Service Manual
Contents
1. Volvo passenger cars are sold in different variants adapted to the specific requirements of the various countries This market adaptation is based on such things as legal regulations tax limitations and specific wishes of the market concerned For this reason illustrations and text may appear in this Service manual which are not relevant to the cars in your own country Group 85 89 Body equipment Contents Contents Alphabetical index on page 44 Page Operation Group 85 Interior Trim panels 2 1 9 a Door trim panels 2 1 2 3 Side trim panels 3 A3 A4 Rear wall trim panel 3 5 B and C pillar trim panels 3 A6 A8 Sill trim panel 4 Ag Front seats Exploded view drawing 5 Parts removal fitting 6 B1 B21 Rear seats parts removal fitting 11 C1 C9 Headlining removal fitting 13 D1 D5 Carpeting removal fitting 14 E1 E3 Group 86 Bumpers Front bumper removal disassembly assembly fitting 15 F1 F3 Rear bumper removal disassembly assembly fitting 16 61 65 f Group 87 Heating and ventilation General 18 11 12 Checking the heating system 19 13 Heater assembly removal fitting 21 1 4 Heater control panels exploded view drawing 22 Heater control panel and op2. 35065 Fit the carpeting Cut the new carpeting to size using the old carpeting as a template Insert the wiring for the seat heating and seat belts through the carpeting at the correct point Glue the carpeting in position over a width of about 5 cm at the incisions Close the snap fasteners and fit the parts removed under Operation E1 Group 86 Bumpers f Front bumper f Group 86 Bumpers Front bumper removal disassembly assembly fitting Fl Remove the front bumper Raise the retracting headlights Remove the direction indicators and auxiliary driving lights at left and right f Remove the self tapping screws under the bumper Remove the nuts Pull the bumper forwards and out of the body Disconnect the wiring for the fog lights at the connec tor Release the transmitter for the ambient air tempera ture Remove the bumper from the car 36 003 F2 Disassemble the front bumper and remove the grille F3 Assemble and fit the front bumper Note the position of the strips A Fitting is in reverse order to removal Position and secure the bumper Group 86 Bumpers Rear bumper G Rear bumper removal disassembly assembly fitting GI Remove the the rear wheel housing liners Release the screws Remove the bolt 1 and take the liner out of the wheel housing G2 Disconnect the wiring Disconnect the wiring for the number plate light and rear fog lamps behind the spare
3. Remove the seat belt slide rail Remove the cable clip from the sill Partly release the side trim panel alongside the right hand rear seat Release the cable clamp on the inner wall Remove the cable towards the front 390 X5 Fit and adjust the cable Screw in the adjusting mechanism 1 fully Move the tailgate lock to the closed position Move the adjuster plate 2 of the operating mecha nism to the middle position Fit the cable in reverse order to removal Check the fuel filler cap and tailgate release mecha nism for correct operation Adjusting The release action of the hinged fuel filler cap can be adjusted by slightly tilting the release mechanism The release action of the tailgate can be adjusted with the adjuster plate 2 Important the operating cable of the tailgate release unit must never be tensioned otherwise this will cause the built in switch to remain on and so disturb the normal working of the alarm system Group 85 89 Body and Fittings Alphabetical Index Trim panels Door trim panel Boot side trim panel Rear wall trim panel A pillar trim panel B pillar trim panel C pillar trim panel Sill trim panel ick Panels under dashboard removal fitting 2 32 Seats See Front seats and Rear seats Front seats Exploded view drawing 5 Removal Adjusting mechanism cover panel remova
4. Operation 04 To remove the capacity ri necessary to remove the disassemble the temperature con however be removed in order to 02 Remove the capacity regulating valve Note the drawing shows the capacity regulating valve in the vacuum operated variant the method of removal fitting is the same for both variants The vacuum operated variant with auxiliary valve has an operating rod however at both left and right Remove the operating mechanism 1 Remove the foam rubber joint 2 Press in the four locking tabs 3 of the cover plate Remove the cover plate and take the regulating valve s 4 out of the heater unit 03 Remove the defroster regulating valve Remove the cup washer 1 from the valve shaft vacuum operated variant Slide the shaft 2 out of the heater unit using 8 screwdriver to lever it out Remove the end piece 3 Withdraw the valve 4 through the opening Note the lower surface of the shaft is flat Grease the shaft lightly when fitting and support the heater unit 04 Remove fit the temperature control valve and or the air control valve Remove the heater assembly Remove the left and right side ducts 1 from the floor air vent Remove the booster motor 2 Remove the screws 3 all round and take off the clip 4 Remove the heater upper section 5 Withdraw the temperature control valve 6 and or the air control valve 7 from the heater unit Group 8
5. Release the staple at the top end and remove the heating element from the padding Cut the padding free at the lower end and take it off the frame Group 85 Interior Front seats parts removal fitting B9 Remove the back pad Release the operating cable from the back pad cut the staple at 1 Liftthe rod out ofthe two retaining strips 2 at thetop end Unhook the springs at the sides and remove the back pad from the backrest 3 B10 Remove the lumbar support Remove the screws at left and right 1 Rotate the two brackets 2 a quarter turn and remove them from the backrest frame B11 Remove the lower spring Bend open the retaining strips 3 at left and right Remove the spring B12 Remove the backrest locking mechanism Remove the spring 1 from the lower edge left and right and disconnect the cable from the pin Release the adjusting mechanism 2 from the brac ket Press in the clip 3 and remove the cable together with the adjusting mechanism and the operating arm 4 from the backrest Press in the clips 5 and remove the bracket 6 from the backrest Important when assembling adjust the cable so that it is just tension free Group 85 Interior 390 5050 Front seats parts removal fitting B13 Remove the seat cushion upholstery and pad ding Cut through the staples all round and remove the tw
6. panel before tightening the screws w2 Remove fit the lock Remove the side panel at rear right in the car Remove the lock retaining nut behind the hinged panel Remove the lock from the inside the lock is retained by the slotted hole of the remote control mechanism 41 Group 89 Miscellaneous Remote control cable fuel filler cap tailgate removal fitting el filler cap tailgate remote control cable X Removing fitting the fu xt Disconnect the fuel filler cap tailgate cable from the operating mechanism alongside the front seat Remove the button and the trim cover from the operating mechanism see Operation A9 Remove the bolt 1 Take the cable out of the lever x2 Disconnect the cable from the tailgate catch Remove the rear wall centre panel see Operation A5 Release the catch Carefully remove the two cable guides 1 from the catch using a screwdriver 1 Disconnect the cable from the tank lock rele ase mechanism Remove the side trim panel from the boot Remove the bolt from the release mechanism Carefully remove the two cable guides 1 from the bracket arms and take out the release mechanism Note make sure that the release mechanism is hooked into position behind the lock of the hinged filler cap 42 Group 89 Miscellaneous Remote contro cable fuel filler cap tailgate removal fitting x4 Remove the cable Remove both rear seat cushions
7. 7 Heating and ventilation Vacuum diaphragm units removal fitting P Removing fitting the vacuum diaphragm units If the vacuum diaphragm units are being renewed on their own it is not necessary to remove the dashboard Remove the vacuum diaphragm units A Capacity regulating valve B Defroster regulating valve C Capacity regulating valve auxiliary valve D Air control valve Disconnect the vacuum hose from the connecting pipe 1 Disconnect the operating arm bolt 2 Remove the nuts 3 When renewing vacuum diaphragm unit D on the car use an angle head ring spanner Remove the vacuum diaphragm unit P2 Fit and adjust the vacuum diaphragm units Locate and secure the vacuum diaphragm unit Press the operating arm of the vacuum diaphragm unitinthe direction indicated by the arrows and fasten in position Secure the vacuum hoses on the connecting pipes 1 note the colours A Blue B Orange C Green D Red Group 87 Heating and ventilation Air inlets ducts removal fitting Q Removing fitting the air inlets ducts Q1 Remove the dashboard air inlets Note this method is applicable to all dash mounted air inlets Remove the grille by levering it away from the outer most pivot point 1 Press in the four locking tabs 2 and at the same time pull the air inlet out of the dashboard The air inlets are fitted in reverse order to removal Mak
8. and D no B L Moe HE 1234 B yes B L REC Went 1234 B and D yes AC M 1234 yes AC MAX REC II 4 Cand D yes Depending upon the switch setting the booster fan will run at one of the indicated speeds REC setting is automatically engaged Group 87 Heating and ventilation Heater assembly removal fitting K Removing fitting the heater assembly K1 Remove the dashboard See Operations R1 R 14 K2 Remove the heater unit operations in the engine compartment Pinch off the coolant hoses 1 Release the hose clips 2 and disconnect the hoses from the heater radiator collect the escaping fluid Remove the two nuts 3 Remove the bracket 4 from the fan housing K3 Remove the heater unit operations inside the car Remove the relay from the fan housing bracket Remove the two screws Lift out the heater unit K4 Fit the heater unit Fitting is in reverse order to removal 21 Group 87 Heating and ventilation Heater control panels Heater control panels Group 87 Heating and ventilation Control panel and operating cables removal fitting L Removing fitting the control panel and operating cables L1 Preparations Disconnect the battery negative cable Remove the instrument panel see Operations R6 R7 L2 Remove the operating cable vacuum opera ted valves Release the screw 1 on the heater housing take the
9. anel and the booster switch Important The check must be carried out with the engine running otherwise no vacuum will be present Switching from one position to another takes about 5 seconds Open all the air inlets on the dashboard Air conditioning The table also includes a brief check of the functioning of the air conditioning system in so far as this affects the operation of the heating and ventilation system A full system check and the repair and maintenance of the air conditioning are dealt with in a separate Service Manual Note that the air conditioning is automatically engaged when certain positions of the heating system are selected see last column Malfunctions In the case of a malfunction check the functioning of the vacuum valve s shown in the last column the vacuum lines from the inlet manifold and the electric wiring The removal fitting of the various parts of the heating system is described later in this section For the wiring diagrams refer to the Repairs and maintenance Service Manual Section 3 Group 87 Heating and ventilation General Push button Airflow Booster Vacuum Air conditioning setting through fan speed diaphragm on if fitted openings unit s i energized OFF REC 1 D DEF bx Hn Iv 1234 A yes DEF REC 1234 Aand D yes FLOOR MIL IV 1234 Aand B no FLOOR REC 12 334 A Band D no VENT Lu 12 34 VENT REC M 1234 C
10. belt removal fitting 40 V4 V5 Hinged fuel filler Removal fitting 41 wi Lock removal fitting 41 w2 2 Remote control cable renewal 42 7 5 Tailgate remote control cable renewal m verise 42 X1 X5 Tailgate remote control cable renewal 225 42 X1 X5 2 TES Te SIRE
11. e 35052 B19 Remove the tension spring from the seat slides Hook the spring out of the slide B20 Remove the height adjustment operating handle and rods driver s seat Remove the screw 1 and take the handle off the seat Remove the clip 2 at left and right and take the rods 3 and 4 off the seat B21 Assemble and fit the seat The seat parts removal operations also indicate the points requiring special attention when fitting Fitting is completed in reverse order to removal 3505 Group 85 Interior Rear seats parts removal fitting C Rear seats removing and fitting parts I Remove the rear seat cushion Press the cushion down Press the catch 1 rearwards and pull the cushion up Unhook the cushion at the rear end c2 Fit the rear seat cushion Hook the cushion into the bracket at the rear end Press the cushion down atthe front end and locate the catch behind the bracket 2 Remove the cushion upholstery padding Cut through the staples Release the rods Fold the upholstery to one side Release the hooks at the top end Remove the upholstery Take the padding off the wire frame C4 Remove the rear seat backrest Tilt the backrest forwards to an angle of about 45 Move the locking device 1 upwards Press the arms 2 inwards and at the same time pull up the backrest Take the backrest out of the hing
12. e point at the other side Group 85 Interior Rear seats parts removal fitting 35038 Fitting C5 Remove the backrest upholstery Unscrew the lock pin 1 from the backrest Cut through the staples at the lower edge Remove the two small rods 2 Pull the rods 3 out of the locking device and remove them from the upholstery Slide the upholstery off the backrest Remove the padding C6 Remove the backrest locking device First remove the side panel Remove the screws Remove the backrest centre attachment bracket Remove both backrests Remove the bolts C8 Renew the plastic hinge Pressthetab inwards and pull the bush out of the hole c9 The rear seats rear seat parts are fitted in reverse order to removal Group 85 Interior Headlining removal fitting D Removing fitting the headlining Remove A B and C pillar trim panels Interior light D2 Remove the grab handles Remove the cover and lens 1 and the light fitting 2 Release the two screws 3 and remove the grab handle and baseplate from the roof D3 Remove the sun visors Release the screw 1 and remove the sun visor from the roof header panel Release the screw 2 and remove the clamp 3 using a screwdriver with a wide blade tip D4 Remove the headlining Support the headlining and pull loose the headlining mounting strips above the side windows and doo
13. e sure that the hose is properly secured to the air inlet housing Q2 Remove the rear compartment air duct Remove the tunnel console and the front seat s Make minimum incisions in the carpet so as to reach the screws 1 and 2 Important when making the incisions take care not to cut the wiring under the carpet Remove the screws 1 and 2 under the carpet Press down the rubber sleeves 3 Pull the pipe slightly to the rear and remove the sleeves Pull the pipe rearwards and remove it from under the carpet Fit the air inlets ducts Fitting is in reverse order to removal 30 Group 88 Interior fittings Dashboard exploded view Group 88 Interior fittings Exploded view of dashboard Group 88 Interior fittings Dashboard removal fitting R Removing fitting the dashboard RI Preparations Remove the two A pillar trim panels under the dashboard Remove the tunnel console front and rear sections see Operations T1 T4 Remove the steering wheel the trim covers from the steering column and the steering column stalks see the Repairs and Maintenance Service Manual Section 6 R2 Remove the panels under the dashboard Remove the A pillar lower trim panel A at the driver s side Remove the expander fasteners 1 Take the panel out from under the dashboard Fitting Hook the lip 2 over the tunnel console side panel Support the panels at point 3 on
14. e the upper connector Release the wiring harness connectors for the centre console Remove the dashboard assembly R14 Fit the dashboard The dashboard is fitted in reverse order to removal Group 88 Interior fittings Dashboard transferring parts S Transferring parts to the dashboard 51 Heater trunking Remove at the top the cover panel 1 and the rubber joint 9 screws Remove the large diameter trunking 2 at left and right Remove the branch pipe 3 together with the round distributing pipes 4 Remove the connecting piece 52 Fuse box Remove the screws and take out the fuse holder Remove the fuse box cover and casing 53 4 as son Remove the heater control panel Remove the screws Cut through the wiring harness tie fasteners and remove the panel and wiring harness assembly Group 88 Interior fittings Heater trunking behind dashboard exploded view 54 Instrument rear mask Remove the junction block the screws from the instrument binnacle rear mask the instrument binnacle rear mask Group 88 Interior fittings Note Tunnel console removal fitting transferring parts T Tunnel console removal fitting transferring parts in order to remove the console front section the rear section must be removed first T Remove the console rear section Re
15. eat backrest B4 Fit the head restraint Locate the circlips and slide the head restraint into the seat backrest 85081 Group 85 Interior 3500 Front seats parts removal fitting B5 Remove the seat backrest Rake the backrest until the clevis pins 1 can be reached at left and right Release the two staples on the lower edge of the backrest Release the staple holding the elastic Disconnect the seat heating wiring at the connector Remove the hairpin clips and clevis pins and lift the backrest off the cushion B6 Remove the lumbar support handwheel and the backrest release knob Turn the lumbar support handwheel 1 counter cloc kwise until it rotates freely and then pull it out of the backrest Remove the protective grommet 2 from the bac krest Pull off the backrest release knob 3 and remove the guide 4 B7 Remove the backrest upholstery Cut through the staples on the backrest lower edge and pull the two rods out of the upholstery 1 Slide the upholstery upwards Press the rods out of the cross spring 2 at the bottom and hook them out of the backrest at the top 3 Note the loops of the cross spring to which the rods are attached are bent at an angle to the rear Press in the clips 4 of the head restraint guide and remove the backrest upholstery together with the head restraint upholstery from the seat B8 Remove the heating element and padding
16. emoval fitting Heating and ventilation General E 18 Checking Heater assembly Removal fitting n 21 Heater control panels exploded view drawing 322 Control panel and operating cables removal fitting 23 Heater unit exploded view drawing s2 Heater radiator remova Booster fan assembly removal fit ng 4124 7555 eraann enea 228 Regulating valves in heater unit removal fitting Vacuum diaphragm units remo val fitting eee erena 29 Air inlets ducts removal fitting 30 Dashboard Exploded view drawing Dashboard removal fitting Panels under the dashboard removal fitting 132 Dashboard releasing Instrument panel removal Glove box removal Dashboard wiring disconnecting mE Transferring parts Heater trunking behind dashboard exploded view drawing 36 Glove box removal 07 34 Instrument panel removal 33 Tunnel consoles Console rear section removal 37 Console front section removal 37 Lockable console between rear seats removal fitting 7 38 F2 F3 G1 G3 G4 G5 G5 11 12 13 K1 K4 L1 L6 1 4 1 5 01 05 P1 P2 01 03 1 14 R2 R6 R7 R8 R11 R12 51 54 R8 R7 1 3 T4 U1 U3 Group 85 89 Body and Fittings Alphabetical Index Page Operation Seat belts Front seat belt removal fitting 39 V1 V3 Rear seat
17. enewing parts 09 Ut Remove the lockable console assembly Remove the ashtray 1 Remove the screws 2 and take the ashtray unit out of the console Open the console hinged cover 3 to the raised position press in the catch 4 Remove the screws 5 inside the console at the rear end Remove the rear seat backrests Remove the seat belt anchorage bolts at left and right Remove the lockable console assembly U2 Disassemble the lockable console assembly Slide the catch 4 out of the console Remove the leaf spring 6 Remove the screw 7 at the rear end Swing the hinge up and take off the cover Remove the two screws and take off the hinge Press in the clips inside the cover and at the same time press out the lock Assemble and fit the lockable console assembly Fitting is in reverse order to removal 38 Group 88 Interior fittings Front seat belt removal fitting V1 V3 Removing fitting a front seat belt Preparations vi Remove the side trim panel alongside the rear seat see Operation 4 Remove the B pillar trim panel see Operation 7 sso v2 Remove the inertia reel seat belt assembly Release the lower slide rail 1 and slip the belt off the rail if necessary unhook the slide rail rear end from the body Remove the screw 2 from the anchorage plate pivot the swing link to the rear and unhook the spring 3 from the upper anchorage point Remove the screw 4 Remo
18. erating cables removal fitting 23 L1 L6 Heater unit exploded view drawing 25 Heater radiator removal fitting 26 1 4 iy Booster fan assembly removal fitting 27 1 5 Regulating valves in heater unit removal fitting 28 01 04 Vacuum diaphragm units removal fitting 29 1 2 E Air inlets ducts removal fitting 30 01 03 Group 88 Interior fittings 3 A Dashboard exploded view drawing 31 Dashboard removal fitting 32 R1 R14 Dashboard transferring parts 35 51 54 Heater trunking behind dashboard exploded view drawing 36 Tunnel console removal fitting transferring parts 37 TI T4 y Lockable console between rear seats removal fitting 38 01 03 i A Front seat belt removal fitting 39 VI V3 Rear seat belt removal fitting 40 V4 V7 gt Group 89 Miscellaneous X Hinged fuel filler cap removal fitting 41 W1 W2 2 Remote control cable fuel filler cap tailgate removal fitting 42 5 y Order number TP 35415 1 We reserve the right to make alterations 1 Group 85 Interior Trim panels removal fitting Group 85 Interior A Trim panels Al Removing fitting a door trim panel Carry out Operation A to as shown in the drawings Take the trim panel off the door 3509 2 Remove the armrest and door bin Remove the screws at the rear of the trim panel Take the armrest and or door bin off the trim panel 35030 Gr
19. he cables are disconnected at the heater housing the control panel can be removed toge ther with the cables If the control panel is being renewed on its own pull the panel part way out of the dashboard remove the clamps from the outer cables and disconnect the inner cables from the operating arms L6 Group 87 Heating and ventilation Heater radiator removal fitting M Removing and fitting the heater radiator Preparations Disconnect the battery negative cable Remove the console side panels the tunnel console front and rear sections See Operations T1 T4 M2 Remove the heater radiator operations in the engine compartment Pinch off the coolant hoses Release the hose clips and disconnect the hoses from the heater radiator collect the escaping fluid M3 Remove the heater radiator operations insi de the car Remove the connecting sleeves 1 the screws in the cover panel 2 under the heater radiator Lift out the heater radiator 3 M4 Fit the heater radiator Fitting is in reverse order to removal Note Top up with coolant Run the engine warm and check the heater for correct operation Check the coolant level and top up as necessary 26 Group 87 Heating and ventilation Booster fan assembly removal fitting N Removing fitting the booster fan assembly Preparations Disconnect the battery nega
20. im panel away from the A pillar note the clips at the right hand side AAEE ANSATS Group 85 Interior Trim panels removal fitting 85036 3037 7 Renew the B pillar trim panel Remove the cap 1 and screw 2 Pull the trim panel away from the B pillar first at the top 3 and then at the bottom 4 Remove the seat belt upper anchorage bolt Take the belt out of the trim panel A8 Renew the C pillar trim panel Partly release the tailgate weatherseal Press the trim panel off the C pillar using a screwdri ver 3 snap fasteners 9 Renew the sill trim panel Remove the trim cover from the remote control lever at the driver s side rectangular button and two bolts Remove the sill trim panel with a screwdriver Group 85 Interior Front seats B Front seats Group 85 Interior Front seats parts removal fitting B Front seats removing fitting parts B1 Remove the front seat Remove the bolts Disconnect the wiring at the connectors Remove the seat B2 Remove the adjusting mechanism cover Remove the plugs from the handwheel and the cover panel 1 Remove the lock nuts 2 with a socket head screwdri ver and take off the handwheel 3 Remove the screw 4 Remove the cover panel from the seat adjusting mechanism B3 Remove the head restraint Press the upholstery down remove the circlips and pull the head restraint up and out of the s
21. l n nn 6 Head restraint removal fitting 6 Backrest removal 7 Lumbar support handwheel and backrest release knob removal 7 Lumbar support removal 8 Backrest locking mechanism removal mm d Backrest upholstery removal 7 J B Heating element removal Back pad removal Seat cushion upholstery and padding removal Seat frame upper lower section separating nnns 9 Seat belt pressure switch cushion removal Seat frame parts removal Rear seats Rear seat cushion removal fitting eene n Cushion upholstery and padding removal REN Backrest Backrest upholstery removal Backrest locking device 12 Backrest centre attachment bracket removal 12 Headlining Removal fitting n 13 Grab handles removal fitting 13 Sun visors removal fitting 13 Carpeting removal fitting 14 44 Alphabetical Index Operation 1 2 4 5 A6 A7 A8 9 R2 B1 B2 B3 B4 B5 B6 B10 B12 B7 B8 B9 13 14 15 B16 B17 B21 C1 C2 C3 C5 C6 C7 C8 1 05 02 03 1 Page Operation Bumpers Front bumper removal 415 Front bumper disassembly 15 Front bumper assembly fitting 15 Rear bumper removal 16 Rear bumper disassembly aM Rear bumper assembly fitting AT Number plate lighting r
22. move the screws 1 the cover plate and the screw 2 Slidethe handbrake handle forwards and off the lever Prise the top end of the switch panel 3 out of the console Disconnect the wiring at the connectors and remove the panel Take the console off the tunnel 72 Remove the console locker cover Open the hinged cover to the raised position Pull the locker 4 up and out of the console note the limiting strap 5 Remove the screws 6 and take the cover off the console T3 Remove the cover inside panel Remove the screws 7 Take the inside panel 8 off the cover note the hinge and the limiting strap T4 Remove the console front section Remove the ashtray 1 and the screw 2 from the ashtray unit disconnect the wiring for the lighting and cigar lighter and remove the ashtray unit 3 from the console Pull the two stowage trays 4 out of the console and remove the two screws 5 Release the gear lever dust gaiter from the console and remove the two screws 6 Press the switch panel 7 up and out of the catches and put it to one side Remove the console side panels 8 at left and right These are held in place with grip fastening tape position correctly when fitting Take the console off the tunnel Group 88 Interior fittings Lockable console between rear seats removal fitting renewing parts U Lockable console between rear seats removal fitting r
23. o rods at the side from the seat belt lock 1 Remove the clamps at the front end Release the upholstery from the lugs 2 and remove the upholstery together with the padding from the frame B14 Remove the upholstery and heating element from the padding Remove the staples at the rear end and fold the sides of the upholstery inwards 3 Cut through the guide eyes 4 of the pull rods and remove the upholstery and heating element from the padding Note the heating element can be removed from the rear of the cushion without removing or disassem bling the seat release the upholstery at the rear end and remove the staples B15 Remove the seat frame upper section Unhook the springs 1 at left and right Remove the bolts and fitted sleeves A Seat without height adjustment B Seat with height adjustment Tap the plastic plugs 2 out of the Remove the seat frame upper section Important the upper section complete with adjus ting mechanism is set at the factory and must always be renewed as a complete unit B16 Remove the seat belt pressure switch The switch is clamped under the spring mat Group 85 Interior Front seats parts removal fitting 17 Remove the seat springs Remove the rod from the clamps at the front end and unhook the springs at the rear B18 Remove the front handle from the cushion Press the springs down at left and right Tap the handle forwards and off the fram
24. oup 85 Interior Trim panels removal fitting Renew the boot side trim panel Remove the floor mat Remove the lens from the rear light unit Open the side panel hinged cover 1 Partly release the tailgate weatherseal 2 Remove the C pillar trim panel 3 Remove the screws 4 Unhook the seat belt webbing and remove the trim panel note the retaining clip A4 Renew the rear compartment side trim panel Remove the side trim panel from the boot Remove the seat backrest and cushion Remove the B pillar trim panel Release the sill trim panel 1 at the rear end Take the trim panel off the side panel A Take the door bin out of the trim panel B Remove the screws 2 Remove the backrest release knob 3 Remove the seat belt attachment Take the belt out of the trim panel Lift the trim panel up and remove 5 Renew the rear wall trim panel Remove the spare wheel cover two bayonet catches 1 Partly release the tailgate weatherseal Remove the lenses from the rear light units 2 Open the side panel covers 3 Remove the bulb holders 4 Remove the screws 5 at left and right and take the trim panel out of the boot AG Renew the A pillar trim panels Above the dashboard Partly release the door weatherseal Pull the trim panel away from the A pillar Under the dashboard Remove at the left the bonnet release knob 1 Remove the screw 2 Pull the tr
25. outer cable out of the clamp and disconnect the inner cable from the operating arm Release the control panel and pull it part way out of the dashboard see the following operation Release the clip 2 on the control panel and hook the inner cable out of the operating arm Pull the cable out of the dashboard L3 Remove the control panel vacuum operated variant Disconnect the operating cable from the heater hou sing see the above operation Remove the screws 3 Pull back the control panel Release the connectors at the rear of the panel Release the vacuum connecting block complete with hoses Remove the control panel together with the operating cable from the dashboard L4 Disconnect the cables from the heater hou sing mechanically operated valves Release the screws and take the outer cables out of the clamps Disconnect the inner cables from the operating arms Note if the control panel is being removed on its own only disconnect cable 1 Group 87 Heating and ventilation Control panel and operating cables removal fitting Fit and adjust the cables and control panel Fitting is in reverse order to removal Make sure that the valves can close fully If necessary adjust the setting of the outer cable L5 Remove the control panel and or operating cables mechanically operated valves Release the control panel retaining screws When ali t
26. ove the glo ve box from the dashboard R9 Remove the heater control panel See Operations 11 16 Group 88 Interior fittings Dashboard removal fitting 38010 R10 Release the dashboard Partly release the door weatherseals at both sides Remove the end panels 1 at both sides Remove the screws 2 Remove the dashboard brackets from the heater housing Take the wiring harness behind the glove box out of the clips at left and right Disconnect the wiring from the throttle switch Pull the dashboard sufficiently rearwards so that the connections can be reached at the rear of the dashbo ard R11 Disconnect the wiring behind the dashboard at the right the connector for the ambient air temperature transmitter blue brown green yellow the connector for the Electronic Control Unit the door switch connector 3 connectors against the bulkhead 2 connectors for the booster fan R12 Disconnect the wiring behind the dashboard at the left the door switch connector the connectors the connector panel the connector blue brown brown red green the lower connector of the CEM the connector earthing cable on the body the two red power supply cables on the fuse box the connector orange brown red asou R13 Remove the dashboard assembly Release the lower two screws and then remove the upper screw of the CEM Lift out the CEM and releas
27. rs Pull the headlining forwards and out of the rear end cover moulding Remove the headlining via the tailgate opening Important make sure that the headlining does not bend Group 85 Interior Carpeting removal fitting D5 Fit the headlining e t E Fit the mounting strips at the marked locations Insert the headlining via the tailgate opening Slide the headlining into the rear end cover moulding Position the headlining at the front end and fit the sun visors E Press the mounting strips securely into place gt Fit the A and C pillar trim panels le i Slide the mounting strips into position and fit the B pillar trim panel 1 E Fit the interior light and the grab handles E Removing fitting the carpeting El Remove Both front seat assemblies and the rear seat cushions The tunnel console The cover panels under the dashboard At left and right the sill trim panels and the panels under the A pillars The lower slide rail remove the bolt slip the seat belt off the slide rail and unhook the rail from the body E2 Remove the carpeting Note the electric wiring Cut off the carpeting as shown by the hatched area in the drawing at the air inlet unit as high as possible at the foot pedals in the middle between the snap fasteners Release the two snap fasteners 1 Pull the carpeting out from under the side trim panels
28. the A pillar trim panels R3 Release the relay box Disconnect the battery negative cable Remove the cover from the relay box Remove the screws and lower the relay box into the car interior R4 Removal operations outside the car Remove the windscreen wiper arms Remove the trim mouldings under the windscreen Remove the four screws 32 Group 88 Interior fittings Dashboard removal fitting R5 Remove the switches Press in the tab via the hole and pull the tumbler switches 1 out of the panel Pull the lighting switch 2 to the left and out of the panel Remove the booster fan switch 3 R6 Release the dashboard Remove the cover plate 1 Remove the screws 2 Pull the dashboard panel rearwards so that the instru ment panel can be reached Release the connectors at the rear of the dashboard panel Note the connector of the information centre switch is connected directly to the instrument panel and can only be released after the instrument panel has been removed from the dashboard R7 Remove the instrument panel Remove the screws at the left First move the left hand side of the instrument panel rearwards and then hook it out at the right Release the connectors at the rear of the panel Take the instrument panel out of the dashboard R8 Remove the glove box Remove the screws and pull the glove box out of the dashboard Release the lighting connectors and rem
29. tive cable Remove the glove box Remove the cover plate under the dashboard NI N2 Remove the booster motor Disconnect the booster motor wiring at the connec tors Disconnect the hose Remove the screws all round and disconnect the earthing cable Turn the booster assembly so that the flat section can slide past the vacuum diaphragm unit and then take the booster motor out of the heater housing N3 Remove the fan wheel Remove the nut 1 Take the fan wheel and the stop plate 2 off the motor shaft Important small balancing weights 3 are clipped at intervals around the fan wheel these must never be removed or relocated N4 Remove the resistor Disconnect the wiring at the connector and remove the relay from the bracket Remove the screws Remove the mounting frame and the resistor N5 Assemble fit the booster fan and resistor Assembly fitting is in reverse order to removal Take special note of the seal when fitting the booster motor M Group 87 Heating and ventilation Regulating valves in heater unit removal fitting O Removing fitting the regulating valves in the heater unit 01 Preparations Disconnect the battery negative cable Remove the dashboard assembly see operations R1 R14 e Operations 02 and 03 it is not egulating valve and the defroster regulating valv heater unit from the car The heater unit must trol valve and the air control valve
30. ve the upper bolt 5 Remove the bolt 6 and screw 7 from the belt retracting unit Remove the seat belt assembly v3 Remove the belt lock Take out the front seat Remove the bolt 8 and take the belt lock off the seat Fitting Fitting is in reverse order to removal 39 Group 88 Interior fittings Rear seat belt removal fitting V4 V7 Removing fitting a rear seat belt v4 Preparations Remove the side trim panel from the boot the rear seat cushion the stowage bin from the side wall alongside the rear seat the C pillar trim panel Lower the headlining at the rear end until the upper anchorage point of the seat belt can be reached see Operations 01 04 3 V5 A iS Remove the inertia reel seat belt assembly Remove the bolt 1 from the upper anchorage point the bolt 2 from the belt retracting unit the anchorage bolt 3 Take out the seat belt assembly V6 Remove the belt lock Remove the rear seat backrest Release the bolt 4 and remove the belt lock v7 Fitting Fitting is in reverse order to removal 35022 Group 89 Miscellaneous Hinged fuel filler cap removal fitting Group 89 Miscellaneous W Removing fitting the hinged fuel filler cap 002 Remove the hinged panel Open the panel Remove the screws 1 Take off the panel Remove the two rubber stops from the panel Fitting position the
31. wheel at the con nectors G3 Remove the bumper Remove the nuts at left and right Remove the towing eye securing bolt from the bum per and take the bumper off the car 16 Group 86 Bumpers Rear bumper G4 Disassemble the bumper and remove the number plate lighting G5 Assemble and fit the rear bumper Note the position of the strips A Fitting is in reverse order to removal When fitting make sure that the wiring for the number plate lighting is not pinched off between the bumper and the body Position and secure the bumper Group 87 Heating and ventilation General Group 87 Heating and ventilation 1 General The heating system of the Volvo 480 comprises a heater housing 1 which contains the heater radiator 2 the booster fan 3 a number of regulating valves and when the car is equipped with air conditioning the condensor 4 The heater radiator through which coolant flows constantly is maintained at operating temperature when the engine has warmed up The temperature in the passenger compartment is regulated by directing part of the inflowing air through the heater radiator The regulating valves which direct the air to the various inlets are vacuum operated on models which are pre engineered for air conditioning and mechanically operated on other variants In both cases the temperature control valve is mechanically operated recirculation valve 5 operated
32. with the button marked REC can used to recirculate 90 of the air volume already in the car mixed with 10 ventilation air from the outside alternatively it can be used to refresh the interior completely with ventilation air n Control panel vacuum operated Pushing in the buttons on the dash mounted control panel activates one or more vacuum valves in the heater unit Depending on the setting thus selected the airflow is directed through the various ducts of the heater unit 1 to one or more air inlets T aS The required temperature setting is obtained by mo ving the temperature slide 1 37 005 18 Group 87 Heating and ventilation Rear bumper 12 The booster fan The booster fan is located in the heater housing and has four speed settings The rotational speed of the fan is electronically controlled and is dependent upon the setting of the booster switch and the button selection on the dash mounted control panel This means that the fan will not always rotate at the speed which has been selected with the booster switch In the AC MAX position the fan will always run at speed 4 when the OFF push button is engaged the fan will always run at speed 1 Checking the heating system 13 General The table on the following page shows through which openings and at what velocity air should flow at different settings of the control p
Download Pdf Manuals
Related Search