unit (brake servo) to the firewall.
- The air hydraulic brake power assist unit (brake servo)
Note: Watch out for the seal between the air hydraulic brake power assist unit (brake servo) and the firewall.
Installing new air hydraulic brake power assist unit (brake servo)
Transfer cable clip and seal to the new air hydraulic brake power assist unit (brake servo).Use a new seal if necessary
Air hydraulic
Install: - brake power assist unit (brake servo) with the connection for the non-return valve in the four o'cloc
- 25 NmFour new mounting nuts.Tighten to .
Non-return
Connect: - valve and vacuum hose to air hydraulic brake power assist unit (brake servo).
Raising subframe

Subframe,
Raise: - using previously installed tools 999 5517 and 5518.
Rear
Check of the
that frame to halfwheel
steering of tools'
shaftbolt length.
joint does Now repeat
not catch in with front of frame.
the bodywork opening when raising the frame.-
- Frame, until its bushings are only a few millimeters from the frame members, in the same order as above.
Note: It is important to raise the frame in the correct order, otherwise the steering wheel shaft joint will catch in
Mounting subframe
- Position and apply a jacking unit under the LH side of the frame.
Support
Install: - brackets and bolts, loosely.
Tools 999
Remove: - 5517 and 5518.
Subframe
Install: - bolts.
Note: Be careful of the washer on the front bolt. Use new bolts (4 x M14).Grease bolt threads.

- 105 Nm (77.5 ft. lbs.)Tighten bolts to plus 120 degrees. Use protractors 951 2050.
- 50 Nm (36.9 ft. lbs.)Now tighten support bracket bolts to .
- Move jacking unit to RH side and repeat as above.
In cars with turbo
Turbo
Install: - air pipe to hose connection by lower intercooler connection.
Finishing work with car jacked up
Bolt -to negative lead clip on frame member.

Install:
- Cable pipe to subframe.
-
Front protective cover.Push front of cover home.Push it forward and push it up at the back so the cover guide fits
- Bolts.
Installing gaiter, nut, bolt and locking lug

Install: -
Gaiter on steering wheel shaft joint/bodywork opening.Make sure that gaiter ends up in the correct position. Push
- 20 Nm (14.8 ft. lbs.)Steering wheel shaft joint to steering wheel shaft. Use new locknut. Tighten to .

- Locking lug
Installing master cylinder
25 Nm-(18.4 ft. lbs.)Master cylinder to air hydraulic brake power assist unit (brake servo) Tighten to ..
Connect:
- Connect hose from clutch master cylinder to brake fluid reservoir.
- Remove hose pliers.
-
Fill brake fluid reservoir. Use genuine Volvo DOT 4+ brake fluid when topping up.Bleed clutch if necessary and
Connecting components
Brake pipes
Connect: - to mountings on firewall.
- Electrical lead on mountings on air hydraulic brake power assist unit (brake servo).
- EBD, AC, level sensor, horn and anti-theft alarm connectors.
- Torque bracket to torque arm.
Note: Use new bolt and locknut.
35 Nm- (25.8 ft. lbs.)Nut toss . plus 90.

Tighten:
Ground- braids to firewall.

Connect:
- Air hose to air filter casing.
- Sparkplug leads to coil and mountings on air filter casing.
- Battery positive leads to mountings on battery shelf.
- Battery leads to battery.
Finishing work
Remove
As the and pedal
air brake installlever
brakearm
light
is switch.
disconnected from the air hydraulic brake power assist unit (brake servo), it is imp
In cars with SRS:
20 Nm
Install: - (14.8 ft. lbs.)Knee-guard.Tighten to
-
Sound insulation under steering wheel.Clean off any brake fluid spillage with lukewarm water and car-wash sham

In cars with automatic transmission:
Oil radiator
Connect: - hose to radiator.Use new O-ring.
In cars with turbo:
Turbo air
Connect: - pipe to hose connection by upper intercooler connection.
- Engine oil radiator hose to radiator.Use new O-ring.
Vacuum Brake Booster: Service and RepairPush Rod Bushing, Replacing
Bushing, push rod, replacing
Remove bushing
Remove:
the driver's side soundproofing panel.
-- push rod clip
- push rod from brake pedal
- the small bushing from the brake pedal.
Install the new bushing

Lubricate the new bushing using grease, P/N 1161241-3.
the bushing
Install: - on the brake pedal
- the push rod and the clip
- the soundproofing panel.
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair
Vacuum Brake Booster Check Valve: Service and Repair

1. Disconnect vacuum hose from check valve.
2. Pry out check valve using two screwdrivers, then remove seal.
3. Install new seal, ensuring flange is properly aligned in cylinder.
4. Lubricate seal with grease, then press valve carefully into place.
5. Ensure seal does not move out of its position.
6. Connect vacuum hose, ensure highest point is at attachment to valve.
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications

SPECIFICATIONS
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 5755
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Electrical Specification

SPECIFICATIONS
Power supply ....................................................................................................................................................................
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Electrical Specification

Mounting bolts .................................................................................................................................................................
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and In

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 5772

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, R
[MMMM1]
Preparations
[MMMM2]
Remove:
[MMMM3]

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair >
Control Module, Replacement [MMMM] > Page 5775

[MMMM4]
Connect:
[MMMM5]
Function check
Warning!
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Control Module, R
[NNNNA1]


> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram Information and Inst

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Voltage Protection Relay, ABS > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and I

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5807
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5808

- Unscrew cover.
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information and Instruction

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Page 5822
Preparations
Disconnect
front endfrom
of carEBD
Protective

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Page 5823

TheO-ring
- Captive washer
-
Check
seal^

-
Finishing
-
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Ins

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 5837

Remove:-
Disconnect
brake connector:-
Removeparking
brake switch:-
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation
TRACS switch
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation > Page 5841
- Ignition off.
-
EB2 Installing
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS Wheel Sensor -
No.109
Date:FEBRUARY, 1998

9995694-8 U.S. $43.65 $50.85
(EG-139-98-06)
9995694-8 CANADA $61.11 $71.19

(EG-339-98-06)

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5846

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 5858
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Sensor [KKKK]
[KKKKA1]
Preparations
- Ignition off.
- Remove wheel.
[KKKKA2]
Removing sensor

- Remove connector.
[KKKKA3]
Installing sensor
[KKKKA4]

[KKKKA5]
Installing wheel
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel
Sensor [KKKK] > Page 5861

- Install wheel.
[KKKKA6]
Operational checks
[LLLLA1]
Preparations
4-door cars:
5-door cars:
[LLLLA2]

[LLLLA3]
[LLLLA4]

[LLLLA5]

[LLLLA6]
Finishing
[LLLLA7]
Operational checks


- Wheel sensor
-

Strip insulation

Strip cable pairs
Twist cable ends





Foldheat-shrink
tubing is
asintended
illustrated
to(arrow).
provide Carefully
good electrical
pull the
insulation.Hold
heat-shrink tubing
a putty
over
knife
thebehind
soldered
thecable
heat-shrink
splices.tub

Checking ABS system
Ignition
After repairsoff.

Special tools:
999 5242
Remove:
Clean:
Install/reconnect:

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Igni
GROUP:33
NO:01
DATE:May, 1998
TITLE:
BULLETIN REFERENCE
F. STOCK VEHICLES
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 5885

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Igni
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 5890


starter wheel
switch; covers.
Caution!

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3301 > M
Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:
BULLETIN REFERENCE
F. STOCK VEHICLES
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition
Switch: > 3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 5896

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3330002
Ignition Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition
Switch: > 3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 5901


starter wheel
switch; covers.
Caution!

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 5902
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 5905

1/1 Battery

2/2 Fog lamp relay

Page 5906

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
Page 5907

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

Page 5908

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

Page 5909


11A/1-9 Main fuses

Page 5910

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

Page 5911



Page 5912

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

Page 5913

C70 all

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5914
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Start Switch
Start switch
Removal
Note!
Preparations
Start switch
Installation
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Start Switch > Page 5917
Removal
Preparations
Installation
> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations
Fuses
> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5922

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions

> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page
5928

1/1 Battery

2/2 Fog lamp relay

5929

2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch
5930

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna

5931

7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid

5932


11A/1-9 Main fuses

5933

15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs

5934



5935

Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =

5936

C70 all

> Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Positive Battery & Alt. Cable - Available as Spare Part
Battery Cable: Technical Service BulletinsPositive Battery & Alt. Cable - Available as Spare Part
Section
3
Group
37
No.0001
Year
99
Month
06
850/S70/V70/C701993-1998
Positive battery cable and alternator cable available as separate spare part
Background:
If for any reason the positive battery cable or the cable between the alternator and the starter motor needs to be replaced
This bulletin describes how to replace the two cables separately.
Materials:
Positive battery cable 1 9456836-7

Alternator cable 1 9456841-7
REMOVING ENGINE COOLING FAN/SHROUD
Remove/Disconnect:
- Disconnect the negative and positive battery cable from battery
- Fresh air duct to the air cleaner housing.
> Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Positive Battery & Alt. Cable - Available as Spare Part > Page
5942

- The four- (4) screws that hold the fan shroud and relay bracket
- Engine cooling fan connector from relay.
- TURBOS ONLY: The charge air hose from the intercooler
- The ground wire for the cooling fan
- Vacuum hoses from EGR controller.
NOTE:
Use a small screwdriver and carefully push off the hoses from the two fittings on the controller. Do not pull on hose
- Release the wires from the two tie straps on the shroud.
- The connector for the EGR controller valve.
- The relay holder with relays.
- The two screws holding the EVAP purge valve to the shroud.
- The hose from the fuel tank on the purge valve (if needed)
- Move fan with shroud away from radiator slightly and remove from car.
- Protect radiator with shield P/N 9995474
Installing new battery cable AA
Installing alternator cable BB
AA Installing new battery cable
IMPORTANT:
The existing positive battery cable MUST NOT be removed.
At the battery;
- Remove the power supply wire from the positive battery terminal (10 mm nut)
- Cutoff the terminal from the battery cable 100 mm (4.0 inch) down from the terminal and insulate the cut off end co
- Loosen up the clamp holding the positive cable to the battery tray.
5943

At the starter solenoid:
- Remove the cover over the starter solenoid.
- Remove the terminal (eyelet) form the battery cable from the solenoid stud. (13 mm nut)
- Cut off the terminal (eyelet) from the cable 25 mm (1 inch) from the terminal (eyelet) and insulate the end complete
On M/Y 1993/94; Route the new battery cable parallel to the old one and on the outside of the wiring harness duct. Sec
On M/Y 1995-up;
Route the cable so that the "hose" over the cable runs through the transmission dip stick bracket (1) and then follows th
- Install the cable terminal (eyelet) on the starter solenoid with the 13 mm nut and torque to 15 NM (12 lbs)
- Reattach the solenoid cover.

- Attach the new battery cable to the clamp (2) on the side of the battery tray.
- Attach the power supply wire on the stud of the positive battery terminal. (10 mm nut , 8 NM (5 lbs)
- Reinstall all components that have been removed from the engine compartment in reverse order as of how they wer
- Reconnect the positive battery and negative cable and reset radio code and the clock.
- Start the engine and check to ensure electrical systems operate properly
Important;
Make sure the battery cable is not chafing and/or pinched at any point along the full length of the battery cable.
5944

BB Installing alternator cable
At the starter motor solenoid:
DO NOT REMOVE THE OLD CABLE BETWEEN THE STARTER SOLENOID AND THE ALTERNATOR.
Remove engine cooling fan with shroud according to step 1. In this bulletin.
Remove
- Cover over the starter solenoid.
- Nut holding the cables on the starter solenoid, (13-mm.)
- Locate and remove from the solenoid stud, the cable terminal (eyelet) for the alternator cable (red cable, thinner of
- Cutoff the red cable 25 mm (1.0 inch) from the terminal (eyelet) and insulate the cut off completely end with tape a
On the alternator:
Remove;
- Cover cap for the cable on the alternator.
- Nut on 8+, 13 mm.
- Cable from 8+ on the alternator.
- Cut off the cable 25 mm (1 inch) from the B+ terminal (eyelet) and insulate it completely with tape as per illustratio
Install new alternator cable
5945

- Route the new alternator cable parallel to the old cable and secure it with tie straps.
- Install the cable terminals (eyelet's) on both the Alternator and the starter solenoid. Toque the 13 mm nuts to 15 Nm
- Reinstall the 8+ protective cap and the cover over the starter solenoid.
Important;
make sure the two red cables and the fusible link wire (gray) are correctly installed on the starter solenoid stud and
- Reinstall all components that have been removed from the engine compartment in reverse order as of how they wer
- Reconnect the positive and negative battery cable and reset radio code and clock.
- Start the engine and check to ensure electrical system operate properly.
26964-2
0.3 hr
Engine cooling fan/shroud,remove/re-install nonturbo
turbo 0.3 hr
37928-3 Install alternator cable 0.4 hr
37927-3 Install positive battery cable 0.4 hr
> Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair
Alternator Pulley: Service and Repair
Pulley, replacing
Special tools: 951 2849 , 999 5760 , 951 2036
NOTE:
As the illustrations in this service information are used for different model years and / or models, some va
Removal
Preparatory work
Engine, Cooling and Exhaust - Engine -Drive Belts, mounts, Brackets and Accessories - Drive Belt - Servic
Switch off the ignition and remove the key.Disconnect the auxiliaries belt according to Repacing the Auxiliaries
Removing a pulley without freewheel
NOTE: The rotor shaft is left-hand threaded. Remove the pulley and the nut. Use ring wrench 951 2036 and twelv
Removing a pulley with freewheel
> Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Page 5951

Remove the dust cover.Remove the pulley from the rotor shaft. Use tools 999 5760 and 951 2849 as illustrated.R
Installation
Installing a pulley without freewheel
Install the pulley and the nut. Use ring wrench 951 2036 and twelve point socket 951 2849.Tighten.Install the aux
Installing a pulley with freewheel
Thread the pulley on to the rotor shaft.Tighten. Use tools 999 5760 and 951 2849 as illustrated.Install the dust co
> Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Electrical Specifications
Voltage Regulator: Electrical Specifications

Generator/Charge Regulator
Generators, Electrical and Mechanical Data:
* /phase. Use a low ohmmeter.
Generator
> Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Electrical Specifications > Page 5956


Charge Regulators, Electrical and Mechanical Data:

* This load is reached when the engine is running.
Charge Regulators

Voltage Regulator: Mechanical Specifications

Generator/Charge Regulator
* /phase. Use a low ohmmeter.
Generator


Charge Regulators, Electrical and Mechanical Data:

Charge Regulators

> Starting and Charging > Charging System > Voltage Regulator > Component Information > Diagrams > Diagram Information and Instructions
Voltage Regulator: Diagram Information and Instructions

> Starting and Charging > Charging System > Voltage Regulator > Component Information > Diagrams > Diagram Information and Instructions > Page 5967

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Starting and Charging > Charging System > Voltage Regulator > Component Information > Diagrams > Page 5976
Voltage Regulator: Service and Repair
Governor
- Remove the 3 screws for the rear section.
- Undo the catches and detach the cover using a screwdriver.
- Remove the 2 screws for the generator (GEN).
- Pull the generator (GEN) upwards / away.
Installation:
- In reverse order.
> Starting and Charging > Starting System > Ignition Lock > Ignition Lock Cable > Component Information > Adjustments
Ignition Lock Cable: Adjustments

1. Preparations
- Remove:
Battery negative lead.Center console as per steps 3 and 4 of Shift Cable A/T replacement. See: Transmissi
2. Remove:
- Steering column covers
- Soundproofing panel and knee bolster underneath dashboard
- Fold back carpet and remove side panel.
3. Disconnect cable from ignition switch

- Move gear shift lever to position P.
- Turn ignition key to position I or 11.
- Depress cable end locking tabs in ignition switch and withdraw cable.
Basic Adjustment Of Cable

4. Move gear shift lever from P to another position.
- approx. 7 mm (0.28 inch).Clearance between locking tabs at ignition switch end is
Adjust at the gear lever end.
> Starting and Charging > Starting System > Ignition Lock > Ignition Lock Cable > Component Information > Adjustments > Page 5982

5. Turn ignition key to position I or II.
- Press cable into position in ignition lock.
- Ensure that locking tabs are securely engaged in ignition lock.
approx. 0.5-1.0 mm (0.19-0.4 inch).Check that clearance between cable and locking plate is
Check Of Key Lock Function
6.
Ignition
Move key should
gear shift lever tobeposition
easy toP.-
remove from ignition lock.
- If key cannot be removed, cable is too short.
Adjust by slackening cable at adjustment point and repeat check.
7. Move lever to position other than P.
- It should not be possible to remove the ignition key from ignition lock.
- If key can be removed, cable is too long.
Adjust by tightening cable at adjustment point until key cannot be removed.

8. Check of shift-lock override function
- Move gear shift lever to position P and turn ignition key to position I or II.
Do NOT depress brake pedal.
- Depress the override button.
Try moving the gear shift from position P.It should be possible to move the gear shift selector.
- Return lever to position P and remove ignition key.
Press override button.It should not now be possible to move lever from position P.Override function shoul
- If adjustment is needed, adjust as per step 9.
9. Adjustment of shift-lock override function

- If the gear shift selector can be moved from the P position with the ignition key removed from the ignition loc
Tighten cable by turning at adjustment point approx. 1 turn in the direction of the arrow on the picture.Che
- If required tighten cable 1/2 turns more, turning adjuster in the direction of the arrow on the picture.
Supplementary Work
10. Reinstall side panel and fold back carpet.
- Install:
20 Nm.Knee bolster, tighten nuts to:

Soundproofing panelSteering column coversCenter console as per step 8 of Shift Cable A/T replacement.
Ignition Lock Cable: Service and Repair

1. Preparations
- Remove:
Battery negative leadCenter console as per steps 3 and 4 of Shift Cable A/T replacement, refer to Transmi
2. Remove:
- Steering column covers
- Soundproofing panel and knee bolster underneath dashboard
- Fold back carpet and remove side panel.
3. Disconnect cable from ignition switch

- Turn ignition key to position I or II.
- Depress cable end locking tabs in ignition switch and withdraw cable.
4. Removal
- Disconnect cable from adjustment point and locking plate in gear selector housing.
- Right-hand drive models only, remove:
Lamp holder from light molding.Remove cable from retaining clip and cable.

5. Installation of new cable
- Insert cable in opening in center console.
- On right-hand drive models only:
Ensure that cable is positioned to left of heater drain hose as illustrated. See arrow.
- Secure cable with retaining clip
- Connect cable to locking plate
- Install cable adjuster in gear selector housing.
6. Left-hand drive models:

- Insert cable in ignition switch.
- Clip cable in position.
- Four clips are used on left-hand drive models.
- Insert cable in ignition switch.
- Clip cable in position.
Two clips are used on right-hand drive models.
Basic Adjustment Of Cable

8. Move gear shift lever from P to another position.
- approx. 7 mm (0.28 inch).Clearance between locking tabs at ignition switch end is
Adjust at the gear lever end.
9. Turn ignition key to position I or II.

- Press cable into position in ignition lock.
- Ensure that locking tabs are securely engaged in ignition lock.
- approx. 0.5-1 mm (0.19-0.4 inch).Move gear shift lever to position P. Check that clearance between cable an
Check Of Key Lock Function

10. Move gear shift lever to position P.
- Ignition key should be easy to remove from ignition lock.
- If key cannot be removed, cable is too short.
- Adjust by slackening cable at adjustment point and repeat check.

11. Move lever to position other than P.
- It should not be possible to remove the ignition key from ignition lock.
- If key can be removed, cable is too long.
Adjust by tightening cable at adjustment point until key cannot be removed.
12. Check Of Shift-lock Override Function

- Move gear shift lever to position P and turn ignition key to position I or II.
- Do NOT depress brake pedal.
- Depress the override button.
Try moving the gear shift from position P.It should be possible to move the gear shift selector.
- Return lever to position P and remove ignition key
- Press override button.
It should not now be possible to move lever from position P.Override function should operate only when i
- If adjustment is needed, proceed to next step.
13. Adjustment of shift-lock override function
- If the gear shift selector can be moved from the P position with the ignition key removed from the ignition loc
Tighten cable by turning at adjustment point approx. 1 turn in the direction of the arrow on the picture.Che

Supplementary work
14. Reinstall side panel and fold back carpet.

- Install:
20 Nm.
Knee bolster, tighten nuts to: Soundproofing panelSteering column coversCenter console as per step 8 of S
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3301 > May > 98 > Campaign - Malfun
GROUP:33
NO:01
DATE:May, 1998
TITLE:
BULLETIN REFERENCE
F. STOCK VEHICLES
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3301 > May > 98 >
Campaign - Malfunctioning Ignition Switch > Page 5998

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3330002 > May > 98 > Campaign - Sta
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Recalls for Ignition Switch: > 3330002 > May > 98 >
Campaign - Starter/Ignition Switch Replacement > Page 6003


starter wheel
switch; covers.
Caution!

> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3301 > May >
Ignition Switch
GROUP:33
NO:01
DATE:May, 1998
TITLE:
BULLETIN REFERENCE
F. STOCK VEHICLES
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: >
3301 > May > 98 > Campaign - Malfunctioning Ignition Switch > Page 6009

874471590-490221
874476745-490980875416734-435703876416734-435703
NOTE:

6. Stock Vehicles
Retailer Allowance

Note:
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 3330002 > Ma
Switch Replacement
Section3
Group33
No.0002
Year98
Month05
Remove 1
Note!
> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: >
3330002 > May > 98 > Campaign - Starter/Ignition Switch Replacement > Page 6014


starter wheel
switch; covers.
Caution!

> Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Page 6015
> Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions

> Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6018

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Start Switch
Start switch
Removal
Note!
Preparations
Start switch
Installation
> Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Start Switch > Page 6030
Removal
Preparations
Installation
> Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions
Starter Motor: Diagram Information and Instructions

> Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6035

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 6044
Starter Motor: Service and Repair
Starter motor, replacing
Removal
- Disconnect the battery negative lead.
Caution! When removing/installing the battery leads observe warnings.
- Remove the air cleaner housing.
- Remove the solenoid from the air cleaner housing.
-
Remove the air cleaner (ACL) housing. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performa
-
Starterthe
Remove motor
frontbracket withdrawn
screw for during
the starter motormodel year 2002.
bracket.-
- Disconnect the connector and cable for the solenoid.
- Remove the screws (2 pcs) that hold the starter motor to the transmission.
- Remove the starter motor.
Removing the solenoid
- Slacken off the nut. Remove the cable

> Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 6045

- Remove the 3 screws.
- Lift the solenoid. Unhook the solenoid and the spring and hook.
Installation Starter motor and solenoid
- To install, reverse the removal procedure.
-
To install the air cleaner housing, see Brake pipe master cylinder / ABS unit, replacing:Install the air cleaner (AC
-
Tightening
6 NMScrew
torques-
for the starter motor bracket: ............................................................................................................
- 40 NMScrews for the starter motor/transmission: ................................................................................................
> Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Fuses
> Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6049

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions

> Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6055

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Relays
Electrical Accessory Panel: LocationsRelays
Position of Relays in Engine Compartment Central Electrical Unit:
101/102 Cruise control103 Fuel pump (FP)104/108 Main lighting relay / bulb failure warning sensor.105 Overload r
Position of Relays in Passenger Compartment Central Electrical Unit:
201 Fog lamp relay.203 Intermittent windshield wiper.204 Intermittent rear windshield wiper.207 Exhaust temperatu
> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Relays > Page 6069
Electrical Accessory Panel: LocationsFuses
Fuses In Central Electrical Unit (Engine Compartment) Part 1 of 2

> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal
Electrical Accessory Panel: Service and RepairCentral Electrical Unit Removal
IA1 Central Electrical Unit - General Information:
The central electrical unit has been designed for accessories. Fuse 35 has been reserved for accessories. If further acc
IA2 Fuse, List:
SeeIgnition on.cover for the position and rated output of fuses, or See: Fuse/Application and IDIf uncertain whether a
inside the
- Check for a voltage on both test outputs on the fuse.
IA3 Removing Central Electrical Unit:

battery negative lead (disconnect).
Remove:-
- windshield wipers and panel according to CA1 - CA6. See: Wiper and Washer Systems/Wiper Motor/Service an
- central electrical unit cover (four screws).
- all relays in the passenger compartment central electrical unit. See: Relay Replacement via Passenger Compartm
> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal >
Page 6072

- central electrical unit screws (four).
- Open the cable duct

- Lift up the central electrical unit.
NOTE: Ensure that there is a good seal between the central electrical unit and firewall.
To repair wiring and connectors see Volvo's replacement parts kit 914 8210, which contains repair instructions and s
> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal > Page 6073
Electrical Accessory Panel: Service and RepairRelay Replacement via Engine Compartment
DA1 Removing Relay(s):
The central electrical unit is located by the cowl panel on the left or right depending on the model. The engine compa

Remove:-
- cover screws.
- cover.
- relay(s).
DA2 Installing
- Replace relay. Position of relays as illustrated.

- Test relay function.
- Install cover and screws. Check that the cover has an airtight seal with the edges of the central electrical unit.
> Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal > Page 6074
Electrical Accessory Panel: Service and RepairRelay Replacement via Passenger Compartment
DB1 Removing Relay(s):
The passenger compartment central electrical unit is located on the driver's side under the soundproofing panel.

Remove:-
- soundproofing panel screws.
- soundproofing panel.
- relay(s).
DB2 Installing
- Replace relay. Position of relays as illustrated:

- Install soundproofing panel and screws.
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 6078

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6090

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
DC1 Removing:

Remove:-
DC2 Installing:
- Install relay.
> Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Locations
Grounding Point: Locations

Wiring Diagram
> Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 6103

Component Location
Component I.D. List



Ground points 31/4, 31/5, 31/7, 31/11, 31/12, 31/15, 31/44, 31/47 & 31/48

Ground points 31/50, 31/51, 31/52, 31/52, 31/55 & 31/71
> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6110

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information >
Locations > Page 6118

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page
6125

Panel Locations
6126

Relays
6127

Panel Locations
6128

Other Relays
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6129
Fuses
6130

Panel Locations
6131

Relays
6132

Panel Locations
6133

Other Relays
> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations
Fuses
> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6137

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > TJ4523 > Ju
Start/DTC's 233/234/321
Wiring Harness: Customer InterestImmobilizer System - No Start/DTC's 233/234/321

TIE - Technical Journal
Title IMMO failure cable terminals, start prevented, DTC 233, 234, 321
Ref No US4523.1.1 en-GB
Partner 3 US 7510 Volvo Cars North America
Func Group 3660
Func Desc automatic monitoring and control
Status Released
Status Date 2010-07-26
Issue Date 2010-07-20
Reference
Attachment
Vehicle Type
CSC
DTC
Text
CSC= Customer symptom Code
Note!
DESCRIPTION:
When diagnosing an intermittent no start condition the immoblizer system should be checked for DTCs. Immoblizer D
> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness:
> TJ4523 > Jul > 10 > Immobilizer System - No Start/DTC's 233/234/321 > Page 6154

or oxidation.
Check the male/female pin contact for connector 4/22 7/39 and to ECM (Engine control module) BEFORE any hardwa
Note:
If any hardware is being replaced without correcting defect terminals, it might end up with an immo code mismatch
PARTS REQUIRED:
Wire terminal P/N 30656669
Wire terminal P//N 30656670
Terminal removal tool P/N 9512637 (sold by SPX)
SERVICE:
First read out diagnostic trouble codes (DTCs) for the immobilizer system.
233 = Antenna ring
234 = Transponder communication
321 = Initiation signal from the ECM.




If any of the above DTC's are found in the vehicle then there may be loose connection between the wire terminals in th
VOLVO STANDARD TIME GUIDE OPERATION NUMBER:
36001-2 Diagnostic trouble codes (DTCs) read out and set to zero See VSTG
36194-3 Wire terminals immobilizer replace See VSTG
- Claims may be submitted under the new car warranty when there is a documented customer complaint using claim
> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: >
System - No Start/DTC's 233/234/321
Wiring Harness: All Technical Service BulletinsImmobilizer System - No Start/DTC's 233/234/321

Func Group 3660
Status Released
Reference
Attachment
Vehicle Type
CSC
DTC
Text
Note!
DESCRIPTION:
> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Wiring Harness: > TJ4523 > Jul > 10 > Immobilizer System - No Start/DTC's 233/234/321 > Page 6163

or oxidation.
Note:
PARTS REQUIRED:
SERVICE:
233 = Antenna ring




> Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Relays
Electrical Accessory Panel: LocationsRelays
> Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Relays > Page 6172
Electrical Accessory Panel: LocationsFuses

> Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal
Electrical Accessory Panel: Service and RepairCentral Electrical Unit Removal
IA1 Central Electrical Unit - General Information:
The central electrical unit has been designed for accessories. Fuse 35 has been reserved for accessories. If further acc
IA2 Fuse, List:
SeeIgnition on.cover for the position and rated output of fuses, or See: Fuse/Application and IDIf uncertain whether a
inside the
- Check for a voltage on both test outputs on the fuse.
IA3 Removing Central Electrical Unit:

battery negative lead (disconnect).
Remove:-
- windshield wipers and panel according to CA1 - CA6. See: Wiper and Washer Systems/Wiper Motor/Service an
- central electrical unit cover (four screws).
- all relays in the passenger compartment central electrical unit. See: Relay Replacement via Passenger Compartm
> Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Central Electrical Unit Removal > Page 6175

- central electrical unit screws (four).
- Open the cable duct

- Lift up the central electrical unit.
NOTE: Ensure that there is a good seal between the central electrical unit and firewall.
To repair wiring and connectors see Volvo's replacement parts kit 914 8210, which contains repair instructions and s
Electrical Accessory Panel: Service and RepairRelay Replacement via Engine Compartment
DA1 Removing Relay(s):
The central electrical unit is located by the cowl panel on the left or right depending on the model. The engine compa

Remove:-
- cover screws.
- cover.
- relay(s).
DA2 Installing
- Replace relay. Position of relays as illustrated.

- Install cover and screws. Check that the cover has an airtight seal with the edges of the central electrical unit.
Electrical Accessory Panel: Service and RepairRelay Replacement via Passenger Compartment
DB1 Removing Relay(s):
The passenger compartment central electrical unit is located on the driver's side under the soundproofing panel.

Remove:-
- soundproofing panel screws.
- soundproofing panel.
- relay(s).
DB2 Installing
- Replace relay. Position of relays as illustrated:

- Install soundproofing panel and screws.
> Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
Fuses
> Power and Ground Distribution > Fuse > Component Information > Locations > Page 6181

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuses
> Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6193

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
DC1 Removing:

Remove:-
DC2 Installing:
- Install relay.
> Power and Ground Distribution > Grounding Point > Component Information > Locations
Grounding Point: Locations

Wiring Diagram
> Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 6206

Component Location
Component I.D. List



Ground points 31/4, 31/5, 31/7, 31/11, 31/12, 31/15, 31/44, 31/47 & 31/48

Ground points 31/50, 31/51, 31/52, 31/52, 31/55 & 31/71
> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Selector Shaft: Service and Repair

SPECIAL TOOLS
REMOVAL
Removing Of Gear Position Sensor
1. Preparations
- Remove:
(ACL)
Battery Entire Air Cleaner Air intake manifold Battery shelf ACL bracket.
2. Removal
- Remove:
> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6213

3. Replacement of control shaft seal ring.
- Use a small, rounded screwdriver to remove the old seal ring.
Take care not to damage shaft.
- Reinstall a new seal ring.
Apply ATF to the ring.Use tool No. 999 5476, or equivalent to tap the new ring into place.
INSTALLATION
Reinstallation And Adjustment Of Gear Position Sensor
4. Reinstallation
- Tighten nut.
> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6214

5. Adjustment
- Adjust gear position sensor, refer to Powertrain Management.
6. Reinstallation, continue
-Install:
Dipstick pipe bracket.

Rod arm on control shaft.
16 Nm.Tighten to:
Transmission cable on rod arm with washer and lock clips.

- Install:
8. Checking DTCs
- Using
Airafilter
suitable scanBattery
bracket tool, check
shelfthat
ACL DTC's have with
complete been inlet
cleared.
pipe. Battery. Reconnect battery leads.
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Fuses
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6219

Panel Locations

Relays

Panel Locations

Other Relays
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations
Fuses
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6226

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Power and Ground Distribution > Relay Box > Component Information > Locations
Fuses
> Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6238

Panel Locations

Relays

Panel Locations

Other Relays
Fuses

Panel Locations

Relays

Panel Locations

Other Relays
> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > TJ4523 > Jul > 10 > Immobilizer Sys
Wiring Harness: Customer InterestImmobilizer System - No Start/DTC's 233/234/321

Func Group 3660
Status Released
Reference
Attachment
Vehicle Type
CSC
DTC
Text
Note!
DESCRIPTION:
> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > TJ4523 > Jul > 10 >
Immobilizer System - No Start/DTC's 233/234/321 > Page 6255

or oxidation.
Note:
PARTS REQUIRED:
SERVICE:
233 = Antenna ring




> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > TJ4523 > Jul > 10 > Im
233/234/321
Wiring Harness: All Technical Service BulletinsImmobilizer System - No Start/DTC's 233/234/321

Func Group 3660
Status Released
Reference
Attachment
Vehicle Type
CSC
DTC
Text
Note!
DESCRIPTION:
> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > TJ4523
> Jul > 10 > Immobilizer System - No Start/DTC's 233/234/321 > Page 6264

or oxidation.
Note:
PARTS REQUIRED:
SERVICE:
233 = Antenna ring




> Steering and Suspension > Alignment > System Information > Specifications
Alignment: Specifications
Alignment Specs
Front Axle
Caster 3.351.0
Max Deviation 1.0
Camber 01.0
Max Deviation 0.20.7
Toe-in 0.330.1
Max Deviation 0.1
Rear Axle
Camber (non-AWD) -10.5
Camber (AWD) -0.450.75
Toe-in (non-AWD) 0.10.2
Thrust angle 00.25
> Steering and Suspension > Alignment > System Information > Specifications > Page 6272
Alignment: Description and Operation
Camber
Camber (C) refers to the wheel leaning in or outwards. The angle is considered positive if the wheel leans outwards a
Road holding is better with negative camber because the wheel stands upright when the body rolls.
Positive camber gives better feel for the road through the steering wheel. With an extreme wrong camber the tires we
Caster
The caster angle (B) is the angle between vertical line (A) and a line which goes through the center of the lower ball
Note! Caster angle cannot be adjusted.

King pin inclination
Originally king pin inclination (D) referred to king pin lean. Because the car does not have a king pin the inclination
TOE-IN
Toe-in
With toe-in the front part of the wheel points inwards. Toe-in can either be measured as an angle or as a difference b
Note!
Toe-in should always be adjusted in relation to the car's driving geometric axis (thrust line) which is derived from th
Toe-out

Toe-out or incorrect toe-in cause vibrations that increase tire wear. Tires slide sideways. Too much toe-in causes wea
Ackerman angles
The wheels follow different radii when cornering.In order to ensure that they turn at the same center, and to minimiz
> Steering and Suspension > Alignment > System Information > Service and Repair > Alignment
Alignment: Service and RepairAlignment
Preliminary Checks
The wheel alignment must be correct to achieve satisfactory steering characteristics and to minimize tire wear. The alig
NOTE: All settings must be measured with the car unladen.
Since the following defects may affect the wheel alignment, they must be rectified, if necessary, before measuring and/
1. Different tire pressures.2. Differences in tire wear.3. Play in front wheel bearings.4. Play in ball joints or control a
Checking
NOTE:
Adjustment of the camber, if applicable, must always be carried out before adjusting the toe-in. Since the rear wheels
1. Jack up front end of car: Place hoist under control arms as close as possible to ball joints.2. Check for play in:
- steering gear or tie rod (track rod) ball joints.
- wheel bearings.
- spring strut upper mountings.
NOTE: If play is present in any of above, corrective action must first be taken.
3. Set up measuring equipment:
a. Set up and calibrate equipment as per equipment instructions.
> Steering and Suspension > Alignment > System Information > Service and Repair > Alignment > Page 6277

b. Place turntables under front wheels. Use turntables which take up lateral movement.
NOTE: Car must be parked horizontally when front wheels are on turntables, to ensure that correct camber and
c. Bounce front end vigorously up and down a few times or turntables to ensure that suspension returns to normal
4. Checking camber.
0 1.0 1.0
a. Measure camber on each side. Correct value:. Value may differ by a maximum of between left and right whee
3.35 1.0 1.05. Checking caster: Measure caster on each side. Correct value: . Value may differ by a maximum of be
6. Checking toe-in:
a. Ensure that the instruments are adjusted relative to each other at the front and rear. This is extremely important
toe-in measured relative to the thrust axis of car. The thrust axis is defined as the line bisecting the angle betw
NOTE:
15' The angle between the longitudinal axis of symmetry and the thrust axis is known as the thrust angle. Thi
A. Axis of symmetry of wheels.B. Thrust axis.C. Thrust angle.
NOTE: The deviations in the adjoining figure are highly exaggerated for illustration purposes.

20' 6' (0.3 0.1)
b. Correct value: measured across both wheels.c. Measure toe-in at hub level, either as an angle or as the differen
3.6 1 mm (0.14 0.04 inch)at the rear and front respectively of the wheel. Example: Measurement at A should
Toe-In
Adjust toe-in by altering length of tie rods (track rods) after undoing locknuts. Increasing tie rod length increases angle
NOTE: 2 mm (0.08 inch) Length of tie rods must not differ by more than as measured between end of thread and loc

agent, P/N 1161432-8, after tightening nuts.
Camber
NOTES:
- 0 1The camber must be adjusted if the measured value exceeds a tolerance of .
- 1The difference between the left and right sides must not exceed .
1. Jack up car and remove wheel.2. Cars with sleeves in steering knuckle (stub axle carrier): Remove upper sleeve (o
0.5
1required) from steering knuckle (stub axle carrier). Removal of one sleeve will produce a change in camber of a
3. Cars without sleeves in steering knuckle (stub axle carrier): Replace bolts and nuts, and adjust as described below.
NOTE: Install new bolts and nuts.
a. Tighten bolts slightly without preventing movement of steering knuckle (stub axle carrier) outward or inward w
with a degree of resistance) Move steering knuckle outward or inward to extent permitted by play between bo
65 Nm (48 ft. lbs.) 90b. After adjustment, tighten both bolts toand through further .
4. Mount wheel.
110 Nm (81 ft. lbs.)a. Lubricate wheel locating pin on hub with anti-rust agent, P/N 1161030-0.b. First tighten w
NOTE: Also see specifications.

5. Recheck camber and toe-in.
Rear
Checking/Adjusting Rear Wheel Alignment

1. Lift up rear suspension.
Wheel
Check bearings.
for play in:-
- Support arm bushings.
- Control arm bushings.
2. Set up test equipment.
Set up and calibrate test equipment according to its instructions.The car should be on a flat surface with the whee
3. Checking camber angle.
-0.25 0.75
Nominal camber angle .If the camber angle is outside these parameters check control arms for damage.

4. Checking toe-in.
-
Check that the instruments are adjusted in relation to each other on the front and rear axles. This important so
- 0.1 0.2The correct toe-in is , over both wheels.
- maximum 0.25Permitted deviation from the axis of symmetry (angle of thrust) should be .
5. Unscrew the nut for the track rod inner screw slightly.
90 Nm (66.4 ft. lbs.)Adjust by turning the eccentric screws to increase or decrease toe-in.Tightening torques .
Alignment: Service and RepairAdjustments
General
General
For the car to have good steering properties and a minimum of tire wear the wheels must be correctly aligned. The w
Note! All measurements should be made with the car empty.
Corrections Before Wheel Alignment
The following may also affect the wheel angles. Before measuring and adjusting these faults should be rectified.1. D
Front Alignment
Checking And Adjusting The Wheel Alignment
Note! When checking and adjusting front wheel alignment the following applies:
- Any camber angle adjustment must always be made before adjusting the toe-in
-
Because the rear wheels have adjustable toe-in, the front wheels must always be adjusted in relation to the car's g
Note! All measurements must be made with the car empty. Check the tire pressure on all tires. See specification
Lift Up Front end

Lift under the control arms as close to the ball joints as possible.
the for
Check steering gear or tie rods
play in:-
- the wheel bearings
- the upper spring strut mountings
If there is play in any of the above components it must be corrected refer to the relevant repair information.
Set Up The Test Equipment

Set up and calibrate test equipment according to its instructions.
Position the turntables under the front wheels. Use turntables which take up lateral movement.
Note! The car must stand level when the front wheels are on the turntables. So that the correct values are obtained w
Bounce the front suspension heavily a few times when the car has been set onto the turntables. This must be done for
Checking Camber Angle

Check the camber angle on both sides.
0 1.0Correct value: .
1.0The camber angle may vary by a maximum of between the left and right wheels.

If the camber angle is outside these values, see Adjusting camber angle.
Adjusting Camber Angle
Note! 0 1 must not exceed 1. Adjust the camber angle if it lies outside the tolerance when checked. The variation b
Carry out the following when adjusting:
Raise cars and remove wheel
Cars with sleeves in the stub axles;
0.5 1.Remove the upper, if necessary both sleeves from the stub axle. This depends on how large the adjustment need
Cars without sleeves in the stub axles;
Replace screws and nuts and adjust as follows.
Note! Install new screws and nuts to stub axle
Tighten the screws slightly but not more than that necessary to allow the stub axle to be moved with some resistance
65 Nm (47.9 ft. lbs.) 90.Post adjustment, tighten both the screws to a angle-tighten
Install Wheels
Lubricate hub guide for rims with suitable rustproofing agent.
110 Nm (81.1 ft. lbs.)Install wheel studs lightly. Tighten crosswise to
Check camber angle and toe-in again.
Checking Caster Angle

3.35 1.0. 1.0 Check the caster angle on both sides. Correct value: The caster angle must not vary by more than betw
Checking Toe-In
Check that the instruments are adjusted in relation to each other on front and rear axles. This is important so that the
Note!
15 The difference between the wheel symmetry line and the thrust line is called the thrust angle. This angle may de
A. Wheel symmetry lineB. Thrust lineC. Thrust angle
Note! The differences in the adjacent diagram are exaggerated in order to illustrate the differences.

To set the rear wheel toe-in, see checking and adjusting the alignment of the rear wheels
Toe-In 20' 6'Correct value: measured over both wheels.
Measurements are taken at the height of the hub as an angular measurement or as the difference in mm between the f
Example.
3.6 1 mThe measurement at A must be greater than at a.
Adjusting toe-in
Adjustment is made with the tie rods after loosening the lock nuts. Longer rods give a greater angle and vice versa. S
Note! more than 2 mm.

The lengths of the tie rods must not vary between themselves by Measure between the lock nut and the edge of thre
Steering wheel position

Minor deviation, adjust at the same time as the toe-in adjustment a
For major steering wheel deviation, refer to Steering, Steering Column, Service and Repair.
> Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R Information
Front Steering Knuckle: Technical Service BulletinsBall Joint/Steering Knuckle - Additional R&R Information
Section
6
Group
61
No.0002
Year
99
Month
06
850/S70/V701993-
Ball joint/steering knuckle, removing
Background:
This service bulletin is a supplement to existing information. The bulletin describes an updated method on how to remo
Update service manuals: Please write: "To remove the ball joint/steering knuckle see Service Bulletin 61-0002" in the l
> Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R
Information > Page 6290

1
Preparations
Caution!
Safety goggles must be worn when blowing clean area with compressed air.
Blow clean around the ball joint with compressed air.
Generously spray with rust penetrator the area around the ball joint and the retaining screw and nut for the ball joint.
Separate ball joint from knuckle
Caution!
Do not open up the slot on the knuckle which clamps the ball joint. Doing so may damage knuckle.
If retaining screw is rusted stuck, loosen nut a few turns and canfully tap on the screw using a drift and hammer.
Remove the nut and screw.
Spray the ball joint with rust penetrator again.
Caution!
The inner diameter of the socket must be larger then the bottom diameter of the ball joint. Failing to do so may dam

Use a socket or equivalent as extension see illustration.
Warning!
Eye protection must be worn. Do not use a steel hammer. A brass or copper hammer must be used.
Carefully knock on the socket to loosen the ball joint from the knuckle.
Verify that the ball joint is loose from the knuckle. If needed install protective sleeve 999 5562 on the ball joint boot an
Use Holder 9995563 on the control arm when the ball joint is detached.
Installing the ball joint
Clean off any rust and/or debris from the knuckle and the ball joint.
Apply a light coat of lubrication in on the bolt of the ball joint.
Install ball joint to the steering knuckle.


IMPORTANT:
Press ball joint up so that the tapered end is visible before torquing the retaining screw/nut. (see illustration, arrow)
Install new retaining screw and nut and torque to 50 NM (35 lbs)
> Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6293
Front Steering Knuckle: Service and Repair
Removing stub axle
Raise the car.Remove
- the wheel
- the anti-roll bar link from the spring strut. Use a fixed wrench as a counterhold
- the ABS sensor. Hang up sensor with a piece of wire
- ABS sensor cable from spring strut
- brake caliper and limiter mounting screws

- the limiter. Hang caliper up with a piece of wire.

- drive shaft screw. Use a screwdriver as counterhold on the brake disc
- locating pin holding brake disc
-
10 - 15 mm.
brake disc.Slacken off end of the drive shaft in the hub by knocking the drive shaft into the hub approximately U
- tie rod ends from the steering arm. Use puller 999 52S9.
- both screws retaining the spring strut in the stub axle.

Pry out the stub axle.Pull out the drive shaft and fold to one side. Hang up drive shaft on a hook 999 5045.
Note! Take care not to damage the drive shaft boot.
- nut on ball joint. Use a Torx wrench as counterhold

- stub axle.
Installing stub axle

Install
- stub axle on the trailing arm
- 80 Nmnew nut on the ball joint. Tighten to . Use a Torx wrench as counterhold.
Note! Make sure that the mating surfaces on the ball joint and link are clean.

Clean the splines on the drive shaft.Turn in the stub axle and locate the drive shaft in the hub.Install drive shaft screw
Install
- 90
both screws retaining the spring strut in the stub axle. Use new screws and nuts. Tighten to 105 Nm and angle-tig
- 50 Nmanti-roll bar link to the spring strut. Use a new nut. Tighten to
- ABS sensor cable
- 10 NmABS sensor onto stub axle. Tighten ABS sensor to
Note! Ensure that the sensor seat in the stub axle is absolutely clean. Clean the ABS sensor with a soft brush.
- 70 Nm.tie rod end onto the stub axle. Use a new nut. Tighten to
-
8 Nm.brake disc. Tighten brake disc locating pin to
Note! Ensure that the brake disk and wheel rim hub mating surfaces are clean.
50 NmTighten drive shaft screw to . Use a screwdriver as counterhold on the brake disc.

- 100 Nm.brake caliper and limiter. Use new screws. Tighten to
- the wheel according to Installing wheels.
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications

Volume .................................................................................................................................................................................
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 6303
Power Steering Fluid: Fluid Type Specifications

[1]Transmission oil grade ...................................................................................................................................................
[1]_________________________________: Volvo P/N 11 61 317-1

> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Gear Pressure Line W/O-Ring Seal .................................................................................................................................

> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Mounting Bolts .................................................................................................................................................................

> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6311
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Pressure Specifications
Pump Pressure ............................................................................................................................................................
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6312
Power Steering Pump: Description and Operation
Design
The power steering pump is of the vane type and is mounted on a bracket on the engine. The pump is driven from the
1. To steering gear.2. From steering gear.
Operation
The pump rotor is provided with ten radially movable vanes and rotates in an annular housing, in which the vanes are
Control Valve

The pump incorporates a control valve which regulates the fluid flow as well as the maximum fluid pressure. When t
Power Steering Pump: Testing and Inspection
Checking Power Steering Balance and Pump Pressure
Note! The car must be lowered when the work is carried out.
Preparations
- Place paper over the generator (GEN) as protection against oil

- Push the coolant hose to the control module to one side
- Install lock grip pliers on the power steering pump return hose.
Connect test instrument
- 999 5055Connect instrument between the pump and the steering gear pressure hose.
- 999 5175 999 5319Use nipples and
- 999 5175 999 5319Connect nipple with the pipe screw and washers from nipple .
Note! Connect the pipe from the instrument cock to the pressure pipe for the steering gear. The cock should be paral
Remove
- lock grip pliers
- paper over the generator (GEN).
- Position the manometer in the engine compartment so that it can be read off from the driver's seat.

- Remove the battery negative lead
- Remove the steering wheel module with the two torx screws on the reverse of steering wheel
- Disconnect the connector. Lift out the entire steering wheel module.
- 998 8695
Install tool instead of the steering wheel module. The tool is used to prevent a diagnostic trouble code (DTC) bei
- Install the battery negative lead.
Checking balance when turning wheel to right


- Start the engine
- Turn the steering wheel to almost the right limit position
- 999 8081Connect torque wrench to the steering wheel screw
- 1.2 MPa (12 kp/cm).Turn the torque wrench slowly to the right. Read off the torque just as the manometer reach
Note! 1.2 MPa It is extremely important to read off the torque just as the manometer displays because the pressure r
Checking the balance when turning the steering wheel to the left
- Turn the wheel nearly to the left limit position. Read oft the torque in the same way as for the right-hand side.
Interpreting the torque measurements
- 3.2-4.2 Nm (32-42 kp/cm). 0.7 Nm (7 kp/cm)

The torque must be between The reading must not deviate by more than between the right and left-hand sides.
Note! If deviation is greater the steering gear must be replaced.
Checking pump pressure
Left limit position
- Start the engine

- Turn the steering wheel to the left and press it to the limit position for a maximum of 10 seconds while reading of
- 10.2 - 11 MPa.Correct pressure:
Right limit position
- Turn the steering wheel to the right limit position and read the manometer according to the previous operation.
The pump capacity

- 10.2 - 11 MPaShut the cock for a maximum of 10 seconds. If the pump is not faulty the manometer pressure sho
-
If the pressure lies outside the above values:Recondition or replace the pump
- Switch off the engine.
Disconnecting the measuring instrument
Remove
- the battery negative lead

- 998 8695tool .
10 Nm. Place the bottom section of the steering wheel module on the steering wheel (1). Connect the connector (2).F
- Install lock grip pliers on the oil pump return hose.
Note! Place paper over the generator (GEN) as protection against oil.
- Disconnect the test instrument and the nipples

- Connect the pressure hose to the pump. Use a new 0-ring.
Remove
- lock grip pliers

- the paper over the generator (GEN).
Install
- the coolant pipe for the control module.

> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and RepairPower Steering Pump
Replacement
Tool Required
^ 999 5443 Puller
^ 999 5444 Press Tool
Removal
1. Drain off approximately 3 liters of coolant. Drain cock is located at left-hand side of car under radiator.
2. Disconnect coolant hose from thermostat housing.3. Disconnect:
a. Fluid hose clip from dipstick tube. b. Cooling air hose to control module box.
4. Remove drive belt from pump. Use 3/8" ratchet or similar tool to relieve tension on automatic belt tensioner. Rem
5. Remove guard plate bolt and spacer sleeve.6. Slacken pressure hose union 1/4 turn.7. Slacken guard plate lower m
a. 3 bolts through drive pulley holes. b. 2 bolts on left-hand side.
9. Lift pump straight upward:
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6321

a. Collect spillage fluid, if any, in a small container.b. Disconnect pressure hose from pump. Remove original O-
NOTE: Hose must not be shortened beyond marking stripe at end. Take care to avoid damage to reservoir co
d. Raise front end of car so that wheels are free to turn. Turn steering wheel from lock to lock. Use container to c
and pressure hoses. Take care to avoid spillage of fluid into generator.
10. Mount pump in vise.
11. Remove drive pulley. Use puller.
Installation
1. Mount drive pulley. Lubricate pump shaft with fluid. Use press tool.
2. Remove reservoir mounting clips. Use adjustable pliers and screwdriver.3. Raise locking tab and remove O-ring.
4. Assemble reservoir and pump Use new O-ring. Ensure that locking tabs are seated securely.

5. Install pump:
25 Nm (18 ft. lbs.)

25 Nm (18 ft. lbs.)
25 Nm (18 ft. lbs.)a. Place protective paper over generator (pump may still contain fluid).b. Install mounting bol
6. Install/reconnect:
a. Return and pressure hoses. Fit new O-ring on pressure hose.b. Clip securing hoses to dipstick tube.c. Coolant h
7. Install:
a. Pump drive belt.b. Cooling-air hose to control module box.
8. Top up with coolant.9. Fill power steering reservoir with fluid and bleed system.
a. Turn steering wheel repeatedly from lock to lock and top up fluid as required.b. Lower car.c. Apply parking br
- A. Turn steering wheel slowly to right and hold in limit position for 10 seconds.
- B. Turn steering wheel slowly to left and hold in limit position for 10 seconds.
e. Repeated steps A and B 20 times. Move car after 10 times to avoid damage to tires.
Disassemble
Tool Required
^ 999 5443 Puller
^^ 999
999 5444
5515 Press
Drift Tool

1. Separate fluid reservoir from pump.
a. Use screwdriver and adjustable pliers. Raise locking tabs in clips and press out clips with pliers.b. Remove O-r
2. Remove drive pulley from pump. Use puller.
3. Remove control valve from pump housing. Remove nut, control valve and spring. Remove O-ring from nut.
4. Remove:
a. Pump shaft and bearing from housing.b. Snap ring (circlip). Withdraw shaft and bearing from housing. Use pre

5. Measure bearing position on shaft. Note dimension.
NOTE: New bearing must be installed in same position on shaft.
6. Press bearing off pump shaft.
7. Remove shaft seal. Use screwdriver, taking care to avoid damage to pump housing.
NOTE: Matchmark end cover and housing by scribing.

8. Remove end cover locking ring:
a. Press out ring by inserting drift in hole in pump housing. b. Remove ring with screwdriver.

9. Separate end cover from pump housing.
a. Mount pump horizontally in vise. This is necessary to ensure that rotor does not fall out of housing when cover
10. Remove:
- O-ring from pump housing.
- Pump ring locating pins.
- Pump ring.
- Rotor and vanes.
- Pressure plate.
- O-ring from pressure plate.
- Pressure plate locating pin.
- Spring.
- O-ring from retainer in pump housing.
11. Tap out O-ring retainer from pump housing. Use drift.
12. Wash and inspect all components thoroughly. Replace damaged or worn components.

CAUTION: Always oil new components, as well as machined surfaces of pump housing, with ATF fluid prior t
NOTE: O-rings/seals must be replaced in all cases. Oil components prior to installation.
Assemble
Tool Required
^ 999 5515 Drift
^ 999 5184 Drift
^ 999 5444 Press Tool
1. Mount bearing on shaft. Support bearing inner race with drift. Press bearing onto shaft, ensuring that it is installed
2. Install O-ring retainer.
a. Remove O-ring if already mounted in retainer. b. Oil retainer with fluid and tap carefully into retainer seat. Use
3. Install in pump housing:
a. O-ring in retainer.b. seal in pump housing. Use drift. Tap seal into seat in housing.

4. Install pressure plate in pump housing:
a. Install locating pin and spring in housing. b. Fit new O-ring in pressure plate. c. Align one of two locating pin h
5. Install:
- Pump ring locating pins (two).
- Pump ring, with three markings facing upward.
- Rotor. Turn rotor downward so that machined out section adjacent to splines faces forward towards drive pull
- Rotor vanes.
- End cover O-ring in pump housing.
6. Install end cover in pump housing. Press end cover into pump housing. Install snap ring (circlip).
NOTE: Take care to align scribed marks with each other as illustrated.

7. Install pump shaft and bearing:
a. Push shaft into pump Housing until bearing reaches stop.b. Install snap ring (circlip) with rounded side facing
8. Install control valve. Install:

- O-ring on nut.
- Spring.
- Control valve.
- 75 Nm (55 ft. lbs.)Nut. Tighten to .
9. Install drive pulley. Grease pump shaft, then press on pulley. Use press tool. Press until nut meets end of shaft.
10. Install fluid reservoir. Install/mount:

- O-ring on reservoir pipe branch.
- Reservoir on pump with mounting clips. Ensure that clip locking tabs are seated in position.
11. Install power steering pump.
Power Steering Pump: Service and RepairReplacing Power Steering Pump
Removing power steering pump

Preparation
Remove
- cold air inlet hose to control module

- oil hose from mounting on top of power steering pump.
- Remove drive belt from the power steering pump.

- Use a fixed wrench and turn clockwise to take load off the automatic tensioner.
- Remove drive belt.

- Install lock grip pliers on the hose from the fluid reservoir as close to the power steering pump as possible.
Note! (GEN) Place paper over the Generator as protection against oil.
- Slacken off hose clamp and remove hose.
- Lift fluid reservoir. Remove the lock grip pliers and drain the oil into a suitable container.
- Reinstall the fluid reservoir and lock grip pliers to avoid further oil spillage.
Removing power steering pump


- Remove the power steering pump three mounting screws through the pulley holes.
- Remove oil hose holder and connector. Push holder to one side.
- Remove the pressure hose from the power steering pump.
- Remove the O-ring.
- Collect any oil.
- Remove power steering pump by lifting straight up.
- Raise front suspension so that wheels hang free.
- Turn the steering wheel between full locks. Collect fluid spillage from pressure and return hoses.
Installing power steering pump

Installing power steering pump
Note! (GEN) Place paper over the Generator as protection against oil.
Install
- servo pump
- 25 Nm (18.44 ft. lbs.).the three mounting screws through the pulley. Tighten to
- oil hose holder and connector
- return and pressure pipe. Use a new O-ring on the pressure pipe
- drive belt
- cold air inlet hose to the control module.
Finishing
Top up oil level in the servo reservoir and bleed the system

- For the correct oil quality, see specification.
- Repeatedly turn the steering wheel to full lock. Top up oil if necessary.
- Lower the car.
- Set the parking brake. Start the engine.
- A Turn steering wheel slowly to right and hold in limit position for 10 seconds.
- B Turn steering wheel slowly to right and hold in limit position for 10 seconds.
- Repeat steps A and B 20 times.
Note! Move car after the operation has been carried out 10 times to avoid damage to the tires.
> Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
WARNING: The manufacturer provides arming and disarming instructions as part of each applicable service p
Read and understand all applicable service procedures and safety precautions completely before beginning work
Failure to follow all SRS service precuations and procedures may result in damage to the vehicle, personal injur
> Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions

> Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6341

1/1 Battery

2/2 Fog lamp relay


2/22 A/C relay

3/1 Ignition switch

3/2 Light switch
3/37 Horn switches
3/95 TRACS switch

4/4 Rheostat

6/15 Sunroof motor
6/25 Starter motor
6/26 Generator
6/28 Blower fan
6/34 Power antenna


7/22 RPM sensor
7/79 Accelerometer
7/102 Microphone

8/6-10 Injectors
8/17 EGR converter
8/18 EVAP valve
8/49 Stop solenoid



11A/1-9 Main fuses


15/4 151-rail
15/8 X-rail
16/1 Radio
16/2 Amplifier
16/9 Antenna
16/10 Horn 1
16/11 Horn 2
16/15 CD-changer
16/19 Alarm horn
16/35 Alarm siren
16/36 TV receiver
16/46 RTI Display
16/48 CD-player RTI
16/68 Antenna
16/72 Dolby module

20/2 Distributor
20/3-7 Spark plugs
20/22-26 Glow plugs





Colors:
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Countries/Markets:
A = Austria
AUS = Australia
B = Belgium
CDN = Canada
CH = Switzerland
D = Germany
DK = Denmark
E = Spain
FIN = Finland
GB = Great Britain
J = Japan
KOR = Korea
N = Norway
NL = Holland
S = Sweden
Other:
ALTER = Alternative
C70 = 2-door
EXC = Exclusive
IMMO = Immobilizer
LATE = Late version
LH = Left-hand side
OTHERS = Others
S70 = 4-door
V70 = 5-door
W/O = Without
USA and Canada:
MOD1 =

MOD2 =


C70 all

> Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair
Steering Column Cover: Service and Repair
Replacing Steering Column Cover
Removal
Preparations
- Remove the ignition key.

- Lower and pull the steering wheel out as far as possible.
Steering column cover
- Undo the screws.

- Pull the lower cover loose and remove it.
- Fold up the upper cover.
- Remove the mounting for the apron molding by beginning unhooking from the side.
Installation
- Locate the lower cover. Check that the seals for the stalks are correctly positioned.
- Position the upper cover. Press the apron molding into place. Begin pressing from the center.
- Place the upper cover on the lower cover guides. Press the lower cover into place. Check that the seals for the sta
- Install the screws.
- Everything else is installed in reverse order.
> Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Steering Wheel Lock - Updated Replacement P
Steering Column Lock: Technical Service BulletinsSteering Wheel Lock - Updated Replacement Procedure
850, S70/V70/C701992-
Section:
6
Group:64
No:0011
Year:02
Month:03
Reference: This bulletin replaces Service Bulletin 64-0011 dated January 2000, which should be discarded.
Replacing the steering wheel lock
Background:Updated method for replacing the steering wheel lock assembly.
Preparations
Battery 1
- Make a note of the radio code if an anti-theft radio is installed.
- Switch off the ignition.
The steering column 2

- Fold down the steering wheel adjuster lever.
- Raise the steering wheel to the uppermost position.
Removal
Remove: 3
Warning!
The battery must be disconnected when the module is removed or installed.
> Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Steering Wheel Lock - Updated
Replacement Procedure > Page 6357

- the steering wheel according to the method in VADIS.
- the upper cover for the steering column. Use long Torx TX 15 tool.
- the lower cover for the steering column. Use a Torx TX 25 tool.
Caution!
Be careful not to damage the contact reel and wiring harness during work.
Remove:
-
the turn signal stalk.Allow the stalk to hang from the wiring harness.
- the lever for the windshield wipers. Disconnect one of the connectors. Leave the lever hanging from the other conne
- contact reel.
- the holder for the steering lock lighting.
Removing the lock 4

Warning!
Use protective goggles.
Center punch the screwheads.

- pre-drill the screw heads (1) for the mounting. Use an 3 mm drill bit (A).
- Drill out the screw heads (1). Use an 8 mm drill bit (B).
Note!
To easier remove the screws, it is helpful to use left handed (reverse) drill bits to unscrew the screws. Cobalt drills a
Remove:
- Connector for ignition lock.
- Wire for steering wheel lock.
- Remove the lock.
Installation
Installing a new steering wheel lock 5
- Position the new steering wheel lock.
- Install new security screws (1).
- Install connector for ignition lock.

- Install cable for steering wheel lock.
- Verify steering wheel lock function.
Install: 6
Note
Do not forget to connect the disassembled connector.
Caution!
Ensure that the boot for the windshield wiper lever is in place.

Caution!
Ensure that no wiring is trapped when the steering column covers are installed.
- the holder for the steering lock lighting. Use a new bulb.
- contact reel.
- the lever for the windshield wipers.
- the lever for the turn signal lamps.
- the upper cover for the steering column. Use a long Torx TX 15 tool.
- the steering wheel. Tighten to 40 ft.lb. Install the airbag module. Tighten to 10 ft.lb.
Final adjustments 7
- Adjust the steering wheel setting.
- Fold up the adjustment lever.
- Connect the battery negative lead.
- Program the radio if applicable.
WARRANTY STATEMENT:
Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using type 01
> Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Page 6360
Steering Column Lock: Description and Operation

The upper section of the steering shaft is equipped with a torque-limiting steering lock. The unit consists essentially of
Steering Column Lock: Service and Repair
Replacing the Steering Wheel Lock
Preparations
Battery
- Make a note of the radio code if an anti-theft radio is installed.
- Switch off the ignition.
The Steering Column
- Fold down the steering wheel adjuster lever.
- Raise the steering wheel to the uppermost position.
Removal
Remove:
Warning! The battery must be disconnected when the SRS steering wheel module is removed or installed.
- the steering wheel according to the method in VADIS.
- the upper cover for the steering column. Use long Torx TX 15 tool.
Caution! Be careful not to damage the contact reel and wiring harness during work.

Remove:
- the turn signal stalk.
Allow the stalk to hang from the wiring harness.
Disconnect one of the connectors. Leave the lever hanging from the other connector.
- contact reel.
- the holder for the steering lock lighting.
Removing the lock
Warning! Use protective goggles.
Center punch the screw heads.
- Pre-drill the screw heads (1) for the mounting. Use an 3 mm drill bit (A).
- Drill out the screw heads (1). Use an 8 mm drill bit (B).
Note! To easier remove the screws, it is helpful to use left handed (reverse) drill bits to unscrew the screws. Cobalt d
Remove:
- Connector for ignition lock.
- Wire for steering wheel lock.
- Remove the lock.
Installation

Installing a new steering wheel lock
- Position the new steering wheel lock.
- Install new security screws (1).
- Install connector for ignition lock.
- Install cable for steering wheel lock.
- Verify steering wheel lock function.
Install:
- Note! Do not forget to connect the disassembled connector.
- Caution! Ensure that the boot for the windshield wiper lever is in place.
- Caution! Ensure that no wiring is trapped when the steering column covers are installed.
- the holder for the steering lock lighting. Use a new bulb.
- contact reel.
- the lever for the turn signal lamps.
- the upper cover for the steering column. Use a long Torx TX 15 tool.
- 40 ft.lb.the steering wheel. Tighten to
10 ft.lb.Install the airbag module. Tighten to
Final adjustments
- Adjust the steering wheel setting.

- Fold up the adjustment lever.
- Connect the battery negative lead.
- Program the radio if applicable.

> Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications
Steering Gear: Mechanical Specifications
General Specifications
No. of steering wheel turns, lock-to-lock .............................................................................................................................
Dimension Specifications
Clearance between preload piston and cover ...................................................................................................................
Center Mounting Bolts .....................................................................................................................................................
Subframe ....................................................................................................................................................................
Crash Guard Bolts ............................................................................................................................................................

> Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 6368
Steering Gear: Pressure, Vacuum and Temperature Specifications

Pump Pressure When Reading Steering Axle Torque: 1.2 MPa
Steering Gear: Capacity Specifications
Lubricant ..............................................................................................................................................................................
Steering Gear: Fluid Type Specifications
Lubrication ...........................................................................................................................................................................
> Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6371
Steering Gear: Description and Operation
Design
The steering gear is of the rack and pinion type in which both the mechanical and power steering components are com

Operation Of Gear And Fluid
A. Neutral position: The power steering fluid flows freely through the steering gear.B. Steering to left: High-pressure
through the rotary valve into one of the external fluid lines to act on the piston (20), moving the rack (10) to the r
C. Steering to right: In this case also, high-pressure fluid from the pump enters the valve housing through the upper c
the rotary valve, the fluid is admitted to the other external fluid line and acts on the other side of the piston (20), m

Rotary Valve Assembly
The input shaft actuates the pinion through two drivers, each of which is provided with a circumferential clearance o
> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Gear Unit
Steering Gear: Service and RepairGear Unit
Removal
Tool Required
^ 999 5006 Lifting Yoke
^ 999 5033 Support Rails
^ 999 5259 Puller
^ 999 5460 Lifting Hook
NOTE:
Ensure that the front wheels are pointing straight ahead. Also lock the steering wheel with the steering lock before und
Removal
1. Mount support rails, lifting yoke and lifting hook. Jack up car slightly to relieve load on engine mountings2. Remo
a. Front wheels.
b. Tie rod (track rod) ends from steering arms. Use puller.
3. On one side, measure length of tie rod (track rod) relative to steering gear housing. Note dimension.
> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Gear Unit > Page 6376

4. Remove:
a. Splashguard under engine (If equipt.).b. Fluid line brackets and clips at front and rear.
5. Remove nuts (five) securing steering gear to subframe.
6. Position hoist under rear of subframe.7. Remove:
10-15 mm (0.39-0.59 inch)a. Bolts (two on each side) securing subframe brackets to body.b. Bolts (one on each
8. Lower subframe at rear.
NOTE: Ensure that steering gear bolts clear subframe.
9. Remove hoist.
10. Place container under steering gear to collect fluid.11. Disconnect fluid lines from steering gear.12. Remove:
a. Set bolt in lower universal joint. Push joint clear of steering gear.b. Bolt securing steering gear to rear engine m

c. Steering gear, towards right.
Installation
Installation
1. When replacing steering gear transfer heat shield and center mounting bracket. Do not tighten bracket bolts at this
lines.
2. Check that tie rod (track rod) position is the same as when removed.
3. Install steering gear from right-hand side.4. Reconnect steering gear input shaft to lower universal joint.
20 Nm (15 ft. lbs.)
a. Tighten joint set bolt to. b. Install bolt locking spring.c. Connect fluid lines loosely to steering gear. Use new O

5. Raise subframe at rear with hoist. Insert steering gear mounting bolts while raising frame.6. Install subframe brack
105 Nm (77 ft. lbs.) 120

50 Nm (37 ft. lbs.)a. Install new subframe bolts loosely. Transfer hoist to front of subframe. Replace front bolts b
7. Tighten:
50 Nm (37 ft. lbs.)
80 Nm (59 ft. lbs.)a. Steering gear nuts to . Use new nuts b. Steering gear center mounting bolt (if bracket has be
8. Install and tighten fluid line brackets and clips at front and rear.
9. Install/reconnect:
70 Nm (52 ft. lbs.)
a. Tie rods (track rods) to steering arms. Use new nuts. Tighten to .b. Splashguard under engine (If equipt.).
10. Mount wheels:
110 Nm (81 ft. lbs.)a. Lubricate wheel locating pin on hub with anti-rust agent P/N 1161030-0.b. First tighten bo

11. Fill power steering reservoir with fluid and bleed system:
a. Turn steering wheel repeatedly from lock to lock and top up fluid as required.b. Lower car.c. Apply parking br
(1) Turn steering wheel slowly to right and hold in limit position for 10 seconds.(2) Turn steering wheel slowl
e. Repeated steps (1) and (2) 20 times. Move car after 10 times to avoid damage to tires.
12. Check toe-in.
Disassemble
Tool Required
^ 999 5046 Fixture
^ 999 2250 Stand
^ 999 5154 Stand
^ 999 5179 Socket
^ 999 5333 Pin Spanner
^ 999 5389 Dressing Tool
1. Clean outside of steering gear. Disconnect pressure lines and remove O-rings.
NOTE: Pressure lines on later cars are provided with tapered seals.
2. Mount steering gear in fixture and stand. Use U-bolt 1272597-4 and intermediate piece 1272679-0 to mount assem

3. Drain fluid from steering gear:
a. Place container under fluid line connections to collect fluid. Turn pinion shaft back and forth with socket 999 5
fluid.
b. Adjust rack approximately to mid-position.
4. Inspect inner and outer ball joints for signs of wear.5. Remove:
a. Outer ball joints .b. Clamps and boots (gaiters).c. Boot sealing rings on housing.
6. Remove left-hand tie rod (track rod) and slacken right-hand rod a few turns.
a. Use adjustable wrench and adjustable pliers. Position wrench as far along rack as possible to act as counterhold
NOTE:
Rods are provided with spacers on certain versions. Use counterhold, otherwise rack and pinion may be dam

7. Remove:
a. Sealant covering locking wire hole.b. Rack bushing locking wire.c. Turn end sleeve with hook spanner until lo
NOTE: It may be necessary to use a pointed chisel to pry out the end of the wire.
8. Clean rack bushing and seal by blowing with compressed air. Hold pinion shaft with socket and handle. Blow thro
bushing and seal emerge. Tie rod (track rod) will act as stop to prevent escape of bushing.
NOTE: Use hearing protectors since compressed air may produce loud noise.
9. Remove:
a. Tie rod (track rod). b. Bushing and seal.

10. Remove preload assembly Use pin spanner to remove cover. Remove cover, spring and preload piston.

11. Remove piston dust seal and snap ring (Circlip). Use screwdriver to remove dust seal, taking care to avoid damage
housing.
12. Remove pinion cover. Insert chisel and tap off cover.
13. Remove pinion locknut. Use socket and handle to counterhold pinion shaft when removing locknut.
14. Remove pinion assembly. Use brass drift and hammer to tap out assembly from lower end.

15. Remove rack. Withdraw rack carefully to avoid damage to internal surfaces of rack and housing.
16. Tap out pinion ball bearing from above. Remove snap ring (circlip) and tap out bearing with drift.
24 mm (9.45 inch)17. Tap out pinion lower seal and bushing from underneath. Use long extension bar and o.d. socke
18. Tap out rack seal and backing ring from steering gear housing:
25 mm (9.84 inch)
a. Use two extension bars and o.d. socket.b. Insert extension bars and socket through steering gear housing, ensu
NOTE: Take care to avoid damage to internal surfaces of housing.

19. Piston seal. Replace piston seal only if damaged or if car has covered more than 40,000 km (25,000 miles).
20. Remove from pinion:
a. Socket (1). b. Dust seal (2).c. Snap ring (circlip) (3). d. Seal (4). e. Roller bearing (5).
NOTE: The four teflon seals on the rotary valve sleeve must not be removed.
21. Clean and inspect all components. Inspect:

- Boots (gaiters); replace as required.
- Boot seals; replace as required.
- All components for wear, corrosion, cracks and pressure damage.
- Pinion and valve sleeve. Complete steering gear must be replaced if these components are damaged.
NOTE: Carefully clean and dress threads in steering gear housing. Use dressing tool for preload device cover.
Assemble
Tool Required
^ 999 1801 Handle
^ 999 5277 Drift
^ 999 5388 Drift
^ 999 5393 Drift
^ 999 5179 Socket
^ 999 5519 Drift
^ 999 5182 Protective Sleeve

^ 999 5333 Pin Spanner
^ 999 2706 Drift
^ 999 8081 Torque Wrench
^ 951 2050 Angle Gauge
40,000 km (25,000 miles)1. Replace piston seal only if damaged or if car has covered more than. Fit O-ring, then te
40-50C (104-122F)ring to if difficult to fit.
2. Install new pinion bushing in steering gear housing.

a. Use handle and drift.
NOTE: Take care when installing bushing. Pinion may freeze (seize) if bushing is deformed.
b. Check that bushing is seated against shoulder in housing by visual observation through preload assembly open
3. Install new seal in steering gear housing Use handle and drift.
NOTE: Tap in seal carefully.

4. Install pinion ball bearing Use handle and drift. Install snap ring (circlip).
5. Install seal and backing ring on rack:
a. Protect teeth with wide strip of tape. Oil tape with fluid. b. Mount seal carefully on rack with lip facing piston s
6. Pack rack teeth with steering gear grease. Use Volvo grease, P/N 1161001-1, or equivalent.
7. Install rack with seal and backing ring. Guide rack into position, taking care to avoid damage to internal surfaces o
inserted, press to ensure that seal and backing ring are firmly seated. Tap end of rack gently with plastic mallet.

8. Check position of seal. Inspect through pressure line connection. Seal should be past center of opening when rack
9. Press rack backward.
NOTE: Press rack backward until end barely projects beyond housing opening. Do not press further or seal will
10. Install:
a. Seal and bushing on rack.b. O-ring on bushing.c. Seal on rack. Take care when fitting seal and ensure that plas
11. Install bushing and seal in steering gear housing:
a. Align bushing so that locking wire hole is opposite hole in housing.b. Press home bushing.
NOTE: Take care to ensure that O-ring is not damaged by edges of hole in housing.

12. Install locking wire. Insert locking wire hook in hole in bushing. Turn bushing with hook spanner until wire is in p
P/N 1161277-7.
NOTE: Use new locking wire.
13. Install pinion assembly:

a. Pack pinion teeth with grease, P/N1161001-1.
b. Install assembly in housing with flat on pinion shaft for universal joint clamping bolt aligned as shown. Take c
82 mm (3.23 inch)
+ 10sleeve when installing pinion assembly. Check that pinion and rack are engaged correctly with each other

37 Nm (27 ft. lbs.)
14. Install pinion locknut. Use new nut. Tighten to . Use socket and handle as counterhold. Remove socket.15. Check
deformed or rack is skew.
16. Install pinion shaft bearing:
a. Lubricate bearing with grease, P/N 1161001-1. b. Install bearing. Use drift. Tap bearing gently into position in
17. Mount upper seal on pinion shaft:
a. Grease seal. Mount seal on protective sleeve. Install seal with spring facing downward.b. Remove protective sl
NOTE: Seal cannot be finally installed with this tool.

18. Tap seal into position:
a. Use drift to tap seal gently into position. b. Install snap ring (circlip). Pack space between seal and dust seal wi
19. Install pinion dust seal. Use protective sleeve. Tap dust seal into position with drift.

20. Install new pinion cover.
a. Fill cover with grease, P/N 1161001-1. b. Install cover using drift.
21. Install:
a. Preload assembly components. Apply locking fluid to threads of new cover. b. Piston (greased).c. Spring.d. Co
5.0-5.6 Nm (3.7-4.1 ft. lbs.)22. Tighten cover. Adjust rack to mid-position: Tighten preload bolt to. Use pin spanner
50- 55slacken bolt . Use angle gauge.
23. Check steering gear torque. Attach torque wrench and socket to pinion shaft. Move rack back and forth to end lim
point on rack, set rack to this position and repeat torquing of preload device cover. If torque is still too high, repla

24. Install spacers (If equipt.).
a. Install spacers on rack (at each end). b. Install spacers with flat side facing housing.
NOTE: Inside radius on spacer should be seated age tie rod [track rod).
25. Install tie rod (track rod):

a. When re-using tie rods (track rods), the right and left rods may be interchanged to alter the locking edge positio
defective locking edge must not be re-used.
b. Tighten with an adjustable pliers and counterhold with an adjustable wrench as illustrated.
NOTE: A counterhold is essential to prevent damage to the rack and pinion.

26. Lock tie rod (track rod) to rack. Press ball joint edges into recesses in rack. Do not turn rack more than necessary t
lock rod. Press spacers (If equipt.) against tie rod (track rod).

20 g
27. Fit boots (gaiters). Pack each boot with of grease, P/N 1161001-1. Fit boots and secure at each end.28. Install ball
29. Remove steering gear from fixture and connect pressure lines.
7.5 Nm (5.5 ft. lbs.)
16.5 Nm (12.2 ft. lbs.)
a. Install new O-rings (If equipt.). Tighten to.b. (lines with tapered seals): Tighten to .c. Fill steering gear with flu
30. Install steering gear.
Steering Gear: Service and RepairReplacing Steering Gear
Special Tools
999 5716999 5259999 5460
Note!
Ensure that the front wheels are pointing straight ahead. Also lock the steering wheel with the steering lock before det
Removing the steering gear
Connect brackets 999 5716-21 and 999 5716-land lifting hooks 999 5460-21.Lift the engine to relieve the load on the
Remove
- the front wheels.

- tie rod ends from tie rods. Use puller 999 5259.
On one side, measure the length of the tie rod relative to the steering gear housing.

Note the measurement
Remove the oil line brackets and clips at front and rear.
Remove the collision protection system over the steering gear (2 screws). (Applies only to right-hand drive cars).
Place a container under the steering gear.Disconnect the oil lines from the steering gear and pull them forward so tha

Remove the five nuts securing the steering gear to the subframe.
Remove the plastic nut holding the tab in the right fender liner and bend the tab to one side.Remove the screws for th
Position a mobile jack at the rear edge of the sub-frame.
the four
Remove - screws holding the sub-frame brackets to the bodywork on both sides.
- the two screws together with the brackets and washers.
10 - 15 mm (0.39" - 0.5979).
Slacken off the front sub-frame screws Lower the rear edge of the sub-frame. Ensure that the steering gear screws re
the screw
Remove - in the steering shaft joint. Push the joint clear of the steering gear.
- the screw securing the steering gear to the rear engine pad.
Allow the steering gear to rest on the sub-frame and remove the heat deflector plate (TX25). (Applies only to right-h
Installing steering gear

Note! When replacing the steering gear and the mounting for the center mounting: Do not tighten the bracket screws
Left-hand drive cars Transfer the heat shield.
Right and left hand drive cars

Transfer the mounting for the center mounting.Plug the open ends of pipe couplings.
Check that the tie rod is in the same position as when it was removed.
50 Nm (36.9 ft. lbs.).
20 Nm (14.8 ft. lbs.).

Lift the steering gear in from the right.Allow the steering gear to rest on the sub-frame and install the heat deflector p

new screws
Do not tighten yet. 105 Nm (77.4 ft. lbs.) 120.
50 Nm (36.9 ft. lbs.).Raise the subframe at the rear. Use a mobile jack. Insert the steering gear mounting screws whi
Tighten
- steering gear to 50 Nm (36.9 ft. lbs.). Use new nuts.

- 80 Nm (59.0 ft. lbs.).the screw for the steering gear center mounting to
the oil
Install pipes only
(applies with new O-rings. drive cars) -
to right-hand
- the front and rear oil pipe brackets loosely. Tighten the oil pipes.
Install and tighten the oil pipe brackets and clamps at the front and rear.

80 Nm (59.0 ft. lbs.).Install the collision protection on the steering gear. (Applies only to right-hand drive cars.) Tigh
new screws
35 Nm (25.8 ft. lbs.) 90.
Install to the right hand engine mounting.Tighten to and angle tighten Turn the tab in the fender liner back and inst
Install
- 70 Nm (51.6 ft. lbs.).tie rods to steering arms. Use new nuts. Tighten to
-
110 Nm (7.4 ft. lbs.).the wheels. Lubricate the hub guide for rims with rustproofing agent, P/N 1161030- 0. Tigh
Top up the oil level in the servo reservoir and bleed the system.For oil type, see specifications Steering.Repeatedly tu

Lower the car.Apply the parking brake. Start the engine.Check for the oil level during bleeding as below.A. Turn the
Steering Gear: Service and RepairSteering Gear Spacers, Installation
Steering Gear Spacers, Installation
205 mm
Spacers must be installed at each end of the steering gear if the car is equipped with 16" or 17" wheels, and with tires
Note! 0.3 - 0.5 meters. This modification increases the turning circle by
As a further noise reduction measure, the wheel lock limiter may, if required, be ground back.
Note! This applies only to cars with aluminum control arms.
Installation of Spacers
Clean area around boot. Remove clampTake care to avoid damage to boot.Push boot back.
Heat spacers in warm water for a few minutes to facilitate mounting on steering rack
Press spacers onto rackFlat side of spacer should face steering gear housing.Press spacer against inner ball joint on ti
Reinstall Boot
Ensure that rubber sealing strip (A) is in position on steering gear.
Note! Sealing strip is fitted only on right side on right-hand drive cars.

Reinstall boot on steering gear. Use new steel clamp, P/N1387840-0. Included in kit.
Note! Hose clip must not be used.

Steering Gear: Service and RepairReconditioning Steering Gear
Special Tools
951 2050999 1801999 2250999 2706999 5046999 5154999 5179999 5182999 5277999 5333999 5388999 5389999
Disassembling steering gear
Hint: Removing steering gear, see Steering gear, replacement. To install see Steering gear, replacement.
Clean steering gear externallyRemove delivery lines and O-rings from the pipes
Note! Late version delivery lines have conical seals.


Install steering gear in fixture 999 5046 and stand 999 2250 or 999 5154Use U-bolt 1272597-4 and intermediate piec
Drain steering gear oil
Position a container under the pipe connectors. Turn pinion backwards and forwards until the oil is pumped out. Use
Check for wear in outer and inner ball joints.

the outer
Remove: - ball joints
- clamps and boots

- boot sealing rings on steering gear housing.
Note! On steering gear for right-hand drive cars there is only a sealing ring on the right-hand side.
On the left-hand drive cars: Remove the left tie rod and slacken off the right a few turns
On right-hand drive cars:
Remove the right tie rod and slacken off the left a few turnsUse an adjustable spanner and an pipe wrench. Position a
Note! On certain models there are washers on the tie rods.
Caution Use a counterhold, otherwise the rack and pinion can be damaged.
Caution The right/left tie rod stays in place. This is to prevent the end sleeve from escaping. See more below (P6).
Remove:
- the sealant covering the locking wire hole.
- steering rack bushing locking wire.
Turn the end sleeve with a hook wrench so that the locking wire is released and can be removed.

Note! If necessary a screwdriver can also be used to pry the wire out.
Blow through steering rack bushing and seal
Counterhold pinion with socket 999 5179 and a bar.Use compressed air in the outer pipe coupling to force out the bu
Warning The compressed air can cause a loud bang. Use ear defenders.
Remove:
- the tie rod

- the bushing with seal.
Remove the steering rack pre- tensioning assembly

Use a pin spanner 999 5333 on the cover. Remove the cover, spring and pre-tensioning piston.Remove dust cover an
Use a screwdriver for the dust cover. Take care not to damage the pinion or the steering gear housing.Remove pinion
Use a chisel. Tap cover loose.Remove pinion locknut

Counterhold with a socket 999 5179 and the handle, when nut is removed.Remove pinion
Knock lower part of pinion with a hammer and a drift.Remove steering rack
Carefully pull out the steering rack so that the surfaces on the steering rack and housing are not damaged.Tap out the

Remove the snap ring and knock out the bearing with drift.Knock out pinion lower seal and bushing from underneath
25 mm
24
Use a long extension bar and a socket with a exterior diameter.Tap out steering rack seal and support ring from steer
Use two extension shaft and a socket with exterior diameter.Install the extension and the socket through the steering
Caution Take care not to damage the surfaces in the housing.

40,000 km.Replace the piston seal only if it is damaged or if the car has driven more than
socketthe
Remove 999 5179 (1)
pinion:-
- dust cover (2)
- snap ring (3)
- sealing ring (4)
- bearing (5).
Caution The four Teflon sealing rings on the valve sleeve must not be removed.
Clean and check all components

Check:

- boots, change as necessary
- boot seals, change as necessary.
- All components for wear, corrosion, cracking and pressure damage.
- pinion with valve sleeve. If these parts are damaged the steering gear must be replaced.
Caution Thoroughly clean the threads in the steering gear housing. Use cleaning tool 999 5389 for the pre-tensio
Assembling the steering gear

Piston seal
40,000 km
40 - 50C
Replace the piston seal only if it is damaged or if the car has driven more than Install first O-ring and then the Teflon
Use bar 999 1801 and drift 999 5277.
Caution Be careful when installing bushing. If it is deformed the pinion will jam.
Check through the pre-tensioning assembly hole that the bushing is correctly seated in the housing.Install a new seali

Use bar 999 1801 and drift 999 5393.
Note! Carefully tap sealing ring into place.
Install the pinion bearing
Use bar 999 1801 and drift 999 5388. Reinstall snap ring.
Install the sealing ring and support ring on the steering rackApply a wide strip of tape to the cogs as protection. Oil th

Use Volvo grease, P/N 1161001-1Install the steering rack with seal and support ring
Guide the rack in so that it does not damage the housing surfaces. When the rack is at the bottom push so that the sea
Carry out a final inspection of the delivery line terminal. When the rack is pressed against the seal the piston seal sho

Caution
The steering rack should not be pushed back further than that the end is outside the steering gear housing otherwise
Install:
- the seal and bushing on the steering rack

- O-ring on the bushing
- the sealing ring on the steering rack. Take care, Check that the seal plastic ring is in position.
- bushing on the rack. Press sealing ring onto the bushing.
Install the bushing with the seal in the steering gear housing
Align the sleeve so that the hole for the locking wire is opposite the hole in the steering gear housing.Press in the bus

Caution Take care that the O-ring is not damaged by the hole edges in the steering gear housing.
Install locking wire
Caution Use new locking wire.
Insert a loop of wire into hole in sleeve. Turn the bushing with a hook wrench until the thread is in position. Seal the
Install pinion
Part 1 Of 2
Part 2 Of 2

82 mm
10Fill the pinion teeth with grease, P/N 1161001-1.Install the pinion in the housing in the surface for the clamp screw
Install pinion locknut
Use a new nut. Tighten to 37 Nm. Counterhold with a socket 999 5179 and a bar.Check steering rackTo check that th
Install bearing. Use drift 999 5519. Carefully tap the bearing into place in the steering gear housing.Install the upper

Lubricate seal. Thread seal onto the protective sleeve 999 5182. Install the seal on the steering gear with the spring o
Caution The sealing ring cannot be properly finally installed with this tool.
Tap in sealing ring
Use drift 999 5519. Carefully tap the sealing ring into place.Reinstall snap ring. Grease between the sealing ring and
Use protective sleeve 999 5182 according to paragraph (P35). Tap in dust cover. Use drift 999 5519.Install a new sea

Install:
- pre-tensioning assembly components. Apply locking fluid to threads of new cover

- piston greased
- spring
- cover.
Tighten cover
5.0 - 5.6 Nm
50 - 55.
Set steering rack to central position. Tighten pre-tensioning screw to . Use a pin spanner 999 5333 and a torque wren

Connect torque wrench 999 8081 with socket 999 5179 on the pinion shaft. Turn steering rack backwards and forwar
See also Steering gear spacers, installationInstall the spacer washers on the steering rack (both sides).Thread the was
Note! The inner radius of the washers should lie against the tie rods.
Install tie rods

If original rods are to be re-used, exchange left and right tie rods so that another locking surface is used. Rods with w
Caution A counterhold must be used otherwise the steering rack and pinion can be damaged.
Lock the tie rod to the steering rack
Bend ball joints edges down into steering rack recesses. Do not turn the steering rack further than it can reach.Use a

Fill each boot with 20 grams of grease, P/N 1161001-1. Thread on boots and clamp both ends.Install ball joints
7.5 Nm.
16.5 Nm.
Remove steering gear from the fixture and install delivery linesOn early versions: Install new O-rings. Tighten to La
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > TNN64-29 > Apr > 08
Replacement
Steering Shaft: All Technical Service BulletinsSteering - Lower Steering Shaft Replacement
NO: 64-29DATE: 4-22-2008MODEL: See chart belowM. YEAR: See chart belowSUBJECT:Lower steering shaft join
Note!
If using a printed version of this TNN, first check for the latest online version.
Affected vehicles:
Parts:
DescriptionThe lower steering shaft joint that is intended for left-hand drive vehicles is not currently available as a repl
Note!
At replacement, the steering wheel position must always be adjusted and the contact reel reset.
This must be done because the mounting position, in relation to the steering shaft and steering gear, differs on the two j
ServiceAfter replacing the lower steering shaft joint, adjust the steering wheel position and reset the contact reel as per
^ Repair
^ Cleaning, Inspection and Adjustment
^ Body and interior
^ Interior equipment
^ Checking and adjusting components, SRS
^ Adjusting steering wheel position
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 6640006 > Jul > 98 > S
Steering Shaft: All Technical Service BulletinsSteering Column - Knocking Sound

Section
6
Group
64
No.0006
Year
98
Month
07
Reference: TP 6001201, Section 6(60-64, 70-77), Front end, steering; 850 1992-
Steering column, knocking sound
Background:
A knocking or grinding sound may be beard from the steering column when driving on uneven surfaces, when turning
This may have been caused by the locating pin on the Hardy disc catching in its bushing. Therefore a service solution h
A running change has been introduced in production from the following chassis number:
Model Factory Chassis
S70 1 504402 -
S70 2 499979 -
V70 2 453795 -
Materials:
Service kit 1 9475257-3
Steering column, knocking noise
Action to counter knocking noise
Replacing Hardy disc
1
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: >
6640006 > Jul > 98 > Steering Column - Knocking Sound > Page 6433

Remove soundproofing panel (1).
Position the wheels straight ahead.
Mark the position as shown in the illustration (A). Turn the steering wheel so that one of the bolts for the coupling disc
Turn back the steering wheel to its first position and remove the other bolt (D) and nut for the coupling disc.
Remove:
- Shoulder bolt (B).
- The two bolts and nuts (C).
- The coupling disc.
Install new Hardy disc

Remove transport protection from locating pin. Lubricate entire locating pin (E) with grease from service kit.
Install sleeves (2xF) and (2xG).
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: >
6640006 > Jul > 98 > Steering Column - Knocking Sound > Page 6434

Install
- Hardy disc
- Check steering shaft position (A).
- Shoulder bolt and nut loosely.
- Screw, new washer and nut (C). Tighten to 25 Nm (18 ft.lbs).
- Unlock steering wheel lock
- Screw, new washer and nut (D). Tighten to 25 Nm (18 ft.lbs).
- Tighten wing screw and nut (8) to 35 Nm (26 ft.lbs).
Install soundproofing panel.
WARRANTY STATEMENT: Warranty may be submitted under the new car factory warranty when their is a documen
64916-2 Replacing Hardy disc 0.4 hr
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 6640006 > Jul > 98 > Steering Column - Knocking So
Steering Shaft: Customer InterestSteering Column - Knocking Sound

Section
6
Group
64
No.0006
Year
98
Month
07
Reference: TP 6001201, Section 6(60-64, 70-77), Front end, steering; 850 1992-
Steering column, knocking sound
Background:
A knocking or grinding sound may be beard from the steering column when driving on uneven surfaces, when turning
This may have been caused by the locating pin on the Hardy disc catching in its bushing. Therefore a service solution h
A running change has been introduced in production from the following chassis number:
Model Factory Chassis
S70 1 504402 -
S70 2 499979 -
V70 2 453795 -
Materials:
Service kit 1 9475257-3
Steering column, knocking noise
Action to counter knocking noise
Replacing Hardy disc
1
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 6640006 > Jul > 98 > Steering Column
- Knocking Sound > Page 6440

Remove soundproofing panel (1).
Position the wheels straight ahead.
Mark the position as shown in the illustration (A). Turn the steering wheel so that one of the bolts for the coupling disc
Turn back the steering wheel to its first position and remove the other bolt (D) and nut for the coupling disc.
Remove:
- Shoulder bolt (B).
- The two bolts and nuts (C).
- The coupling disc.
Install new Hardy disc

Remove transport protection from locating pin. Lubricate entire locating pin (E) with grease from service kit.
Install sleeves (2xF) and (2xG).
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 6640006 > Jul > 98 > Steering Column
- Knocking Sound > Page 6441

Install
- Hardy disc
- Check steering shaft position (A).
- Shoulder bolt and nut loosely.
- Screw, new washer and nut (C). Tighten to 25 Nm (18 ft.lbs).
- Unlock steering wheel lock
- Screw, new washer and nut (D). Tighten to 25 Nm (18 ft.lbs).
- Tighten wing screw and nut (8) to 35 Nm (26 ft.lbs).
Install soundproofing panel.
WARRANTY STATEMENT: Warranty may be submitted under the new car factory warranty when their is a documen
64916-2 Replacing Hardy disc 0.4 hr
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > TNN64-29 > Apr > 08 > S
Replacement
Steering Shaft: All Technical Service BulletinsSteering - Lower Steering Shaft Replacement
NO: 64-29DATE: 4-22-2008MODEL: See chart belowM. YEAR: See chart belowSUBJECT:Lower steering shaft join
Note!
If using a printed version of this TNN, first check for the latest online version.
Affected vehicles:
Parts:
DescriptionThe lower steering shaft joint that is intended for left-hand drive vehicles is not currently available as a repl
Note!
At replacement, the steering wheel position must always be adjusted and the contact reel reset.
This must be done because the mounting position, in relation to the steering shaft and steering gear, differs on the two j
ServiceAfter replacing the lower steering shaft joint, adjust the steering wheel position and reset the contact reel as per
^ Repair
^ Cleaning, Inspection and Adjustment
^ Body and interior
^ Interior equipment
^ Checking and adjusting components, SRS
^ Adjusting steering wheel position
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 6447
Steering Shaft: Specifications
U joint Clamp Bolt .....................................................................................................................................................
> Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 6448
Steering Shaft: Description and Operation
The steering shaft is in two sections and is provided with two universal joints, one between the upper and lower shaft se
> Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications
Steering Wheel: Specifications
Steering Wheel 40 Nm
Air Bag 10 Nm
> Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Alignment
Steering Wheel: Service and RepairAlignment
Minor misalignment may be corrected as part of toe-in adjustment. If misalignment is major, refer to steering column.
> Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Alignment > Page 6454
Steering Wheel: Service and RepairRelalacing Steering Wheel
Replacing the Steering Wheel
Removal
Preparations
Note! The following procedure applies to cars with SRS.
Caution! The battery must not be connected when the steering wheel module is removed or installed.
Disconnect the battery negative terminal. .
Note! Make a note of the anti-theft radio code. Removing the steering wheel module
- Slacken off the two Torx screws at rear of steering wheel.
Turn the steering wheel 90 in both directions to access the screws
- Disconnect the connector

- Remove the steering wheel module
- Slacken off the screw from the hole in the steering wheel. The screw must always remain in the plastic strap.
Note! Lock the contact reel into position using the locking screw to mark the position for the contact reel.

- Remove the steering wheel screw. Ensure that the front wheels are pointing straight ahead
- Note! Mark / score the steering shaft - steering wheel hub to mark the original position of the steering wheel.
- Lift off the steering wheel.
Take care to ensure that neither connector nor plastic strap and screw catch in the steering wheel during removal.
Installation
Installing the steering wheel

If installing a new steering wheel, mark / score it.

- Route the wiring from the contact reel through the steering wheel
- Carefully install the steering wheel so that both catches on the contact reel are seated in the two recesses in the st
- Note! Check that the markings / scoring correspond between the steering shaft and the steering wheel hub.
- Install the steering wheel screw

- Finger tighten.
Note! Do not turn the steering wheel when it is on the steering shaft. The contact reel is locked and may be damaged
- Remove the screw locking the contact reel. Install the looking screw in the hole in the steering wheel
- 40 Nm.Tighten the screw in the center of the steering wheel. Tighten to
Installing the steering wheel module
- Turn the ignition key to position I to unlock the steering wheel

- Position the lower section of the steering wheel module against the steering wheel (1)
- Connect the connector (2)
- Fold in the steering wheel module using Torx screws from the rear
- First install the right-hand screw. Turn the steering wheel to gain access to the screws
- 10 Nm.Tighten to
Check
Check that the steering wheel can be turned easily.After securing all the components switch on the ignition to positio
Note! Ensure that nobody is inside the car when the battery is being connected.
Check that the SRS warning light goes out.

> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications
Tie Rod End: Specifications

Lock Nut ...........................................................................................................................................................................
Castle Nut .........................................................................................................................................................................
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R Information
Ball Joint: Technical Service BulletinsBall Joint/Steering Knuckle - Additional R&R Information
Section
6
Group
61
No.0002
Year
99
Month
06
850/S70/V701993-
Background:
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R Information >
Page 6466

1
Preparations
Caution!
Caution!
Caution!
Page 6467

Warning!

Page 6468

IMPORTANT:
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Page 6469
Ball Joint: Specifications
Ball Joint
max 0.5 mm.Maximum axial play with normally laden front end:
A B 0.5 mm.Axial play is indicated by the difference between the dimensions and as illustrated. Maximum radial p
> Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair
Control Arm Bushing: Service and Repair
Fig. 3 Front Suspension
1. Raise and support vehicle, then remove nuts securing ball joint to control arm.
2. Fig. 3.Remove control arm mounting bolts, then the control arm,
3. Clean rust from bushing outer sleeves and note position of outer sleeves in relation to control arms.
4. Replace bushings using drift 5481, counterhold 5482 and a hydraulic press.
5. Check position of bushings using gauge 5483.
6. Install control arm and control arm mounting bolts, then the ball joint to control arm nuts. Tighten nuts to specific
7. Lower vehicle and bounce up and down a few times, then tighten control arm bolts to specifications.
> Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair
Front Cross-Member Bushing: Service and Repair
Tool Required
^ 999 5457 Tool consists of: Counterhold (1), nut plate (2), cutter (3), drift (4), spacer sleeve (5), bolt and nut (6).
NOTE: The left front bushing is slightly oval in the hole and cannot be used in the right front hole. The bushings may
1. Jack up car.
2. Remove bushing bolt and washers. Subframe will drop slightly.
3. Install:
- counterhold (1) on top of frame as illustrated.
- cutter (3) and bolt (6). Install from underneath.
4. Tighten large nut on cutter until stop is reached.
5. Remove counterhold: Install nut plate (2), spacer sleeve (5) and bolt (6).6. Withdraw inner section of bushing with
> Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair > Page 6478

illustration.
7. Break off part of flange on outer sleeve of bushing:

a. Use screwdriver and hammer.
NOTE: A chisel must not be used.
b. Split sleeve completely by inserting screwdriver in gap.
8. Pry out bushing. Use screwdriver.
9. Remove inner section of bushing from cutter.
a. Spray universal oil/releasing oil between bushing and cutter to assist removal of bushing from tool.b. Mount bu
10. Position counterhold on top of frame.
11. Install bushing using drift (4) and bolt (6).Tighten nut on bolt to press bushing home fully.
> Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair > Page 6479

NOTE: Check that marks on bushing and frame coincide. Left and right bushings are different.
12. Remove tools.
105 Nm (77 ft. lbs.) 12013. Install new bolt complete with washers. Lubricate bolt thread. Tighten to and through fur
> Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member Bushing > System Information > Service and Repair
Rear Cross-Member Bushing: Service and Repair
NOTE: Bushings may be replaced only one at a time.
1. Remove mounting bolt from engine upper torque rod.2. Release steering wheel lock.3. Remove locking spring, nu
CAUTION:
On cars with SRS, lock steering wheel by removing ignition key. Do not turn front wheels, otherwise steering g
4. Push universal joint up steering shaft.5. Jack up car.6. Disconnect stabilizer link (anti-roll link) from bar.7. Remov
- both rear bolts from bracket.
- center bolt. Subframe will drop slightly.
NOTE:
The body is provided with a locating pin for the bushing on the left-hand side. When replacing the bus, hang. a l
8. Install cutter (3) and bolt (6) from underneath.
NOTE: Illustration shows bushing at front of subframe.
9. Tighten large nut on cutter until stop is reached.
10. Remove counterhold: Install nut plate (2), spacer sleeve (5) and bolt (6).11. Withdraw inner section of bushing wi
illustration.
12. Break off part of flange on outer sleeve of bushing:
a. Use screwdriver and hammer.
NOTE: A chisel must not be used.
b. Split sleeve completely by inserting screwdriver in gap.
> Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member Bushing > System Information > Service and Repair > Page 6483

13. Pry out bushing. Use screwdriver.
14. Remove inner section of bushing from cutter.
a. Spray universal oil/releasing oil between bushing and cutter to assist removal of bushing from tool.b. Mount bu
15. Position counterhold on top of frame.
16. Install bushing using drift (4) and bolt (6). Tighten nut on bolt to press bushing home fully.
NOTE: Check that marks on bushing and frame coincide. Left and right bushings are different.
17. Remove tools.

105 Nm (77 ft. lbs.) 12018. Install new bolt complete with washers. Lubricate bolt thread. Tighten to and through fur
NOTE: 50 Nm (37 ft. lbs.) Tighten rear bracket bolts to .
> Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member Bushing > System Information > Service and Repair > Page 6484

20 Nm (15 ft. lbs.)19. Reconnect universal joint to steering gear Tighten bolt to. Install locking spring.
20. Reconnect torque rod to engine torque arm. Use new bolt and locknut.
18 Nm (13 ft. lbs.) 120
35 Nm (26 ft. lbs.) 90a. M8. Tighten to and through further .b. M10. Tighten to and through further .
> Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R Information
Front Steering Knuckle: Technical Service BulletinsBall Joint/Steering Knuckle - Additional R&R Information
Section
6
Group
61
No.0002
Year
99
Month
06
850/S70/V701993-
Background:
> Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Ball Joint/Steering Knuckle - Additional R&R

1
Preparations
Caution!
Caution!
Caution!

Warning!


IMPORTANT:
> Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6492
Front Steering Knuckle: Service and Repair
Removing stub axle
Raise the car.Remove
- the wheel
- the anti-roll bar link from the spring strut. Use a fixed wrench as a counterhold
- the ABS sensor. Hang up sensor with a piece of wire
- ABS sensor cable from spring strut
- brake caliper and limiter mounting screws

- the limiter. Hang caliper up with a piece of wire.

- drive shaft screw. Use a screwdriver as counterhold on the brake disc
- locating pin holding brake disc
-
10 - 15 mm.
brake disc.Slacken off end of the drive shaft in the hub by knocking the drive shaft into the hub approximately U
- tie rod ends from the steering arm. Use puller 999 52S9.
- both screws retaining the spring strut in the stub axle.

Pry out the stub axle.Pull out the drive shaft and fold to one side. Hang up drive shaft on a hook 999 5045.
Note! Take care not to damage the drive shaft boot.
- nut on ball joint. Use a Torx wrench as counterhold

- stub axle.
Installing stub axle

Install
- stub axle on the trailing arm
- 80 Nmnew nut on the ball joint. Tighten to . Use a Torx wrench as counterhold.
Note! Make sure that the mating surfaces on the ball joint and link are clean.

Clean the splines on the drive shaft.Turn in the stub axle and locate the drive shaft in the hub.Install drive shaft screw
Install
- 90
both screws retaining the spring strut in the stub axle. Use new screws and nuts. Tighten to 105 Nm and angle-tig
- 50 Nmanti-roll bar link to the spring strut. Use a new nut. Tighten to
- ABS sensor cable
- 10 NmABS sensor onto stub axle. Tighten ABS sensor to
Note! Ensure that the sensor seat in the stub axle is absolutely clean. Clean the ABS sensor with a soft brush.
- 70 Nm.tie rod end onto the stub axle. Use a new nut. Tighten to
-
8 Nm.brake disc. Tighten brake disc locating pin to
Note! Ensure that the brake disk and wheel rim hub mating surfaces are clean.
50 NmTighten drive shaft screw to . Use a screwdriver as counterhold on the brake disc.

- 100 Nm.brake caliper and limiter. Use new screws. Tighten to
- the wheel according to Installing wheels.
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front
Stabilizer Link: SpecificationsFront

Link To:
Bar ..............................................................................................................................................................................
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front > Page 6502
Stabilizer Link: SpecificationsRear

Anti-Roll Bar Link To Lower Control Arm .....................................................................................................................
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring
> Suspension - Squeaking Noise From Rear
Suspension Spring ( Coil / Leaf ): All Technical Service BulletinsSuspension - Squeaking Noise From Rear
TITLE:Rear suspension, squeaking noise
MODELS:1998-2000 V70 XC
SECTION7
GROUP72
NO.0001
YEAR00
MONTH02
REFERENCE:
This Service Bulletin replaces the previous SB 772-0001 from June 1999, which should be discarded.
BACKGROUND
On some cars, a squeaking noise can be heard coming from the rear suspension between the rear spring, bump stop and
AFFECTED VEHICLES
MATERIALS
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Suspension Spring ( Coil / Leaf ): > 7720001 > Feb > 00 > Suspension - Squeaking Noise From Rear > Page 6511

TOOLS
SQUEAKING NOISE FROM REAR SUSPENSION
Special tools:
999 5660, 999 5498, 999 5499, 999 5500, 999 5501, 951 2050
REMOVING THE SPRING
Rear seat backrest
Fold the backrest forward.
Exposing the upper 9hock absorber mounts
Raise the front floor hatch
Remove the side floor panels
Remove the screws from the front floor hatch Pull back the hatch to release it from its front mountings at the front edge
Remove the cover.

Cover for the upper shock absorber mounting
Remove the cover over the upper shock absorber mounting.
The upper shock absorber mounting
Remove the nut for the upper shock absorber mounting.
Special tools:
999 5498, socket for standard shock absorbers
999 5499, wrench for standard shock absorbers
999 5500, socket for Nivomat shock absorbers
999 5501, wrench for Nivomat shock absorbers.
4

Rear jacking point and the control arm mounting
Preparations:
Raise the car
Remove the rear wheel on the relevant side
Loosen off the rear jacking point
Remove the 3 screws from the lateral link. This is to detach the control arm mounting
Press the jacking point backward so that it passes the control arm.
Caution! Do not in any way damage the brake line.
Spring
Remove the nut for the anti-roll bar link mounting
Loosen off the nut for the inner trailing arm mounting 2 turns
Remove the nut for the outer trailing arm mounting Tap out the screw.
Note! The screw is locked with splines. The screw cannot be turned.
Pull the trailing arm downwards.
Remove:
- the spring
- the spring seat

- the bump stop.
Clean the spring seat.
INSTALLING THE SPRING
Spring
Bend the control arm downwards.
Install:
- the new bump stop
- the spring seat
- the spring.
Installing the tensioner
Install the long screw for the tensioner on the mounting
Install mounting 999 5660 on the rear axle member.
Note! Ensure that the rear axle mating surfaces are clean where the tool will be used.
Screw tensioner j4 1470-850 into place. Use the long screw.
8
Installing the outer control arm mounting

Note! The rollers must be in contact with the control arms on both sides.
Press up the control arm using the tensioner so that the screw for the outer mounting on the control arm can be installed
Note! Press in the screw only so far that the splines are not in the bushing.
Note! Ensure that the anti-roll bar link is correctly positioned.
Installing the jacking point
Note! Use a new screw.
Adjust the tensioner so that the mounting for the lateral link can be installed
Install the jacking point. (Do not tighten the screw yet).
10
Tightening
Adjust the tensioner to the normal position.

Normal position
The rear suspension is in the normal position when the distance from the fender edge (1) to the center of the wheel (2) i
Tap in the screw for the outer control mounting so that the splines are in the bushing.

Tighten:
The outer and inner control arm mounting to 80 Nm (60 ft.lb)
The screw for the lateral link to 65 Nm (48 ft.lb). Angle-tighten an additional 60 .
Note! Use 3 new screws.
The mounting for the jacking point to 105 Nm (77 ft.lb).
Angle-tighten an additional 90 .
11
Installing the anti-roll bar link and upper shock absorber mounting
Anti-roll bar link
Install the nut on the anti-roll bar link mounting.
Tighten to 30 Nm (22 ft.lb)

Remove the tensioner.
Upper 9hock absorber mounting
Install the wheel. Tighten to 110 Nm (81 ft.lb)
Lower the car completely
Install a washer and nut on the upper shock absorber mounting.
Tighten the nut:
- for standard shock absorbers to 40 Nm (30 ft.lb)

- for Nivomat shock absorbers with M12 nuts to 40 Nm (30 ft.lb)
- for Nivomat shock absorbers with M1O nuts to 20 Nm (15 ft.lb). Angle-tighten an additional g0.
Special tools:
999 5501, wrench for Nivomat shock absorbers
951 2050, bevel protractor.
Cover on the shock absorber mountings
Install the cover on the upper shock absorber mounting
Tighten to 25 Nm (18 ft.lb).
12
Reassemble the cargo compartment
Align the floor hatch mountings at the front edge Install the screws in the rear edge
Align the hatch with the rear floor hatch. Tighten the screws
Reinstall the side floor hatches
Fold down the front floor hatch.

13
Reposition the backrest
Fold up the backrest.
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf
- Squeaking Noise From Rear
Suspension Spring ( Coil / Leaf ): Customer InterestSuspension - Squeaking Noise From Rear
TITLE:Rear suspension, squeaking noise
MODELS:1998-2000 V70 XC
SECTION7
GROUP72
NO.0001
YEAR00
MONTH02
REFERENCE:
This Service Bulletin replaces the previous SB 772-0001 from June 1999, which should be discarded.
BACKGROUND
On some cars, a squeaking noise can be heard coming from the rear suspension between the rear spring, bump stop and
AFFECTED VEHICLES
MATERIALS
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension
Spring ( Coil / Leaf ): > 7720001 > Feb > 00 > Suspension - Squeaking Noise From Rear > Page 6524

TOOLS
SQUEAKING NOISE FROM REAR SUSPENSION
Special tools:
999 5660, 999 5498, 999 5499, 999 5500, 999 5501, 951 2050
REMOVING THE SPRING
Rear seat backrest
Fold the backrest forward.
Exposing the upper 9hock absorber mounts
Raise the front floor hatch
Remove the side floor panels
Remove the screws from the front floor hatch Pull back the hatch to release it from its front mountings at the front edge
Remove the cover.

Cover for the upper shock absorber mounting
Remove the cover over the upper shock absorber mounting.
The upper shock absorber mounting
Remove the nut for the upper shock absorber mounting.
Special tools:
999 5501, wrench for Nivomat shock absorbers.
4

Rear jacking point and the control arm mounting
Preparations:
Raise the car
Remove the rear wheel on the relevant side
Loosen off the rear jacking point
Remove the 3 screws from the lateral link. This is to detach the control arm mounting
Press the jacking point backward so that it passes the control arm.
Caution! Do not in any way damage the brake line.
Spring
Remove the nut for the anti-roll bar link mounting
Loosen off the nut for the inner trailing arm mounting 2 turns
Remove the nut for the outer trailing arm mounting Tap out the screw.
Note! The screw is locked with splines. The screw cannot be turned.
Pull the trailing arm downwards.
Remove:
- the spring
- the spring seat

- the bump stop.
Clean the spring seat.
INSTALLING THE SPRING
Spring
Bend the control arm downwards.
Install:
- the new bump stop
- the spring seat
- the spring.
Installing the tensioner
Install the long screw for the tensioner on the mounting
Install mounting 999 5660 on the rear axle member.
Note! Ensure that the rear axle mating surfaces are clean where the tool will be used.
Screw tensioner j4 1470-850 into place. Use the long screw.
8
Installing the outer control arm mounting

Note! The rollers must be in contact with the control arms on both sides.
Press up the control arm using the tensioner so that the screw for the outer mounting on the control arm can be installed
Note! Press in the screw only so far that the splines are not in the bushing.
Note! Ensure that the anti-roll bar link is correctly positioned.
Installing the jacking point
Note! Use a new screw.
Adjust the tensioner so that the mounting for the lateral link can be installed
Install the jacking point. (Do not tighten the screw yet).
10
Tightening
Adjust the tensioner to the normal position.

Normal position
The rear suspension is in the normal position when the distance from the fender edge (1) to the center of the wheel (2) i
Tap in the screw for the outer control mounting so that the splines are in the bushing.

Tighten:
The outer and inner control arm mounting to 80 Nm (60 ft.lb)
The screw for the lateral link to 65 Nm (48 ft.lb). Angle-tighten an additional 60 .
Note! Use 3 new screws.
The mounting for the jacking point to 105 Nm (77 ft.lb).
Angle-tighten an additional 90 .
11
Installing the anti-roll bar link and upper shock absorber mounting
Anti-roll bar link
Install the nut on the anti-roll bar link mounting.
Tighten to 30 Nm (22 ft.lb)

Remove the tensioner.
Upper 9hock absorber mounting
Install the wheel. Tighten to 110 Nm (81 ft.lb)
Lower the car completely
Install a washer and nut on the upper shock absorber mounting.
Tighten the nut:
- for standard shock absorbers to 40 Nm (30 ft.lb)

- for Nivomat shock absorbers with M12 nuts to 40 Nm (30 ft.lb)
- for Nivomat shock absorbers with M1O nuts to 20 Nm (15 ft.lb). Angle-tighten an additional g0.
Special tools:
999 5501, wrench for Nivomat shock absorbers
951 2050, bevel protractor.
Cover on the shock absorber mountings
Install the cover on the upper shock absorber mounting
Tighten to 25 Nm (18 ft.lb).
12
Reassemble the cargo compartment
Align the floor hatch mountings at the front edge Install the screws in the rear edge
Align the hatch with the rear floor hatch. Tighten the screws
Reinstall the side floor hatches
Fold down the front floor hatch.

13
Reposition the backrest
Fold up the backrest.
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 6532
Suspension Spring ( Coil / Leaf ): Specifications

Spring Mount To Spring Seat ..........................................................................................................................................

Suspension Spring ( Coil / Leaf ): Description and Operation
The car is equipped with coil springs and with individual wheel suspension. At the lower end, the front spring (1) is sup
Suspension Spring ( Coil / Leaf ): Service and Repair
Special Tools
999 5407999 5466999 5467999 5468999 5469

Note!
3 mm (0.118inch) 7 mm (0.276 inch) When replacing shock absorbers: Early versions of the shock absorber have bee
Remove:
- - the wheel
- - anti-roll bar link from spring strut
-
- ABS sensor from the stub axle.Remove the ABS sensor cable from the spring strut and brake bracket.
Caution Do not disconnect connector.
Caution
Install on support 999 5466 under the control arm. The support should be used to avoid too large a joint angle at
Remove the two screws retaining the spring strut in the stub axle. Then remove the spring strut
Secure the spring strut in a vise as illustrated

Take the load off the spring seat with the spring clamps 999 5407. Set the clamps facing each other. Tighten the c
Caution If only the spring strut mounting is to be installed, continue to remove the mounting nut on the shock ab
Use socket 999 5469 and counterhold 999 5468

Remove:
- the spring seat
- rubber bump stop and gaiter
- spring
- holder for the ABS cable (from 1994 model year).
Check that the spring, spring strut mounting, spring seat, boot and bump stop are not damaged

Note!
3 mm (0.118 inch) 3 mm (0.118 inch)
The following applies when replacing the shock absorber: Model year 1992-1993: Replace the existing washer A
300 mm (11.8 inch) When replacing the spring:Compress the new spring to a length of approximately Use spring
Reassembly
bump
Install on stop
shockwith boot
absorber:-
- 3 mmthe washer (when replacing the shock absorber- replace the existing washer with a thick washer, see (M7)
- 300 mm (11.8 inch)the spring compressed to approximately in length
-
the spring seat.Locate the spring ends in the spring seats.

Install the mounting nut
70 Nm (51.6 ft. lbs.)Tighten it to . Use socket 999 5469 and counterhold 999 5468.
Install:
the spring strut mounting
-- 70 Nm (51 6 ft. lbs.).
washer and nut. Tighten the nut to Use socket 999 5467 and counterhold 999 5468.Remove the spring clamps
Installation
Install the spring strut in the bodywork with the new nuts
25 Nm (18.44 ft. lbs.).Tighten the three spring strut mounting nuts to
1994 model year cars 12.1 mm (0.47 inch)

13mm (0.51 inch) On 1994 model year cars, the size of the holes in the stub axles for the shock absorber mounting s
Note! 13 mm (0.51 inch) diameter Stub axles with mounting holes are also introduced as replacement part and rep
When replacing shock absorbers on cars with the new stub axles, two sleeves, P/N 9153007-1 should be installed. Th
Note! The screws can be stiff in the holes.
Install spring strut to the stub axle

65 Nm (47.9 ft. lbs.).
90.Use new screws and nuts. Tighten to Angle tighten
Installing new bracket for the ABS cable
Model year 1992-1993
Part 1 Of 2
Part 2 Of 2
Install a new bracket on the new shock absorber
Model year 1994-on

Continue to "Install anti-roll bar link to spring strut with new nut"Transfer the existing bracket to the new shock abso
Note! 50 Nm (36.9 ft. lbs.). On early models there is a stamped section for the link fastening in the spring strut. Tig
Install the ABS sensor cable on the spring strut and to the brake line bracket

Secure the ABS lineOn left-hand drive cars:Secure any ABS line excess on the driver's side of the engine compartme
Remove support 999 5466
Install wheel
110 Nm (81.1 ft. lbs.). Lubricate hub guide for rims with rustproofing agent, P/N 1161030-0 Tighten studs lightly. T
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Installing Rear Shock Absorber Bearin
Suspension Strut / Shock Absorber: Technical Service BulletinsSuspension - Installing Rear Shock Absorber Be
Section
7
Group
76
No.0002
Year
98
Month
08
Vehicles involved: W/O Nivomat
76-0002; Installing rear shock absorber bearing; 98/08
Background:
A knocking sound may be heard from the rear of the vehicle. In such case a new nivomat upper bearing and/or washer
Materials:
Service kit x2 272383-1

9140847-6
The kit consists of:- Bearing
- Washer 977991-9
Replacing rear shock absorber bearing
Installing shock absorber upper bearing
Installing new shock absorber upper bearing and washer.
When replacing shock absorber bearing and washer see Service Manual TP 6002201, section 6,7 (65, 72.77) Rear susp
Applies only to Fichtel & Sachs. See illustration (1). Install washer between shock absorber and bearing.
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Installing Rear Shock
Absorber Bearing > Page 6544

Install washer and bearing.
Install a new washer and upper bearing as show in the illustration. (torque spec. is needed for the nut)
(Applies ONLY to Fichtel & Sachs)
Replace both left and right hand side washer and shock absorber bearing mount at the same time.
76144-2 Rear shock absorber bearing, 0.6 hr

replace 2 sides
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber
Suspension Strut / Shock Absorber: SpecificationsShock Absorber

Front:
Shock Absorber To:
Knuckle .................................................................................................................................................................
Rear:
Shock Absorber To:
Rear Axle Member ................................................................................................................................................
Lower Control Arm ...............................................................................................................................................
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 6547
Suspension Strut / Shock Absorber: SpecificationsMounting to Bar

Front:
Bar To:
Sub-Frame .............................................................................................................................................................
Link .......................................................................................................................................................................
Rear:
Bar To:
Rear Axle Member ................................................................................................................................................
Anti-Roll Bar Link ................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 6548
Suspension Strut / Shock Absorber: SpecificationsTightening Strut

Upper Retaining Nut ........................................................................................................................................................

> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 6549
Suspension Strut / Shock Absorber: Description and Operation
The suspension strut (6) consists of a cylindrical tube to which the steering knuckle (stub axle carrier) is attached at the
1. Upper mounting2. Shock absorber3. Protective sleeve4. Spring5. Lower spring seat6. Suspension strut7. Stabilizer
10. Ball joint

Upper Mounting
Suspension Strut Upper Mounting

Suspension Strut / Shock Absorber: Service and Repair
Special Tools
999 5407999 5466999 5467999 5468999 5469

Note!
3 mm (0.118inch) 7 mm (0.276 inch) When replacing shock absorbers: Early versions of the shock absorber have bee
Remove:
- - the wheel
- - anti-roll bar link from spring strut
-
- ABS sensor from the stub axle.Remove the ABS sensor cable from the spring strut and brake bracket.
Caution Do not disconnect connector.
Caution
Install on support 999 5466 under the control arm. The support should be used to avoid too large a joint angle at
Remove the two screws retaining the spring strut in the stub axle. Then remove the spring strut
Secure the spring strut in a vise as illustrated

Take the load off the spring seat with the spring clamps 999 5407. Set the clamps facing each other. Tighten the c
Caution If only the spring strut mounting is to be installed, continue to remove the mounting nut on the shock ab
Use socket 999 5469 and counterhold 999 5468

Remove:
- the spring seat
- rubber bump stop and gaiter
- spring
- holder for the ABS cable (from 1994 model year).
Check that the spring, spring strut mounting, spring seat, boot and bump stop are not damaged

Note!
3 mm (0.118 inch) 3 mm (0.118 inch)
The following applies when replacing the shock absorber: Model year 1992-1993: Replace the existing washer A
300 mm (11.8 inch) When replacing the spring:Compress the new spring to a length of approximately Use spring
Reassembly
bump
Install on stop
shockwith boot
absorber:-
- 3 mmthe washer (when replacing the shock absorber- replace the existing washer with a thick washer, see (M7)
- 300 mm (11.8 inch)the spring compressed to approximately in length
-
the spring seat.Locate the spring ends in the spring seats.

Install the mounting nut
70 Nm (51.6 ft. lbs.)Tighten it to . Use socket 999 5469 and counterhold 999 5468.
Install:
the spring strut mounting
-- 70 Nm (51 6 ft. lbs.).
washer and nut. Tighten the nut to Use socket 999 5467 and counterhold 999 5468.Remove the spring clamps
Installation
Install the spring strut in the bodywork with the new nuts
25 Nm (18.44 ft. lbs.).Tighten the three spring strut mounting nuts to
1994 model year cars 12.1 mm (0.47 inch)

13mm (0.51 inch) On 1994 model year cars, the size of the holes in the stub axles for the shock absorber mounting s
Note! 13 mm (0.51 inch) diameter Stub axles with mounting holes are also introduced as replacement part and rep
When replacing shock absorbers on cars with the new stub axles, two sleeves, P/N 9153007-1 should be installed. Th
Note! The screws can be stiff in the holes.
Install spring strut to the stub axle

65 Nm (47.9 ft. lbs.).
90.Use new screws and nuts. Tighten to Angle tighten
Installing new bracket for the ABS cable
Model year 1992-1993
Part 1 Of 2
Part 2 Of 2
Install a new bracket on the new shock absorber
Model year 1994-on

Continue to "Install anti-roll bar link to spring strut with new nut"Transfer the existing bracket to the new shock abso
Note! 50 Nm (36.9 ft. lbs.). On early models there is a stamped section for the link fastening in the spring strut. Tig
Install the ABS sensor cable on the spring strut and to the brake line bracket

Secure the ABS lineOn left-hand drive cars:Secure any ABS line excess on the driver's side of the engine compartme
Remove support 999 5466
Install wheel
110 Nm (81.1 ft. lbs.). Lubricate hub guide for rims with rustproofing agent, P/N 1161030-0 Tighten studs lightly. T
> Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications
Torque Rod: Specifications

Track Rod To:
Wheel Bearing Housing .............................................................................................................................................

> Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications
Trailing Arm: Specifications

Bushing To Transverse Arm Mounting Bolt ...................................................................................................................
> Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 6563
Trailing Arm: Service and Repair
Special Tools
999 5497951 2050
Note! The rear axle links should be changed on both sides, one at a time. The description shows the left-hand side bein
Remove the nut from the rear axle link mounting screw in the trailing arm
Tap out mounting screw.Use a copper mallet or similar.
On the left-hand side: Remove sound damper bracket screw.
Remove brake pipe from the two mounting clips.Remove trailing arm bracket screws.Leave the bracket hanging from

Bend down the link on the left-hand side from the bodywork locating pin. Use a jimmy bar.Ensure that the trailing ar
Installation
Note! Turn the bushing with the large inner diameter inner sleeve towards the bodywork.
Press the new rear axle link.
Use the same tool as when removing.Remove tool. Install a new mounting screw and nut on the rear axle link.Do no

105 Nm (77.44 ft. lbs.). 90
65 Nm (47.9 ft. lbs.)
60 65 Nm (47.9 ft. lbs.)Install the trailing arm on the bodywork locating pin.Install trailing arm bracket screws finge
Install:
- brake pipe to mounting clip.

- sound damper bracket screw.
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection
Special tools:
999 5418999 5507
Preparations



> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 6569

- 0.020 mm (0.00079")Note test gauge run-out. Hub late

V70 XC AWD L5-2.4L Turbo VIN 56 B5254T (1998)

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

V70 XC AWD L5-2.4L Turbo VIN 56 B5254T (1998)

Caricato da

Copyright:

Formati disponibili

volvo :: Volvo V70 XC AWD L5-2.

Alarm Horn Relay: Locations

Fuse/Relay Identification and Location