PLEASE READ THIS FIRST *
WARNING: When working around steering column and before performing repairs, disconnect and shield battery ground terminal. Disconnect YELLOW and ORANGE Supplemental Inflatable Restraint (SIR) air bag connectors, located on driver’s side of center console, near throttle pedal. Failure to follow precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.
DESCRIPTION & OPERATION
All 960 models are equipped with an analog gauge instrument cluster which is either a Yazaki or VDO type. See Fig. 1. Speedometer is centrally located with a tachometer and clock installed on either side. Smaller gauges for coolant temperature and fuel are at opposite sides of instrument cluster. If equipped, a turbo pressure gauge is incorporated within tachometer. A warning/telltale light bar at bottom of cluster panel displays additional information.
Fig. 1: Identifying Yazaki Or VDO Type Instrument Cluster Courtesy of Volvo Cars of North America
TESTING
FUEL GAUGE TEST
Ensure temperature gauge operates properly, as fuel gauge receives current from temperature gauge. If temperature gauge does not operate correctly, go to TEMPERATURE GAUGE TEST.
If temperature gauge is okay, fuel gauge can be checked with a 68-ohm Test Resistor (999-5824-1). Assemble an adapter from following components: See Fig. 2.
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Gray wire (954 441)
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Terminal (948 291)
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Terminal (942 201)
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Sleeve insulator (948
296)
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Cover (943511)
Fig. 2: Assembling Fuel Gauge Testing Adapter Courtesy of Volvo Cars of North America
Disconnect Gray/White wire from fuel tank sending unit. Connect test resistor between ground and disconnected wire. If gauge is okay it should indicate 1/4 full (15-gallon tank), or 1/5 full (21- gallon tank). If gauge operates as specified, sender is defective.
If needle is not on specified section, ensure gauge is set for 15-gallon or 21-gallon tank. Yazaki gauges use a screw and VDO gauges use a clip if equipped with a 15-gallon tank. See Fig. 3. Clip or screw should be removed for 21-gallon tank.
Fig. 3: Checking For Screw Or Clip At Instrument Cluster Courtesy of Volvo Cars of North America
If gauge is correctly set, but still gives incorrect reading, sender is probably defective. If needle does not move at all,
check continuity of wiring to gauge. If wiring is okay, gauge should be replaced.
If fuel gauge replacement is necessary, check rear side of instrument panel to see if a potentiometer has been installed. If so, gauge will require adjustment.
If not already present, Fuel Gauge Potentiometer Kit (1
398 171-7) will need to be installed in order to adjust fuel gauge. Disconnect negative battery cable. Disconnect fuel gauge sender connector and install resistor to gauge side of wiring. See Fig. 4.
Fig. 4: Installing Resistor In Gauge Side Of Wiring Courtesy of Volvo Cars of North America
Cut Gray/White wire next to 7-pin connector on instrument panel. Using sleeve insulators, join both sides to potentiometer. See Fig. 5. Reconnect negative battery cable. Turn ignition on with engine off. If needle on fuel gauge just touches Red section, go to step 10). If not, go to next step.
Fig. 5: Installing Potentiometer Courtesy of Volvo Cars of North America
Turn ignition off. Disconnect negative battery cable. Using a screwdriver, adjust potentiometer. Initial adjustment is 33 ohms. Reduce by turning screw clockwise until correct needle deflection is obtained.
With negative battery cable still disconnected, seal potentiometer with a drop of paint. Wrap electrical tape around potentiometer to prevent short circuits. Remove test resistor and reconnect wiring. Reconnect negative battery cable.
