Volvo 960 service & repair manual

SCHEDULED SERVICES

1994 Volvo 960

1992-96 MAINTENANCE

Volvo Maintenance & Service Intervals

960 Sedan

960 Wagon

PLEASE READ THIS FIRST *

NOTE: All SERVICE SCHEDULES are listed for normal service vehicles. If vehicle is operated under severe service conditions, see SEVERE SERVICE REQUIREMENTS (PERFORM
W/SERVICE SCHEDULES) for items requiring additional maintenance.

NOTE: This article contains scheduled maintenance service information. Fluid types and capacities listed with each service in this article are only those necessary to perform that scheduled service. For specifications pertaining to fluid capacities for the entire vehicle, fuse and circuit breaker identification, wheel and tire size, battery type, warranty information, or model identification refer to the MAINTENANCE INFORMATION article in this section.

CAUTIONS & WARNINGS

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.

CAUTION: Disconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger’s side of vehicle in case of accidental air bag inflation

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAR WARNING

NOTE: For information on air bag DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

CAUTION: System circuit is grounded by 2 screws beneath the driver’s seat. DO NOT use these screws to ground any other accessory. DO NOT ground any other components near this system.

SIDE IMPACT PROTECTION SYSTEM (SIPS) - 1996 MODELS

NOTE: For information on air bag DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

AIR CONDITIONING SERVICING

CAUTION: Avoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.

WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:
- DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
- DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
- Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
  
  BATTERY WARNING
  
  WARNING: When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section.
  
  REPLACING BLOWN FUSES
  
  Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.
  
  BRAKE SYSTEM
  
  CAUTION: If brake warning light comes on while driving it indicates a low fluid level or failure in one of the braking circuits. If the brake pedal can be depressed further than normal it is an indication that one of the brake circuits is not functioning. Stop vehicle and check brake reservoir fluid level. If level is below MIN mark, DO NOT drive vehicle. Have it towed to a repair shop. If level is between the MIN and MAX marks, proceed cautiously to a repair shop.
  
  BRAKE PAD WEAR INDICATOR
  
  Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
  
  CATALYTIC CONVERTER
  
  Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.
  Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.
  
  ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
  
  WARNING: Many solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.
  
  ENGINE OIL
  
  CAUTION: Never use non-detergent or straight mineral oil.
  
  FUEL SYSTEM SERVICE
  
  WARNING: Relieve fuel system pressure prior to servicing any fuel system component (fuel injection models).
  
  HALOGEN BULBS
  
  Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.
  
  RADIATOR CAP
  
  CAUTION: Always disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.
  
  RADIATOR FAN
  
  WARNING: Keep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.
  
  WHEELS & TIRES
  
  Only wheels tested and approved by the manufacturer should be used on models equipped with Air Dam aerodynamic components.
  
  SERVICE POINT LOCATIONS
  
  Fig. 1: Service Point Locations (1992-94) Courtesy of Volvo Cars of North America.
  
  Fig. 2: Service Point Locations (1995-96) Courtesy of Volvo Cars of North America.
  
  Fig. 3: OBD II Diagnostic Link Connector Location (1996) Courtesy of Volvo Cars of North America.
  
  ADDITIONAL SERVICE INFORMATION
  
  Fig. 4: Releasing Shift Interlock (1992 Models Only) Courtesy of Volvo Cars of North America.
  1. With gear selector in Park, depress brake pedal.
  2. Move gear selector to desired position.
  3. If gear selector DOES NOT MOVE, check fuse #12.
  4. TO MANUALLY RELEASE gear selector, push finger between brushes at base of shifter and push catch forward. (See Fig. 3).
  5. Select a gear.
  NOTE: 1993-96 models have a button located next to shifter.
  
  ALIGNING CAMSHAFT TIMING MARKS
  
  Fig. 5: Aligning Camshaft & Crankshaft Timing Marks Courtesy of Volvo Cars of North America.
  
  Fig. 6: Lubricating Tensioner Pulley Bushing (Pivot Bearing) Courtesy of Volvo Cars of North America.
  
  CAUTION: Lubrication of the Tensioner Pulley Bushing is REQUIRED on 1992-93 Models, it is recommended that the bushing be checked for free play and lubrication on 1994-96 models.
  
  NOTE: For more information regarding camshaft timing belt service refer to the 2.9L 6-CYL article in the ENGINE MECHANICAL section.
  
  Fig. 7: Installing Washer on Timing Belt Tensioner Courtesy of Volvo Cars of North America.
  
  MODEL 960 TIMING BELT REPLACEMENT TABLE
  
  Model
  Part
  20K
  30K
  40K
  50K
  60K
  70K
  90K
  100K
  Year
  
  1992
  Number
  
  271705-6
  
  B
  
  C
  
  X
  
  X
  1993*
  271705-6
  D
  X
  X
  
  1994 271856-7 X X
  
  1995- 271876-5 E
  
  * = Late M/Y 93 960’s (from engine no. 131035) should have M/Y 94 timing belt (P/N 271856-7). See Parts Bulletin 21-13 and Tech DCS 21-02.
  B = See SMB 137A, timing belt replaced at no cost to customer C = See SMB 137A, SB 21-118, install torsion damper, replace
  timing belt at no cost to customer
  D = Recommended timing belt replacement at no cost to customer E = Recommended timing belt replacement
  X = Required timing belt replacement
  
  CAUTION: On 1992 & 1993 960’s, lubricate timing belt tensioner pivot bearing during timing belt replacement.
  
  LUBRICATING AUXILIARY DRIVE BELT TENSIONER
  
  Fig. 8: Auxiliary Drive Belt Tensioner Lubrication Points Courtesy of Volvo Cars of North America.
  
  NOTE: For more information regarding auxiliary drive belt service refer to the
  
  GROUP 26, NO. 700 GREASING OF AUXILIARY DRIVE BELT TENSIONER
  article in the TSB section.
  
  NOTE: The automatic tensioner for the auxiliary drive belt must be greased every 30,000 miles (45,000 km) or if an abnormal noise is heard from the tensioner.
  
  NOTE: The auxiliary drive belt and automatic tensioner must be removed from engine in order to properly lubricate.
  
  FLAME TRAP MAINTENANCE - PCV SYSTEM
  
  Fig. 9: Flame Trap Location
  Courtesy of Volvo Cars of North America.
  
  ELECTRONIC AIR PUMP SYSTEM (1995-96)
  
  Fig. 10: Electronically Controlled Air Pump System (1995-96) Courtesy of Volvo Cars of North America.
  
  BODY LUBRICATION POINTS
  
  Fig. 11: Body Lubrication Points Courtesy of Volvo Cars of North America.
  
  REAR AXLE SERVICE POINTS
  
  Fig. 12: Rear Axle Service Points (Sedan and Wagon) Courtesy of Volvo Cars of North America.
  
  NOTE: All sedan and 1995-96 wagon models have an Independent Rear axle, the 1992-94 wagons have a solid axle.
  
  SUSPENSION TORQUE SPECIFICATIONS
  
  Fig. 13: Front Suspension Torque Specifications (1992-94 All) Courtesy of Volvo Cars of North America.
  
  NOTE: For more information regarding front suspension service refer to the SUSPENSION - FRONT
  article in the STEERING & SUSPENSION section.
  
  Fig. 14: Rear Suspension Torque Specifications (1992-94 Wagon) Courtesy of Volvo Cars of North America.
  
  Fig. 15: Rear Suspension Torque Specifications (1992-94 Sedan) Courtesy of Volvo Cars of North America.
  
  NOTE: For more information regarding rear suspension service refer to the SUSPENSION - REAR
  
  article in the STEERING & SUSPENSION section.
  
  NOTE: All 1995-96 models have a new Independent Rear Axle using
  a transverse composite leaf spring (instead of steel coils).
  
  VEHICLE LIFT POINTS
  
  Fig. 16: Vehicle Lift Points (Typical) Courtesy of Volvo Cars of North America.
  
  NOTE: For more information regarding lifting and hoisting refer to the JACKING & HOISTING article in the
  WHEEL ALIGNMENT section.
  
  INFORMATION LABEL LOCATIONS
  
  Fig. 17: Information Label Locations Courtesy of Volvo Cars of North America.
  
  WHEEL TIGHTENING
  
  Tighten all wheel lug nuts to 63 ft. lbs. (85 N.m) using pattern shown in Fig. 18.
  
  TIRE ROTATION PATTERNS
  
  Fig. 18: Tire Rotation Pattern & Lug Nut Torque Pattern Courtesy of Volvo Cars of North America.
  
  CAMSHAFT TIMING BELT REPLACEMENT INFORMATION
  
  CAUTION: Failure to replace a faulty camshaft timing belt may result in serious engine damage.
  
  The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".
  Many manufacturers changed their maintenance and warranty schedules in the mid-1980’s to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.
  Belts or components should be inspected and replaced if any of the following conditions exist:
- Cracks Or Tears In Belt Surface
- Missing, Damaged, Cracked Or Rounded Teeth
- Oil Contamination
- Damaged Or Faulty Tensioners
- Incorrect Tension Adjustment

Volvo recommends replacement of the camshaft timing belt at the following intervals:

CAMSHAFT TIMING BELT REPLACEMENT INTERVAL TABLE

Application Interval (Miles)

1992-93 (1) ............................................ 30,000

1994 ................................................... 50,000

1995-96 ................................................ 70,000

- First (30,000 Mile) timing belt change to be done by Volvo dealer at no cost.

SEVERE & NORMAL SERVICE DEFINITIONS

NOTE: Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions:

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions:

Normal Service
- Driven More Than 10 Miles Daily
- No Operating Conditions From Severe Service Schedule
  
  Severe Service (Unique Driving Conditions)
- Extended Idling Or Low Speed Operation
- Frequent Short Trips Of Less Than 7 Miles
- Extended Operation In Dusty Or Sandy Conditions
- Trailer Towing Operations
- Driving In Mountainous Conditions

SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES)

NOTE: The following services are to be performed on vehicles subjected to severe service. See SEVERE & NORMAL SERVICE DEFINITIONS. This service is to be performed in addition to the normal services listed in the NORMAL MAINTENANCE SERVICE SCHEDULES.

SEVERE SERVICE CONDITIONS/ACTIONS TABLE

Condition Action Item Perform Every (1)

Extended Idling Or Low Speed Operation	Replace	Engine Oil Filter	&	3,750	Miles	or	3	Months
Frequent Short Trips Of Less Than 7 Miles	Replace	Engine Oil Filter	&	3,750	Miles	or	3	Months
Extended Operation In Dusty Or Sandy Conditions	Replace	Engine Oil Filter	&	3,750	Miles	or	3	Months
Trailer Towing Operations	Replace	Engine Oil Filter	&	3,750	Miles	or	3	Months
Driving In	Replace	Engine Oil	&	3,750	Miles	or	3	Months
Mountainous		Filter
Conditions

- Perform these services at the mileage or number of months (since the last time), whichever comes first.

5000 MILE (8000 KM) SERVICE

5000 MILE (8000 KM) SERVICE

Service Or Inspect Check Fluid Levels
Inspect Coolant Hoses and Clamps Inspect Brake System
Inspect Exhaust System

Inspect Steering Linkage/Front Suspension

Retorque Front & Rear Suspension Bolts (1992-94 Models Only) Lubricate Chassis
Clean Power Antenna Mast Road Test
Replace Engine Oil Oil Filter
Lubrication Specifications

Application Specification

Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)
Ambient Temperature
Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD
-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD
Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD
Power Antenna ...................... WD-40 Or Equivalent Cleaner
1. - SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.

Fluid Capacities

Application ( 1) Quantity

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L)

- Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
- DO NOT use SAE 15W-40 oil in extremely low temperatures.

10,000 MILE (16,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed

Check Fluid Levels

Check Cooling System Hoses and Clamps Check Coolant Strength

Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals Inspect Fuel/Tank/Cap/Lines

Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades

Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges

Lubricate Door Locks Check Body Drain Holes Clean Power Antenna Mast

Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation

Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis

Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines Inspect Shocks/Struts for Leakage Inspect Tire Wear Pattern

Rotate Tires and Adjust Air Pressure (Including Spare) Road Test

Reset Service Reminder Indicator Replace

Engine Oil Oil Filter

Lubrication Specifications

Application Specification

Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)

Ambient Temperature

Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD

-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD

Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD

Power Antenna ...................... WD-40 Or Equivalent Cleaner

(1) - SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.

Fluid Capacities

Application ( 1) Quantity

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L)

- Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
- DO NOT use SAE 15W-40 oil in extremely low temperatures.

20,000 MILE (32,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed Check Fluid Levels

Check Cooling System Hoses and Clamps Check Coolant Strength

Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals Inspect Fuel/Tank/Cap/Lines

Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades

Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges

Lubricate Door Locks Check Body Drain Holes Clean Power Antenna Mast

Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation

Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis

Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines Inspect Shocks/Struts for Leakage Inspect Tire Wear Pattern

Rotate Tires and Adjust Air Pressure (Including Spare) Road Test

Reset Service Reminder Indicator Replace

Engine Oil Oil Filter

Lubrication Specifications

Application Specification

Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)

Ambient Temperature

Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD

-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD

Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD

Power Antenna ...................... WD-40 Or Equivalent Cleaner

(1) - SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.

Fluid Capacities

Application ( 1) Quantity

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L)

- Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
- DO NOT use SAE 15W-40 oil in extremely low temperatures.

30,000 MILE (48,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed Check Fluid Levels

Check Cooling System Hoses and Clamps Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals

Inspect/Adjust Accessory Drive Belts (Replace if Required) Lube Accessory Drive Belt Tensioner (1992-93 Models) Crankcase Ventilation System

Inspect Fuel/Tank/Cap/Lines

Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades

Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges

Lubricate Door Locks Check Body Drain Holes Clean Power Antenna Mast

Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation

Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis

Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines

ABS System Operation

Inspect Shocks/Struts for Leakage

Suspension Bushings, Springs, Arms & Rear Jounce Bumpers Inspect Tire Wear Pattern

Rotate Tires and Adjust Air Pressure (Including Spare) Road Test

Reset Service Reminder Indicator Replace

Engine Oil Oil Filter Spark Plugs

Air Filter Element

Camshaft Timing Belt (1992-93 Models Only) Drain, Flush and Refill Engine Coolant Drain, Refill and Bleed Brake System Fluid Lubrication Specifications

Application Specification

Engine Coolant ....................... 50/50 Mix Ethylene Glycol

and Distilled Water Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)

Ambient Temperature

Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD

-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD

Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD

Automatic Transmission .......................... Dexron-IIE ATF

Power Steering Fluid .................. Dexron-IIE Or Mercon ATF Rear Axle

Without Limited Slip ................. SAE 80W-90 API-GL-5 ( 2)

With Limited Slip ..................... SAE 90 API-GL-5 ( 2)(3)

Limited Slip Additive ............... Volvo Additive (1161129-0)

Wheel Bearings ..................... NLGI Grade 2 Category GC-LB

Drive Shaft U-Joints ............... NLGI Grade 2 Category GC-LB

Steering Linkage (4)(5) ............ NLGI Grade 2 Category GC-LB

Ball Joints (4)(6) ................. NLGI Grade 2 Category GC-LB Aux. Drive Belt Tensioner ............. Volvo Grease (1161246-2) Tensioner Pulley Bushing .... Grease (P/N 116246-2 Or 116247-0) Weatherstrip ........................ Dielectric Silicone Grease

Power Antenna ...................... WD-40 Or Equivalent Cleaner

- SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.
- In Canada and cold climates use SAE 80W API GL-5.
- Supplement with Volvo Additive (1161129-0).
- Use low pressure grease gun to prevent seal damage.
- Fill until lubricant squeezes out from the base of seals.
- Fill ball joint until seal starts to swell.

Fluid Capacities

Application ( 1) Quantity

Brake Master Cylinder .......................... 0.63 Qt. (0.6L)
Cooling System ............................... 10.5 Qts. (10.0L)

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L) Rear Axle (3)
Sedan ........................................ 1.4 Qts. (1.3L)
Wagon ........................................ 1.7 Qts. (1.6L)
Power Steering ................................ 1.05 Qts. (1.0L)
Auxiliary Drive Belt Tensioner ........................ 50g. ( 4)
Tensioner Pulley Bushing ............... (P/N 116246-2) 50g. ( 5)
Tensioner Pulley Bushing ............. (P/N 116247-0) 500g. ( 5)
1. - Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
2. - DO NOT use SAE 15W-40 oil in extremely low temperatures.
3. - If equipped with limited slip differential add lubricant additive (Volvo P/N 1161129-0) first, then add new fluid.
4. - Apply to surfaces between friction plate and cover as well as packing the (4) spring holes. See Fig. 7.
5. - Disassemble Tensioner Pulley, clean all surfaces and check for worn areas. Repack bushing assembly and reinstall.

Service Labor Times

Application ( 1)(2) Hours

3.0L 6.3

- To replace camshaft timing belt, add 1.3 hours.
- Add 0.4 hours to service accessory drive belt tensioner.

40,000 MILE (64,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed Check Fluid Levels

Check Cooling System Hoses and Clamps Check Coolant Strength

Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals Inspect Fuel/Tank/Cap/Lines

Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades

Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges

Lubricate Door Locks

Check Body Drain Holes Clean Power Antenna Mast

Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation

Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis

Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines Inspect Shocks/Struts for Leakage Inspect Tire Wear Pattern

Rotate Tires and Adjust Air Pressure (Including Spare) Road Test

Reset Service Reminder Indicator Replace

Engine Oil Oil Filter

Lubrication Specifications

Application Specification

Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)

Ambient Temperature

Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD

-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD

Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD

Power Antenna ...................... WD-40 Or Equivalent Cleaner

(1) - SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.

Fluid Capacities

Application ( 1) Quantity

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L)

- Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
- DO NOT use SAE 15W-40 oil in extremely low temperatures.

50,000 MILE (80,000 KM) SERVICE

50,000 MILE (80,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed Check Fluid Levels
Check Cooling System Hoses and Clamps Check Coolant Strength
Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals Inspect Fuel/Tank/Cap/Lines
Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades
Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges
Lubricate Door Locks Check Body Drain Holes Clean Power Antenna Mast
Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation
Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis
Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines Inspect Shocks/Struts for Leakage

Drain, Flush and Refill Engine Coolant Accessory Drive Belts (1992-93 Models Only) Camshaft Timing Belt (1994 Models Only) Lubrication Specifications
Application Specification

Brake Fluid ........................ DOT 4 Or DOT 4+ Brake Fluid Engine Oil (1)
Ambient Temperature
Less Than 68 F (20 C) .................. SAE 5W30 API SH/CD
-4 F To 100 F (-20 To 38 C) .......... SAE 10W30 API SH/CD
Greater Than 14 F (-10 C) ............. SAE 15W40 API SH/CD
Power Antenna ...................... WD-40 Or Equivalent Cleaner
1. - SAE 15W-40 or 20W-40 engine oil is recommended for extreme conditions or extended highway operation.

Fluid Capacities

Application ( 1) Quantity

Engine Oil (Includes Oil Filter) (2) ........... 5.9 Qts. (5.7L)

- Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
- DO NOT use SAE 15W-40 oil in extremely low temperatures.

Service Labor Times

Application ( 1)(2) Hours

3.0L 6.3

- To replace camshaft timing belt, add 1.3 hours.
- Add 0.4 hours to service accessory drive belt tensioner.

60,000 MILE (96,000 KM) SERVICE

Service Or Inspect

Verify Last Major Service Was Performed Check Fluid Levels

Check Cooling System Hoses and Clamps Inspect Brake System

Check Exhaust System & Heat Shielding Clean Battery and Battery Terminals

Inspect/Adjust Drive Belts (1992-93 Replace if Required) Lube Accessory Drive Belt Tensioner (1992-93 Models) Clean EGR System (1992-94 Models Only)

Inspect PCV Valve, Flame Guard and Hoses Crankcase Ventilation System

Inspect Fuel/Tank/Cap/Lines

Check Operation of Horn, Wipers/Washers & All Exterior Lights Inspect Condition of Wiper Blades

Check Headlight Alignment

Lubricate Weatherstripping with Silicone Lubricate Door Hinges

Lubricate Door Locks Check Body Drain Holes Clean Power Antenna Mast

Check Seat Belt Webbing and Release Mechanisms Check Parking Brake Operation

Check Shift Interlock Operation

Inspect Steering Linkage/Front Suspension Steering System & Wheel Alignment

Inspect Propeller Shaft, Support Bearings and U-Joints Lubricate Chassis

Inspect Brake Pads, Rotors and Calipers Inspect Brake System Hoses & Lines

ABS System Operation

Inspect Shocks/Struts for Leakage

Suspension Bushings, Springs, Arms & Rear Jounce Bumpers

Spark Plugs

Air Filter Element

Fuel Filter (1992-94 Models) PCV Valve Flame Guard

Accessory Drive Belts (1994-95 Models Only) Camshaft Timing Belt (1992-93 Models Only) Drain, Flush and Refill Engine Coolant Drain, Refill and Bleed Brake System Fluid Lubrication Specifications

Application Specification

Coolant .............................. 50/50 Mix Ethylene Glycol