engine VOLVO 240 1990 Workshop Manual

Volvo 1990 240 Model
stop light pg. 80 Replacing bulbs


Interior light

Insert a screwdriver through the opening in the right side of the housin\
g and depress the catch tab. Pull
out the housing assembly and replace the bulb.

Bulb Power Socket
Interior light 10 W S 8.5 - 8



Engine compartment light, Trunk light
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Volvo 1990 240 Model

Remove screw holding the light assembly Lift it out to remove.
Replace the bulb.
Reinstall by first inserting the guides into one side, then press ir, th\
e light assembly and install the screw.

Bulb Power Socket
Engine compartment light 15 W S 8.5 - 8
Trunk light 15 W S 8.5 - 8

Instrument and heater control lighting

Due to the location of these bulbs their replacement should be carried o\
ut by a Volvo dealer. pg. 81 Fuses


Replacing fuses

The fuse box is positioned in front of the left front door pillar. When \
replacing fuses, check that the
correct amperage is used.
Never use fuses of higher amperage. unless specified by your Volvo deale\
r. If one fuse repeatedly fails,
take the car to your Volvo dealer for fault tracing.
A spare fuse kit is available from your Volvo dealer.
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Volvo 1990 240 Model
The floor mats should be vacuumed or brushed clean regularly, especially\
during the winter when they
should be taken out for drying.
Spots on textile mats can be removed with a mild detergent.

Anti-rust treatment

Your Volvo has been rust protected at the factory. On external surfaces \
a heavy coat of wear resistant
material has been used, while on the internal surfaces a lighter rust in\
hibitor is used.
The rust protection should be inspected regularly by your authorized Vol\
vo dealer. Consult the Volvo
Protection Limited Warranty found in your Warranty Information Booklet f\
or additional terms and
conditions.

For further information, see section titled "What causes rust" or see yo\
ur Volvo dealer. pg. 88 Paint touch-up
Paint touch-up

Paint damage requires immediate attention to avoid rusting. Make it a ha\
bit to check the finish regularly,
for instance when washing the car. Touch-up if necessary.

Paint repairs require special equipment and skill. Contact your Volvo de\
aler for any extensive damages.

Minor scratches can be repaired by using Volvo touch-up paint.
Note: When ordering touch-up paint from your Volvo dealer, use the paint\
code indicated on the
service label. The label is located on the wheel housing in the engine c\
ompartment.

Minor stone chips and scratches

Material:
Primer-can
Paint-can or touch-up bottle
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Volvo 1990 240 Model
pg. 91 Long distance trips, Cold weather
Prior to a long distance trip

Have your car checked at a Volvo dealer. Preventive maintenance will hel\
p to ensure a trouble free trip.
Remember to take along a Volvo dealer directory.
The main items to check are listed below:
1. Brakes, front wheel alignment and steering gear.
2. Engine running condition.
3. Fuel system operation.
4. Oil leaks: engine, transmission, rear axle.
5. Cooling system for leaks or worn hoses.
6. Examine tires carefully, replace worn tires.
7. Battery and terminals.
8. Tool equipment.
9. Lighting.
10. Drive belts, for tightness and wear.
11. All fluid levels.

Cold weather/Engine fuel system

During the winter, large variations in temperature cause condensation to\
form in the fuel tank and can
impair the running of the engine. This can be reduced by adding dry gas \
to the fuel. There is less risk of
condensation forming in the fuel tank if it is kept full or nearly full.\


Engine cooling system

Volvo type C (blue-green) coolant should be used all year round. The c\
ooling system should always
contain water plus anti-freeze and rust inhibitor, even during the summe\
r. Experience has also shown
that extremely weak anti-freeze solutions (10-25 percent) are ineffect\
ive for rust protection. For this
reason, the quantity of antifreeze/summer coolant should be about 50 per\
cent of the solution. This
lowers the freezing point to - 30 ° F (-35 ° C).

Engine lubricating system
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Volvo 1990 240 Model

During the winter, multigrade oil 10W-30 should be used in the engine. \
The viscosity of the engine oil is important. Oil with low viscosity (t\
hinner oil) improves cold-weather
starting as well as decreasing fuel consumption while the engine is warm\
ing up. To avoid difficult cold
start conditions (during extreme winter weather), use of 5W-30 oil, pa\
rticularly the synthetic type, is
recommended.
Be sure to use good quality oil but do not use this cold-weather oil for\
hard driving or in warm weather.
See section "Engine oil" for more information.

Electrical system

The electrical system is subject to greater stresses during the winter. \
Lighting and starter motor are used
more often. The battery capacity is reduced at low air temperature. The \
state of charge must be checked
more frequently, and if necessary the battery should be recharged. The b\
attery can freeze if the state of
charge is too low.

Windshield washers

Anti-freeze washer fluid should also be added to the washer fluid contai\
ner for the windshield and rear
window (tailgate, wagon model) washer.
This is particularly important during the winter because the windshield \
frequently becomes dirty and is
often splashed with water which freezes rapidly. This may necessitate th\
e frequent use of the windshield
washer and wipers. Your Volvo dealer can supply you with suitable anti-f\
reeze for this purpose. Suitable
mixtures of anti-freeze and water are:
Down to +14 ° F (-10 ° C) 1 part anti-freeze 4 parts water.
Down to + 7 ° F (-14 ° C) 1 part anti-freeze 3 parts water.
Down to 0 ° F (-18 ° C) 1 part anti-freeze 2 parts water.
Down to -18 ° F (-28 ° C) 1 part anti-freeze 1 part water.
Use Volvo Teflon lock spray or grease in the locks. They can be purchase\
d from your Volvo dealer
Note: Avoid the use of de-icing sprays as they can cause damage to the
locks.
pg. 92 Service diagnosis
The diagnoses outlined below are intended to serve only as a guide to lo\
cate and temporarily correct
minor faults. Causes of unsatisfactory performance should be investigate\
d and corrected by your Volvo
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Volvo 1990 240 Model
dealer.

Condition: Starter fails to operate (or operates very slowly)
Possible cause Correction
Weak battery or dead cell. With the starting (ignition) switch in the "Driving"
or "On" position, check to see if the warning lights
on the dashboard come on and if they stay on when
the starter is engaged. If the lights do not come on or
if they go off when the starter is engaged, the battery
is discharged or see below.
Loose or corroded battery cable terminals. Check battery terminals and clamps. Clean or
replace if necessary. Check that the starter cable is
secure at its terminals.
The ground strap, which connects the battery
negative (-) terminal to the engine, should also be
checked for corrosion or looseness.
Open circuit between starting (ignition) switch
and starting (ignition) switch terminal on
starter. The circuit is closed if a clicking sound is heard
from the starter when it is engaged. If no clicking
sound is heard, check that the blue wire at the starter
is secure. If still no clicking sound is heard, the
starting (ignition) switch or the wire is defective.
Starter motor defective. If the above checks have been performed, and no
fault is evident, the starter may be defective. NOTE:
In this case the headlight intensity will not dim when
the starter is engaged.
pg. 93 Service diagnosis
Condition: Starter motor operates but engine does not start

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Possible cause Correction
Intake system leaking. Check vacuum hose connections at manifold and
auxiliary air valve.
No fuel reaching engine. Check for fuel in the tank.

Check fuse No 4.
No spark Check that the high tension lead from the coil to the
distributor cap is connected and that the wires to the
distributor and coil are connected.

Check the fuse for the engine control system. The fuse
is located in the engine compartment on the left wheel
housing by the ignition coil.
Spark plugs, high tension leads or distributor
cap wet or defective. Clean the parts with a dry cloth or spray with a moisture
remover. Replace defective or worn parts.

If no fault is found following the above steps, contact
your Volvo dealer.
pg. 94 Service diagnosis
Condition: Erratic idle (misfiring)
Possible cause Correction
Intake system leaking. Check hose connections.
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Volvo 1990 240 Model
Spark plugs, high tension leads or distributor
cap worn (defective) Clean distributor cap and leads, check the cap for
cracks. Replace defective or worn parts.
Worn spark plugs. Remove. Clean or replace spark plugs.
Condition: Engine stalls at irregular intervals
Possible cause Correction
Defective wires. Check wire terminals at: fuel pump, fuse No. 5 and 7, coil, distributor,\
ignition
switch and relays.
Intake system
leaking. Check vacuum hose connections at manifold and auxiliary air valve.
Fuel filter clogged. Clean fuel tank filter and replace line fuel filter.
pg. 95 Service diagnosis
Condition: Excessive fuel consumption
Possible cause Correction
Fuel lines
leaking. Check
tightness.
Spark plugs
worn. Replace plugs.
Condition: Misfiring at highway driving speed

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Possible cause Correction
Spark plugs
fouled. Drive the vehicle in a lower gear and keep the engine rpm higher for a f\
ew miles
in order to remove carbon deposit on the spark plugs. If this procedure \
is not
effective, clean or replace the spark plugs.
pg. 96 Label information
The Vehicle Identification Number should always be quoted in all corresp\
ondence concerning your
vehicle with the dealer and when ordering parts.

1 Vehicle Identification Number (VIN)
VIN plate is located on top left surface of dash. The VIN is also stampe\
d on the right hand door pillar.

2 Vehicle Emission Control Information
Your Volvo is designed to meet all applicable safety and emissions stand\
ards. Evidence of this can be
verified from the certification label on the left wheel valance. For fur\
ther information regarding these
regulations, please consult your Volvo dealer.

3 Model Plate
Vehicle Identification Number (VIN). Codes for color and upholstery et\
c. This plate is located on right
wheel valance.

4 Loads, Capacities, and Tire Pressures

5 Federal Motor Vehicle Safety Standards
(FMVSS) specifications (USA) and Ministry of Transport (CMVSS) Sta\
ndards (Canada)
This label is located on rear facing side of the driver's front door.

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pg. 97 Specifications
98Dimensions and weights
98Cargo space
99Engine
100Cooling system
100Fuel system
100Ignition system
101Power transmission
101Front suspension
102Capacities
102Electrical system
pg. 98 Specifications
Dimensions and weights Sedan models Wagon models
Length 189.9" (482 cm) 190.7" (484 cm)
Width 67.3" (171 cm) 67.3" (171 cm)
Height, curb weight 56.3" (143 cm) 57.5" (146 cm)
Wheelbase 104.3" (265 cm) 104.3" (265 cm)
Ground clearance (full load) 4.7" (12 cm) 4.7" (12 cm)
Track, front
rear 56.3" (143 cm)
53.5"(136cm) 56.3" (143 cm)
53.5" (136cm)
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