VOLVO 120 2-DOOR CARS (120 P) DESCRIPTION OPERATING INSTRUCTIONS SERVICING AB VOLVO GOTHENBURG SWEDEN Service Cables: Volvo, Gothenburg, Sweden
CONTENTS BEFORE YOU START DRIVING YOUR NEW VOLVO PLEASE READ THROUGH THIS INSTRUCTION BOOK CAREFULLY. IT CONTAINS ALL THE INFORMATION YOU NEED TO BE ABLE TO DRIVE AND SERVICE YOUR VEHICLE IN THE BEST POSSIBLE WAY. BY FOLLOWING THE INSTRUCTIONS GIVEN IN THIS BOOK, YOU WILL FIND THAT YOUR VOLVO WILL COME UP TO ALL THE EXPECTATIONS CONCERNING ECONOMICAL OPERATION AND EXCELLENT PERFORMANCE THAT YOU HAVE EVERY RIGHT TO EXPECT OF A TOP-QUALITY VEHICLE.
VOLVO SERVICE 1 DESCRIPTION Volvo Service Organization In order to get the most out of the invested capital represented by a car, it must be looked after and serviced regularly. Volvo has gone to a great deal of trouble in the design and selection of material to ensure that the car in question only requires a minimum of servicing. All this work will be in vain unless we can count on your co-operation - that is to say, that you make sure that your vehicle gets the regular servicing it needs.
DESCRIPTION 7 Engine compartment (B 18 A) Engine The engine is a four-cylinder carburettor unit with overhead valves. The pistons are made of light-alloy and the upper compression rings on each piston are chromed. The main bearing and .big-end bearing shells are replaceable. The crankshaft is statically and dynamically balanced. Engine type B 18 A has an output of 85 h.p. (SAE) and is equipped with a Zenith-Stromberg horizontal carburettor. Engine type B 18 B has an output of 115 h.p.
DESCRIPTION Electrical system The electrical is of the 12-volt type and is fitted with a voltage-regulated dynamo. The starter motor is operated from the instrument panel by the ignition key. This key also forms the main switch for the rest of the electrical system. The cables to the headlights, parking lights and internal lighting, however, are not taken over the ignition switch but can be switched on and off without the ignition key being in position. The Volvo 123 GT is fitted with an alternator.
DESCRIPTION Body Bonnet The bonnet is fitted with a locking catch which is operated from the driving seat by means of a handle located to the left under the dashboard. Pulling out the handle releases the bonnet. When the bonnet locking catch has been released, the bonnet is still retained by a safety catch. Press in this catch as shown in the picture opposite and the bonnet can be lifted up. Closing the bonnet locks it so that it can only be opened by pulling out the release handle.
DESCRIPTION Front seats 12 The front seats can be moved backwards or forwards after the knob (A) is pressed down. If necessary, the seats can be moved further to the rear than permitted by the slide rail by using the extra holes in the seat frames. The backrest inclination of the front seats is smoothly adjusted by means of a knob (B) on the outside of the seat. A catch automatically locks the backrest and thus prevents it from falling forwards. To fold the backrest backwards, release the catch (C).
DESCRIPTION PARIS I nstruments and controls Before you start the car, sit behind the wheel and carefully check through all the instruments and controls. The location of these is shown in the illustration opposite. The instruments and controls are described in more detail on the following pages with reference to the numbers in the illustration. Note that variations may occur on different markets.
DESCRIPTION DESCRIPTION I Temperature gauge 2 Battery charging warning light 3 Trip meter The temperature gauge shows the temperature of the coolant and thus indicates the working temperature of the engine. The pointer on this gauge should remain within the three green sectors. 10 The trip meter, which is graduated in tenths of a mile, can be used to measure even short distances.
DESCRIPTION DESCRIPTION 15 Heater and ventilation system Fresh-air fan switch Pushed right in - closed Interm. pos. - full output Fully out - half output Air-flow FLOOR = Air to front seat floor DEFR = Air to windscreen and to rear seat floor 23 Air temp. This control is used to regulate the temperature of the incoming air. The heating and ventilation system of the car is operated as shown above.
OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Before being delivered, Volvo engines are test-run on test benches and in the vehicles on test tracks. We are therefore assured that all clearances are satisfactory and thus accept no responsibility for damage caused by careless running-in.
OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Gear-changing Gear positions for 4-speed gearbox Engaging the overdrive To engage the overdrive move the overdrive lever located on the right-hand side of the steering column. This switches on the overdrive control light on the instrument panel. To disengage the overdrive, move the lever back to its original position. Normally no extra operation of the accelerator or clutch pedal is necessary when engaging or disengaging the overdrive.
OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Starting the engine Move the selector lever either to the "P" or "N" position. The starter inhibitor switch is automatically disconnected if the selector lever is moved to any of the other positions. The lever can be moved freely between the "N" and "D" positions, while the other positions are provided with a catch. For this reason, the selector lever must first be lifted towards the wheel before it can be moved into any of the other positions.
OPERATING INSTRUCTIONS SERVICING Points worth noting Starting in a garage If you start your vehicle in a garage, always open the garage doors before starting the engine. The exhaust gases from the engine contain the poisonous carbon monoxide gas which is particularly dangerous since it is both invisible and odourless.
SERVICING Maintenance scheme In the maintenance scheme below the servicing procedures have been given certain numbers which refer to the detailed descriptions on the following pages. Some of the work must be carried out by skilled mechanics or requires the use of special tools and these have been marked in colour.
SERVICING Lubrication Chassis maintenance To simplify maintenance of your Volvo, the vehicle has been equipped with ball joints, steering rods and propeller shaft of such a design that they do not require regular lubrication. This has been possible due to the fact that points which normally require lubricating have been packed with very durable grease at the factory and then carefully sealed, thus obviating the need for lubrication.
SERVICING 4 Gearbox, M 30, M 40 6 Gearbox, with overdrive M 41 5 7 The oil in the gearbox should be checked after every 5 000 km (3 000 miles). The oil should be at the level of the filler hole. Top up with the recommended oil if necessary. The oil in the gearbox should be changed after every 40 000 km (25 000 miles). In the case of a new or reconditioned gearbox, the oil should be changed after the first 5 000 km (3 000 miles), on which occasion the gearbox should be flushed thoroughly with gear oil.
SERVICING 11 12 13 14 34 Rear axle with differential brake A rear axle fitted with differential brake is filled at the factory with transmission oil according to the American military standard MIL-L2105 or MIL-L-2105 B provided with an additive for rear axles with differential brake. The same type of oil should be used for topping up and when changing. Oil level checking and changing should take place at the same intervals and in the same way as for a rear axle without differential brake.
SERVICING 19 20 21 22 23 24 36 Air cleaner (B 18 A) The air cleaner should be replaced with a new one after 40 000 km (25 000 miles). Replacement should be more frequent if the driving conditions are dusty. SERVICING 25 NOTE. On no account must the element be moistened or oiled. Air cleaners (B 18 B) The air cleaners should be replaced with new ones after every 20 000 km (12 500 miles). Air cleaners with damping cylinders only require to be replaced every 40 000 km (25 000 miles).
SERVICING 27 28 29 30 Check, replace the sparking plugs The sparking plugs should be removed every 10 000 km (6000 miles) and the electrode gap checked. The gap should be 0.7-0.8 mm (0.0280.32"). After 20 000 km (12500 miles) the plugs should be changed. This replacement should preferably be carried out at a Volvo workshop where the plugs should be tightened with a torque wrench. When fitting new plugs, be sure to fit the right type (see page 54).
SERVICING 33 34 Check the state of charge of the battery The state of charge of the battery should be checked after every 10 000 km (6 000 miles). The check is carried out with the help of a hydrometer, this showing the specific gravity of the electrolyte which varies with the state of charge. See page 55. When checking the battery, check also the terminals and terminal bolts to make sure they are well tightened and smeared with grease or vaseline.
SERVICING SERVICING Power transmission Replacing the bulbs in the front parking lights/flashers Unscrew the two screws by means of a Phillips screw driver and lift off the glass and the metal frame. The bulbs can now be removed by pushing in and twisting anti-clockwise. The larger one is the direction indicator flasher and the smaller one the parking light. Make sure that the glass fits well against the gasket.
SERVICING Wheels and tyres 41 44 Changing a wheel Before the vehicle is jacked up, the handbrake should be applied and one of the gears engaged to ensure that the vehicle stands still. If possible block those wheels remaining on the ground as an extra safety precaution. Remember that the handbrake operates only on the rear wheels. Check the tyre pressure Always make a habit of checking the air pressure in the tyres regularly.
SERVICING Body 42 43 46 Washing When the vehicle is new, it should be washed often to harden the surface finish. Dust and dirt and especially insects and tar spots can damage the paintwork. Washing and polishing are also extremely important from the viewpoint of rust protection. During the winter, make sure that all road salt residue is washed off as soon as possible, otherwise corrosion can easily occur.
SERVICING Chromed parts The chromium-plated and anodized parts should be washed with clean water as soon as they become dirty. This is particularly important if you drive on gravel roads which are treated with chemicals to keep down the dust or in the winter when salt is used to melt down the snow or if you drive near the sea. After washing you can apply wax or anti-rust preparation. 44 Anti-rust treatment 45 Cleaning The Volvo 120 models are anti-rust treated at the factory.
SERVICING SERVICING Engine lubricating system Procedure in cold weather During the winter multigrade oil SAE 10 W-30 or engine oil with a viscosity of SAE 10 W should be used for the engine lubricating system. At continuous temperatures below -20°C (-4 ° F) use multigrade SAE 5 W-20. These oils reach the lubricating points mentioned more easily at low temperature and also facilitate cold starting.
FAULT TRACING The information given below is only intended to serve as a guide in localizing and temporarily correcting minor faults. After having carried out any such measures, have them checked and adjusted by an experienced mechanic. The engine does start although the starter motor turns it round at normal speed 1 Check that there is fuel in the tank. 2 If the engine is warm, starting should be done with the accelerator pedal slowly depressed as far as it will go.
SPECIFICATIONS
SPECIFICATIONS
Lubricating chart
Text for wiring diagrams Wiring diagram Volvo 121/122 S Note that the electrical equipment can vary for the different models on different markets. A = White B = Black C = Blue D = Green E = Grey F = Yellow G = Brown H = Red I = Spare lead Volvo 121/122 S 1. Flasher and parking 23. Fusebox light, left 24. Brake contact 2. Headlight, left 25. Door contact, left 26. Light signal device 3. Horn 4. Headlight, right 27. Horn 5. Flasher and parking 28. Overdrive switch') 29. Roof light light, right 6.
Wiring diagram Volvo 123 GT
TP 539/1 (Engelska) 9.000 10. 67.