Volvo 240 1984 Service Manual
Seruice
Manual
Section 1
(17l
Repairs
and maintenance
7,500
Maintenance
1984
DL, GL
GLE
Turbo,
Mile
Service
(Canadal
Diesel
Contents
lntroduction
Volvo 7.500 Mile Maintenance
7,500 Mile Maintenance
Controls
In
car,.,,..,,..,,.,,,
Exterior,..,,.........
On lift
-
Tires,
-
Front end
-Brakes,,..,........
-
Power transmission
-Rearend...........
Exhaust system, Diese| .....................
-Rearaxle,manualtransmission...........
-
Engine
'Gasoline
'Diesel
Under hood:
-
Engine
F|uids . . . . . . . . . . . . . . .
-
Replacing
821 and 823
-
lMiscellaneous
-
Adiust valves
Replacetiming
B2lNCanadai
-
lMiscellaneous
-
CO emissions check
821F-Turbo:
B23F:................
D24
diesel:
-
Miscellaneous
-
Valve
ldlespeeds..........
-
Setting enginecontrols ..................
-
Compression
Checkingadjust;ng
-
Replacing timing
Road test
lighting
and
wheels
oil and filter:
engines
engine
cooling system ...................
automaric
clearance adjustmert ,.,,,.,,..,,..
test
l.ansmission flLrid....
gear
belt ...................
injecto's
gear
Service Chart
Service Procedures
............
bells ..............
Opeation
1 18 10
41-A6 15
81- 83 1l
c1- c4 18
D1- Dl0 19
E1- E4 22
F1 F4 23
G1-G2 24
H1 25
t1 t2 25
J1- J2
J3-J4
K1- K2
K3- K5
L1-110
M1-M3
N1-N15
01-07
Pt-P15
01-016
R]
S1_
al- a7
h1-h12
cl c6
d1- d7
el - e10
f1 f8
91 933
Page
R16
57
1
2
26
21
28
2A
29
33
34
31
39
44
49
55
58
60
63
64
61
10
73
a2
TP
30600n
7500.08.83
Printed
in
U.S.A.
G,e!PJf,lE99!]ls!e
-
Chaft
-
elviee
7,500 Mile 12,500
km Maintenance
lntroduction
These
designed to assist the technician in
maintenance instructions are
Volvo Maintenance
The Volvo Maintenance Service
the same order as in the Warranties
The certificates in
The
chart, as well as the operations inside the manual, lists the actual mileage when
insoection should be oerformed.
Great care has been
finding
intervals
of
manual
the
exercised to make the chart easy to read. Grouping of mileage and services facilitate
for the service operations.
presented
performing
"Work
in a
the tasks in an efficient and logical manner.
Related
Sequence". Step by step
Service Chan
procedures
and
should be signed by the Service Manager, dated and stamped.
are listed
Maintenance Records Manual
the following
on
pages (see
suoolied with each new vehicle.
Service
procedures
chart). They appear in
the servace
are
Emissions
Items marked EMISSIONS
determined
vice
mainlenance
These items reouire
ce at mileage intervals
trouble-free
part
of emission related
program.
service maintenan-
operation.
have been
shown to ensure
ser-
EMTSSTOTVS
Seruice every 7.500 miles : 12.500 km
Seruiceat:
1 5-
2,
Seruice at:
30-60-90-12o-thou sa nd m
50- 1 0 O- t 50- 2
45-
3 0-
5 0- 7 r, 0 lr- 1 2, 1 50- t 7 5- 2
60- 7' 90- t 0 5- t
lEMrSSrOlrS
(n-t
h o u s a n d k m
IEMTSSTOTVS
t h
0O-
o u s a n d k m
Group 17,7,500
Mile Maintenance
-
Chart
-
Service
Volvo
l
Hazard warning
2
3
4
5
6
7
I
9
In
A2
A3
A5
A6
Exterior
81 Hood hinges
82 Door
83
Blower
Heater controls
Rear demist
AIR
norn
Tu
Headlights
Instrument
car
Power
Pressure test brake
Parking brake
Warning
Auto
Steering
Trunk lid
7,500 Mile
COND control
rn signals
and LIGHTS switch
panel
brake function
lights
trans shift
-
lubrication
hinges
On lift
Tires. wheels
C1 Tires
C2
C3 Wheel
C4 Wheel
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
pressure
Tire
bearing
bearing
Front end
Front shock
Front
springs
Steering
Steering rack
Control
Steering rod
Eall
Steering rod
Control
Stabilizer
gear
arm bushings,
toints
arms
bar and links
absorbers
flasher
control
play
nojse
play
ends
lights
system
(12,500
strut
km) Maintenance
Contlols
and lighting
10
11
12
't4
17
18
All items
be
=
105,000 = 175,000
112,500
120,000
Parking
Brake
lights
Tail lights
Back-up
Reflectors
Fill
washer fluid
Wiper blades
Wiper control
Washer
on this
inspected al 7,500
12,500 km intervals:
miles
7,500 = 12,500
15,000: 25,000
22,500:
30,000
37,500 = 62,500
45,000: 75,000
52,500:
60,000
67,500: 112,500
75,000
82,500 137,500
90,000
97,500 = 162,500
37,500
=
50,000
87,500
=
100,000
--
125,000
=
I50,500
=
187,500
=
200,000
km
lights
lights
and lenses
iets
page
should
mile
Service
=
Chart
O
Group 17,7,500
Mile Maintenance
-
Chart
-
Service
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E1
k.
Brakes
Brake
hoses
Brake lines
Parking brake
Wheel brakes
Power transmission
Clutch
B2lF Turbo
clutch negative
Auto trans:
Propeller
Rear
Rear shock absorbers
Rear
Exhaust system
821-Turbo
B23F
D24
play
and B23F:
play
shift control
shaft
end
suspension
diesel
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J1-J2 Gasoline engines
J3-J4 Diesel
Engine cooling system:
K1 Check
K2
a
Fl!ids:
K3
K4
K5
L1-L10
a
Lt
M1
M2
M3
N 1-N 15
01-07
1
Fluids
Rear axle
lvl46 manual
oil and
filter:
INOTE:
Replace coolant
Brake fluid level
Power
Battery
Automatic
Replace fluid
Check oil level
821 and 823
Auto
Engine
Drive belt tension
Adjust valves
Replace
Turbo intervals!)
engine
anti-freeze
steering
trans: adjust kickdown
controls
timing
transmission
gear
transmission
(all)
gear
belt
EMtSStONS
EMtSSTONS
EMtSStONS
EMtSStONS
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cable
EMtSStONS
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3
-r
Group
17,7,500 Mile Maintenance
-
Chaft
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P2
P3
P4
P5
Pll
P12
P13 Replace
P14
P15 Check fuel lines
01-O16 CO emissions
rm
B21l'lcanada
Exhaust
Damper
Choke control
Breaker
Dwell angle
Pulsair
Positive
Replace
Lubricate distributor
ChecUadjust timing
EGR valve operation
Clean fuel
Check centrifugal advance
system
oil level
points,
crankkcase ventilation
spark
air
rotor etc
plugs
pump
filter
check
strainer
cartridge
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821F-Turbo
Rl
R2 Check turbo
R3 Torque
Check of turbo
R4-R5
R6
R7
R8
R9
R10
R11
R12-R13
R14
R15
R16
Tighten nuts, exhaust
clamp screws
system:
Connectinstrument
Check timing retard
Check full load enrichment
Check overload
Lubricate distributor
Replace
Replace spark
Replace oxygen
reset light
Replace fuel filter
Positive
same: adverse conditions
Replace fuel tank filter
air tilter canridge
crankcase ventilation
seal
protection
plugs
sensor,
pipe
to turbo
system
switch
EMtSStONS
EMtSSTONS
EMtSStONS
Group 17,7,500
Mile Maintenance
-
Chart
-
Service
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Replace air filter
Replace
Replace oxygen sensor,
reset light
Replace fuelfilter
Positive crankcase
Replace fuel tank
D24
Drain condensate
Positive crankcase ventilation
a3
a4
a5
a6
a7
b1-h12
c1-dj
Maintenance
e'l-el0 Compressiontest
f1-f8
g1-933
Cooling
Replacing
Replace fuelfilter
Check luel lines
Drive
Valve
Engine controls
Checking/adjustinginjectors
Replacing timing
cartridge
plugs
spark
ventilation
same; adverse conditions
tilter
diesel
system
belt tension
clearance adjustment
services at 75,000 mile
pressure
air Iilter cartridge
gear
check
intervals:
belts
EMtSStONS
EMtSStONS
EMtSStONS
EMtSStONS
EMtSSIONS
EMtSStONS
EMTSStONS
EMtSStONS
EMtSStONS
EMtSStONS
5
Group 17,7,500
Mile Maintenance
-
Chart
-
Service
Road test
_----
I
Item
Engine
l
l
3
4
5
6
7
8
I
10
Elestrical
l
2
3
4
Drive train
l
2
Manual
transmission
Adjust
Starting ability
Fast idle
ldle
No
No noise from engine
Normal warm up
Normal
Normal
Leaks
Reinstall hardware removed
Staner/alternator
lgnition
Instruments, control lights
Clutch adjustment
Clutch operation
Correct operation
(cold
(warm
stalls on acceleration or deceleration
engine)
engine)
engine operation
acceleration
at Jactory
operation
and steering lock
o
Group
17,7,500
Mile Maintenance
-
Chaft
Service
-
Automatic
1__
o3
5
6
1
8
10
11
12
Biakes
1
3
Steering
1
2
5
transmission
Gear
seloctor
Starter
Run
No slippage
Upshift
No
Kick down
Upshift with
Gear
Gear
Park
Drive
Power
No
Pedal
"Spongy"
Parking
Correct
Stoering wheel
Steering wheel
Steering looseness
Power
operation
to normal
slippage during
selector in 2, downshift
selector in 1, downshift
position
shafts
assist
pullwhen
pulsatlon
steering lunction
play
only in P and
operating temperature
at stall speed
kick down
operation
and bearing noises
braking hard
pedal
brake
brake
steering
position
effort
N
shifting
and braking
and brakino
and return
I
Serines
2
3
Body
't
and
and
__
wheels
equipment
No suspension
Rear axle
Tire unbalance
Accessory
Heater
Speed noises
Body
Visible defects
Clean steering
Note
Check off
Remedy faults
and heater controls
noises
faults detected
noises
tight
operation
wheel
etc
7
Group 17,7,500
Mile Maintenance Service
-
Chaft
-
Services
The seruice charts list mileage
On
the following
mileage
mileage.
when a service should be
page
beyond 90,000
is a list that
up to 90.000 milos
goes
performed
to 300,000 miles = 500,000
and what intervalservices should
'150.0QQ
milqq
=
150,000 km. Space and readability
-
!m
km. lt cross references
pedormed
be
sets a limit.
actual
atthat
8
Gtoup 1/, /.500 Mile Mdinlenance
-
Chart
-
Service
Services
ftileages indicated
below
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000
112,500
120.000
127,500
135,000
142,500
150,000
157,500
165,000
172,500
180,000
187,500
135,000
202,500
210,000
217,500:
225,000
232,500
240,000
247,500
255,000
262,500
270,000
277,500
285,000
292,500
300,000
at the
- ---------
=
12,500
=
25,000
=
37,500
=
50,000
=
62,500
=
75,000
=
87,500
=
100,000
=
112,500
,
125,000
:
137,500
=
150,000
-
162,500
=
175,000
=
187,500
=
200,000
=
212,500
:
225,000
:
237,500
=
250,000
=
262,500
:
275,000
=
247,500
=
300,000
:
312,500
=
325,000
-
337,500
=
350,000
362,500
=
375,000
:
387,500
:
400,000
=
412,500
=
425,000
:
437,500
=
450,000
-
462,500
=
475,000
-
487,500
=
500,000
---
include service
7,500
12,500
15,000
25,000
operat;ons
22.54O 30,000 45,000
37,500 50,000 75,000
performed
at these interyals.
60,000 75,000
100,000 125,000
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9
Group 17, 7,500 Mile Maintenance
-
Controls and lighting
Service
-
Procedures
@
I
D
l-!21
n
l-ll
tl
EI
t,4l
E
Controls
E
@
and
lighting
Hazard warning flasher.
Press in switch.
lights
Blower.
Tu rn on ignition
Check that
tion Off and operates in
blower to run for a brief
(position
and switch indicator light flash.
4).
Check that all four turn indicator
switch.
blower is off with FAN control in
positions
period
Turn off
0l
posi'
1-2-3-4. Allow
at maximum rpm
10
-11-
ry^E,
Heater
Set all contfols in
are closed.
Depress
from
Depress
from floor
blowing
Run
Check
control
vents,
Checkthat
panel.
Switch
Check that REC
to valve functioning
srop
controls,
Heater control
DEF control.
delroster vent
FLOOR
to rear seat.
engine until
that air exiting
to WARIM.
off blower.
engrne.
control.
vent openings.
at normal
air exits from
(recirculate)valve
positions
openings.
Check that heated
when
where
on COLD.
Check that
Check that air is blowing
Also check
operating temperatu-
vents is still
all outlets on instrument
depressing
air flow vents
air is blowing
that air is
cold. Set heater
air now exits
operates. Listen
controt.
c
Group 17,7,500
-
Mile Maintenance
Controls and lighting
-
Check electrically heated rear window
(demist).
Actuate
heater. Check that light in switch comes on.
REAR DEMIST switch
for
rear
window
Service
Switch
for 1G-15 minutes unless key is turned OFF.
is
a spring-back
type.
System
remains
Check AIR COND control.
Start
engine.
Actuate
clutch functions, visually
Switch engine off.
AIR COND switch. Check that
and by sound.
maonetic
ON
Check horn.
Depress
that horn operates
Check
Check that left and right
tor lights as well
panel
after turning
horn contacts
at all
turn signals.
as indicator lights on instrument
flash.
Check that lever returns
steering wheel.
at alternate
places.
points.
front and rear turn indjca-
Check
to neutral
11
Group 17,7,500
-
Controls and lighting
Mile Maintenance
-
Seyice
Check headlights and LIGHTS switch.
Place LIGHTS switch in headlight
between high and low beams. Check in high beam
position
Check in low beam
are on and high beam indicator light is out.
headlights
that
and
position
position.
indicator
that low beam lights
Switch
light are on.
Check instrument
gear
in
Must be accomplished either in a darkened area or
by looking directly
Switch on LIGHTS switch. Check that light intensity increases and decreases by turning rheostat
first clockwise, then
Check
Check that all lights
shift control.
parking
panel
lamp lens
at
counterclockwise.
lights and lights
(openingl
lights.
are on.
10Q
0)
12
Check
nonroc. hrrL6.6.lil
Check thal brake
pressure
brake lights.
peoar.
on
lights come on with
Qr
11
light
0r
Group 17,7,500
-
Mile
Controls
Maintenance
and lighting,
Service
12
Check tail
Check
Check back-up
Set
shift selector to reverse.
Check that both lights
lights.
that all lights
lights.
are on.
are on.
Check rear reflectors
Check that ref
Fill washer
Use
clean water
conditions
lectors and lenses
lluid
and
use
washer
and lenses.
reservoir.
solvent, In below
solvent anti-Ireeze
are
not
damaqed.
freezinq
GtouQt 17,7,500
-
Controls
Mile
Maintenance
and lighting
Service
16
-['
Check wiper
Check
damaged
Wagons:
blade alignment.
blades.
and
a16
check
tail
Check that
free
trom for€ign
gate
wip€r
Check wipers.
Turn
on ighition
Switch
sto6ring column.
Check
rmervat
Check wiper
Forwagon
tins REARA/VIPE/WASH.
on wipers.
spoed. in first
postflon.
k€y.
using WASHMIPE
and second
blade alignment
models:
Check tailgate
blades are not
matter.
blade.
control on
position. ptus
park
and
Dosition.
wiper by actua-
17
Adiust windshield
nozzles.
Washsr
from upper
door
Adjust
sen
and rotate insert.
For
wagon models:
washer altonm6nt.
should hit
l'ets
pillar
edge and approx.
nozzles by insening
Also check tailgate
washer
windshield 10-20
discharge
35 cm
a needle in metal in-
cm
{4-8"}
('12")
from
window
18
14
In
car
Group 17,7,500 Mile Maintenance
-
ln car
-
Sevice
Se,rvice
every 7,500 miles
Check
Remove
trmes,
Depress brake
Pedal
l!nctions.
Pressure
Keep
oeoal Dressure.
Repeat
Pedal
brake Iluid leakage
=
12,500 km
power
vacuum by
position
test brake
brake
with high
position
brake tunction,
depressing brake
pedal,
should drop
start engine.
system.
pedal
deprcssed
pedal pressure
must
not drop. A drop
or booster vacuum
slightly if
20 seconds
for 5
pedal
power
with low
seconds,
indicates
leak.
A1
5
brake
Check
Apply
after
After adjustment,
be obtained
approx.
brake
Check that catch is
Check that
goes
when
Yoke
lever.
lf
There
rruotnq,
parking
parking
pulling
65
console.
on. Release lever and check that light
lever is in bottom
should be at right
yoke
is askew,
should always be at least 2 mm thread
brake.
brake. Adjust if it is notlully
10-11 notches.
adequate braking
pulling
after
lbs.
Adjust through rear
indicator light on instrument
use nuts at cable ends to adjust.
2-8 notches,
operating correctly.
position.
angles to
applied
power
parking
should
pulling
parking
of
A3
force
panel
is out
brake
pro-
15
Group 17,7,500 Mile Maintenance Service
-lncar-
lI
t ,t"
r
[.
nftEIEIddLl
z
Check
Tuln
warning
failure
Check
warning lights.
ignition key
and brake failure
that lights
to driving
lights for
go
position.
charging,
off.
oil
come on.
Check
pressure,
Stan enoine.
that
butb
44
tt
tt
Automatic
transmission.
check shift
control.
Clearance
shall
be the
toward
Check steering.
Turn steering wheel back and
resting on
Check steering wheel
straight
Jack up front end and
arms close to wheels.
Turn steering wheel fully to right and left
tions. Check steering effort and steering
play.
position
in
same as clearance
Dosition"1".
ground.
play
forward.
place
"D"
toward
fonh with wheels
with wheels
stands
oosition
position
in
pointing
under control
gear
(
"N',
"2,'
ou0
0)
posi-
for
16
0
0
Group 17,7,500 Mile
-
Exterior, lubication
Exterior - lubrication
Maintenance Seruice
-
Seflice everv
..\
7,5(n miles : 12.500 km
B1
Lubricate hood hinges.
Use oil can and heaw oil.
82
Lubricate door
striker
Lubricate door hinges with
wax to lubricate door stops.
Check that latches lock in both outer
posrtrons.
Check that
provide positive
oostt|ons.
plates.
Lubricate trunk lid
Lubricate lid/gate hinges.
hinges, door stops and
heavy oil. Use door
door stops are in working order and
locking
in intermediate and outer
(tail
gate
for wagons).
Use heavy oil.
and inner
BiJ
17
Group 17,7,500 Mile Maintenance
-
Tircs, wheels
Service
-
On lift
o
Tires, wheels
pressure arr
atr
Seruice evety 7.500 miles
Check
Check tread depth. Minimum
pressure
too high
l=1/32" 1.
Check wear
incorrect
Check that tires mounted
rear
studded).
:
12,500 km
tires.
pattern.
camber, toe-in
wheels
are the same
allowable is 1 mm
lt may indicate unbalance,
incorrect
or
on both front and both
(radial,
cross-ply, tread,
pressure,
tire
0;
t^
U
18
a t-
==
=-1.
Check tires and tire
qca
riro h16.."ra lrh6l
Generally:
Economy
front and rear,
Comfort
front
and max 5
max
and
and 27-30
persons
persons
3
psi
rear.
pressure.
in vehicle: use
in vehicle: use 26
36
0r)
0r)
psi
psi
Group 17,7,500 Mile
-
Front end
Maintenance Service
-
c3
and 6
play.
o'clock
be
position.
serviced
Check wheel bearing
Rock thewheelat
play,
is
diately.
wheel bearings should
12
Check wheel bearing noise.
Let the wheel fotate freely
wheel
Wheel bearings which are not adjusted
can cause noise.
bearing for noise.
spinning. Check
after
properly
lfthere
imme-
Front
Se|ice every 7,500 miles : 12,500 km
end
Check front
Visually
NOTE:
Do
not mistake moisture on shock absorber for
reaKage.
shock absorbers.
check shock absorbers for leakage.
Check front springs.
Check spring
Check steering
Check steering
attachment
gear
D1
and condition
gear.
rubber bellows for damage.
Check that steering
ing to move
it by hand.
gear
is tirmly attached
by try-
19
Gtoup 17,7,500 Mile
-
Front end
Maintenance Service
D4
Check steering
Jiggle wheel at 3 and
play
along axis of the rack
lornt,
Check
attachment.
Turn
12 and 6 o'clock
check control arm bushings,
spindle
control arm bushings
wheels fully to each side and
and upper strut aftachment
rack for
positions
play.
I o'clock
and inner steering
for each extreme.
positions.
and strut
iiggle
shock absorber
for
Check
rod
wheel at
play.
ou
o,
o
(
Check steering rod
Jiggle
wheels
Judgement
Play along radius of wheel is not
should be remedied immediately.
check ball
Vehicle resting on wheels.
play.
Maximum
rubber bellows.
wheel
pointing
at 3 and I
guideline:
ioints.
play permitted
play.
o'clock
straight ahead.
Check
is 3 mm
lf damaged, service
positions
permitted
(=1/8")
immediately
with
and
Check
or0
D7
e
0
I
20
Group 17,7,500 Mile Maintenance
-
Front end
-
SeNice
IN
Check steering rod
Check rubber seals for damage. Check that
are locked. lf not, correct ilnmediatelv.
Check steering rod for damage. Jiggle with a
pliers.
of
Squeeze
axial
Rubber seal damaged = service immediately.
Rod damaged
Joint worn = service immediatelv.
l/laximum allowable axial
El18"'t.
Check
Check control arms for
Check control
shown in illustration.
Check for wear, cracks
Control arm damaged
Bushing
Bushing damaged
Checkthatjoint does not have anywear.
joints
play,
with
as shown in illustration.
:
control arms.
arm bushings using a
=
play
service immediately.
ends.
pair
a
service
damage.
or other damage.
=
=
service immediately.
pliers
of
immediately.
play
for
seivice immediately.
to check for
joint =
pry
3
bar
nuts
pair
mm
D9
as
Check stabilizer
Check
attachment and rubber
D'0
bar and links.
bushings.
21
Group 17,7,500 Mile Maintenance Setvice
-
Brckes
-
Seruice evety 7,500
Brakes
EXCEPT AS
miles : 12,500 kfi
STATED
E
Check
Check brake
correctly installed
Checkthatbrake
lrom
Gheck brake
Check
and secured. Also
damage and
LnecK Tor teakaoe
brake hoses.
hosesfor leaks.
and that connections
hoses are not
sharp
edges or
lines.
that all brake
do not.ub
Checkthat
chafed
other obiects
lines are correctly
check that
they are free from
against sharp
hoses are
are
tioht.
and areiree
that could
*a
installed
edges.
(
0)
Check
Check that rubber bellows, outer cables and sus-
pension
Service at:
1 5-30-45-60-7 5-go.thousa nd mil es
25-5L7r100-1 25-1
lnteruals: 15.0(n miles : 25.000 km
Check wheel
Bemove wheels.
and wire
lf
cannot be inserted),
lf wire
will have
mtles.
Check for
tion.
parking
in
are
order.
gauge
pad
thickness is less
gauge
fits but liftle
to be replaced
signs of leakage
brake.
50-th ou sand
brakes.
Check
3 mm
pad
=
pads
km
thickness witn mrrror
0.12".
than 3 mm
are
considered worn.
clearance is left,
within less
at caliper or connec-
(wire
than 15,000
gauge
pads
0
0
0
E4
22
Power
Service
transmission
every 7,500 miles:
Diesel.
Group 17,7,500
Power trcnsmission
12,500 km
Mile Maintenance
Service
-
F1
play
play.
of clutch
B23E
Check clutch
Check free
=
1/8"
-3/16".
B21F-Turbo+
Clutch negative
Throw-out
a
spring at
must have a free
play)
Free movement
approx.5/64".
bearing has
pedal
to
allow for wear
movement
rearward
tork. lt should
play.
a small
bracket. Pedal
pre-load
rearward
should
be 3-5 mm
applied by
and clutch
(=negative
be 1-3 mm
F2
fork
=
F3
--L N Tari-Tl 1
i IF -tt" Y+
rr@r
sfrifr 06
Automatic
Adiust
Clearance between
same as
lf necessary,
setecror.
Check
transmission:
shift control.
positions
clearance between
adjust at
propeller
the bottom end
shaft and support
D
and N shall be the
position
2 and 1.
bearings.
Check that U-joint bolts are tight. Turn
find
out it U-joints are worn.
Check suppon bearings
Check that rubber
ged
and are correctly installed.
bellows are not worn or dama-
retainer
and
for
gear
of
shafts to
play.
F4
23
croup 17,7,500 Mile Maintenance
-
Rear end
-
Seruice
Rear end
Seflice every
Check
Manually check shock absorber
Check
Do not
teaKage,
rear shock absorbers.
for leaks.
mistake moisture on shock
attachment.
absorber
{or
7,500 miles : 12,500 km
Check
Use a
brake
spring attachment
rear
suspension,
pry
bar to check bushings
reaction rods,track rod and stabilizer
for trailing arms,
and condition.
NOTE:
There is no need to
que
all bolts. nuts etc
parts
unless
loose. Specifications
provided
tightening
arefoundto be
as a
loose hardware.
Check
retor-
guide
nra
{
are
for
Rerction
A
Body attachment
B
Rear axle
T.ack
Rear axle attachment
c
Body attachment
D
Rear
E
Upper attachment
F
Lower attachment
Shock absorber:
Upper attachment
G
Lower attachment
H
Trailing
I
Body aftachment
Rear attachment {at
Stabilizer:
Front attachment
J
K
Rear attachment
Wheels:
Nuts, tightened
rod :
attachment
(Panhard
rod
Spring:
arm:
rodl:
rear axle) . .
.shock
(
criss-cross
absorberl
.. . . ..
.. . .. .
. . .. .
.
. . .
Nm
110
125..
85
45
115
..
....
ft.
62
62
44
62
32
14
62
62
80
90
62
32
85
lbs.
0
24
T
Group 17,7,500
Exhaust svstem Rear axle. manual transmission
Mile Maintenance
Service
-
Service at:
1130-4860-7 s-go-tho us and mil es
2 5-5 0- 7, I 0 0- 1 2
lntervals: 15.000 miles : 25.000 km
t
1 50- t h o u s a n d k m
5-
Check
Check condition, alignment and suspension.
exhaust
D24
system.
Diesel
a
€**.*"
Seruice
*-
every 7,500 miles : 12,500 km
Check rear axle.
Check for leakage
Oil level
Fluid typer API
Viscosityr
When temperature is steadily below 15'F
use API
Use oils with
with limited siip differential.
should be up to filler
GL-5
SAE 90
GL-5 SAE 80 W oil.
proper
Manual 4-speed transmission with
drive, M46.
for
Check
up to Jiller
are lubricated by the
Fluid type: Automatic Transmission Fluid type
ForG.
leakage and oil Level. Oil level should be
plug
and oil level.
(t\4lL-L-2105
additives for cars equipped
plug
I or C)
hole.
-10'C,
=
over-
hole. Transmission and overdrive
same oil.
25
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