Volvo P 120 Service Manual
P 120
DESCRIPTION
P 120, 4-DOOR
Body frame
The Volvo P 120 has an integral body so that there
A
i
s
no chassis frame. The body is composed of a
number of pressed steel plates, each of which forms
part of the supporting construction.
The body can be suitably divided up into the floor,
side sections, rear section, scuttle, roof, front mud-
guards, doors, luggage compartment and bonnet.
The floor and frame sections (Fig. 1) consist of a
front and rear floor plate (1 and 4) and an inner
cantrail (2), front and rear cross-members (8 and 6),
tunnel (3) and scuttle (Fig, 2). The floor plates are
welded together with the rear seat support. The
tunnel (3), which accommodates the propeller shaft
i
s spot-welded to the floor plates. The rear floor
plate has a longitudinal reinforcing member (5)
on each side at the bottom and between these a
number of cross-members. One of the cross-members (6) is provided with an attachment (7) for the
rear axle tie rod, There is a flanged hole in the rear
floor plate for mounting the fuel tank, the upper
part of which forms part of the floor in the luggage
compartment. The scuttle section (Fig. 2) consists
of the bulkhead (7), wheel arches (5), front upper
cross-member (4) and side plates (3), as well as
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ower cross-members (1 and 2). The bulkhead forms
the front transverse wall of the body and is shaped
with welded end pieces. Two front side members
(8)
project from the front floor. At the front they
are joined together by means of a cross-member
(2) and at the rear they are connected to the front
cross-member under the front seats. Upper side
members (6) project from the upper corner between
the bulkhead and front pillar. These are spot welded to the front pillar, the front side plate and
wheel arch plates. The front axle member and
bumper support bars are attached to the side
members.
Fig. 2.
Scuttle section
Fig. 1.
Floor section (2- and 4-door)
1.
Front floor plate
2.Inner cantrail
3.
Tunnel
4.
Rear floor plate
5.
Reinforcing
member
6.
Rear cross-member
7.
Attachment for rear
8.
axle tie rod
Front cross-member
2.
Front lower
cross-member
Front lower
3.
cross-member
Side plate
4.
Front upper
5.
cross-member
Wheel arch
6.
Upper side member
7.
Bulkhead
8.
Front side member
P 120
The front end is bolted to the upper side mem-
bers, front cross-member and front pillar. The front
mudguards are pressed in one piece and bolted
to the wheel arch plate. The front section forms
the front part of the front end as well as the air
duct to the radiator. The body is noise- and heat-
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nsulated. The insulation consists of "waffle" board
which is stuck on to the plate.
Bonnet
The bonnet is pivoted at the rear on two hinges.
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n the closed position, the bonnet is secured by a
bonnet lock fitted on the front section. The lever
for the bonnet lock is operated by means of a
control
placed underneath the dashboard inside
the vehicle.
Doors sand openings
The doors are built up of an outer and inner plate
together with door arch which is flanged and spot-
welded in one unit. The hinges are fitted to the
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nner plate. The doors are adjustable both longitu-
dinally,
vertically
and laterally. The doors are
provided with a door check. This consists of a flat
bar attached to the door pillar and runs against a
roller in the door. In the open position the flat
bar obstructs the movement of the roller and thus
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mits the movement of the door. The door checks
are fitted to the doors with screws. The pressbutton of the outside door handles operates a lever
which in turn disengages a rotating toothed roller
(tumbler). The inside door handles are fitted to the
remote control which is attached to the inner door
plate with screws. The handle transmits the movement to the toothed roller by means of a link rod.
The lock insert is fitted in the press-button on the
door handle. The doors can be locked from inside
the vehicle by pressing down the locking knobs.
The window winders are of the cable and chain
type. The movement of the window winding handle
i
s transmitted to the window itself by a cable and
chain which are joined together forming an endless
"drive
This is mounted on two pulleys and a
sprocket. The lower pulley is provided with a spring
device for tensioning.
The luggage compartment lid is built up of an outer
and inner plate. The catch for the locking device
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s fitted on the lower edge of the luggage compartment lid. The hinges are fitted at the upper edge
of the lid. The hinges are bolted to the plate under
the rear window through a reinforcing plate. The
Fig. 4.
Roof section (2- and 4-door)
On 4-door models the side section (Fig. 3)
consists of the front pillar (9), intermediate pillar (11),
rear pillar (6), intermediate and outer cantrails (8
and 7), roof former (1), windscreen pillar (10), rear
wheel arch (2) with wheel arch member (5), rear
mudguard (4), back plate and joining plate (3). The
cantrail and wheel arch member are manufactured
of galvanized sheet metal.
The roof section (Fig. 4) consists of a number of
pressed steel plates. The roof plates form the
upper part of the scuttle section, windscreen openi
ng, the roof itself, the opening for the rear window
and the upper limit of the luggage compartment.
The front mudguards, front section and bonnet
make up the front end.
Fig. 3.
Side section (4-door)
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uggage compartment lid is counter-balanced with
torsion rods and can be set in any position when
opening. On chassis up to number 20999, the lock-
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ng device is placed on the body below the lid,
and on vehicles with effect from chassis number
21000, the locking device is fitted on the lid.
Interior fittings and upholstery
FRONT SEATS, LATE PRODUCTION
The front seats are built up on a tubular frame. The
padding consists of foam plastic which is covered
by fabric-backed vinyl. The seat can be adjusted
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ongitudinally by releasing the catch (3, Fig. 5), and
sliding the seat. The seat can be adjusted vertically
at the attachment (4) which is provided with holes
at different heights. The seat can be tilted to the
desired position by means of the adjusting device
(5).
The backrest inclination is variably adjustable
by means of the handwheel (2) which operates an
eccentric. The seat is provided with an adjustable
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umbar support (see Fig. 7), the tension of which
Bild 5.
Front seat (4-door)
1.
Adjustment of lumbar support
2.
Adjustment of backrest inclination
3.
Longitudinal adjustment
4.
Adjustment of seat height
5.
Adjustment of seat inclination
P 120
i
s
adjusted with a screw (1, Fig. 5 and 3, Fig. 7)
on each side of the backrest. The seat cushions are
attached to the seat frame by means of pressfasteners.
REAR SEAT
The rear seat and backrest are built up in principle
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n the same way as the front seats, although in this
case the seat frame consists of a wooden frame.
DOOR UPHOLSTERY
The door upholstery consists of wood-fibre sheeting
lined
with non-woven padding and covered with
upholstery material. It is secured to the door by
means of clips. The front armrest is made of moulded plastic and is screwed to the inner plate of the
door.
HEADLINING
The headlining consists of plastic material stretched
on roof ribs and secured in retainers fitted on the
upper limit of the body sides.
COVERING FOR BULKHEAD AND FLOOR
The sides of the bulkhead are lined with millboard
which is attached with clips. The bulkhead is
covered with plastic-lined felt matting. The floor is
covered with rubber mats.
Bumpers
The bumpers are composed of three parts and the
upper joints are provided with overriders. The bum-
pers are fitted on four support bars, of which the
front ones are attached to the front side members
and the rear ones to the rear side members.
8-3
P120
P 120,2-DOOR
Body frame
The body frame is largely similar to that of the
4-door model. However, the side part is altered
so that there is no longer an intermediate pillar
and the rear mudguard (3, Fig. 6) is extended. The
side section consists of front and rear door pillars
(7 and 4), intermediate and outer cantrails (6 and
5), roof former (1), windscreen pillar (8), rear wheel
arch (2) and rear mudguard (3).
Bonnet
See the 4-door model.
Doors and openings
See the 4-door model.
Interior fittings and upholstery
FRONT SEATS
The front seats on the 2-door vehicle can be
hinged forwards in order to facilitate entry to the
rear seats. They are provided with catches (4) in
order to prevent tilting forwards (see Fig, 7).
OTHER INTERIOR FITTINGS
Concerning other fittings and the bumpers, see the
4-door model.
P 120 STATION WAGON
Body frame
The front end is the same as that on the 2-door and
4-door models, The floor section (Fig. 8) consists of
the front (11), intermediate (3) and rear (4) floor
plates, tunnel, inner cantrail (1), side members (6),
front (10), intermediate (8) and rear (5) cross-mem-
bers.
The front and intermediate floor plates are welded
together at the rear seat support. The tunnel is
spot-welded to the front floor plate (11). Two rear
side members (6) are welded to the lower side of
the intermediate (3) and rear (4) floor plates, one
on each side, and between these a number of
cross-members.
One of the cross-members (8) is
provided with an attachment (9) for the rear axle
tie rod. Both the rear side members are provided
with attachments for the rear axle support arms.
The spare wheel well (7), which is provided with
a lid in the floor, is welded on the lower side of
the rear floor plate. There is a flanged hole in this
for the fuel tank.
Fig. 6.
Side section (2-door)
1.
Roof former
2.
Rear wheel arch
3.
Rear mudguard
4.
Rear pillar
5.
Outer cant rail
6.Intermediate cant rail
7.
Front pillar
8.
Windscreen pillar
P 120
Fig. 9.
Side section, Station Wagon
1.
Roof former
2.Inner frame for side
window
3.
Upper rear pillar
4.
Rear mudguard
5.
Rear intermediate
pillar
6.
Rear wheel arch
7.
Front intermediate
pillar
8.
Outer cantrail
9.
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ntermediate cantrail
10.
Front pillar
Fig. 7.
Front seat (2-door)
1.
Adjustment of seat inclination
2.
Adjustment of seat height
3.
Adjustment of lumbar support
4.
Longitudinal adjustment of seat
5.
Adjustment of backrest inclination
The scuttle section is similar to that on the 2- and
4-door models.
The side section (Fig. 9) consists of the front pillar
(10), intermediate pillar (7), rear section, interme-
diate (9) and outer (8) cantrails, inner and outer
roof formers (1) and windscreen pillar. The rear
section is composed of the rear wheel arch (6), rear
mudguard (4), inner frame (2) for rear side window
and upper (3) and lower rear pillar. The upper part
of the rear mudguard is extended upwards and
forms the outer frame for the rear side window.
Fig. 8.
Floor section,
Station
Wagon
1. I
nner cantrail
2.
Rear seat support
3. I
ntermediate floor plate
4.
Rear floor plate
5.
Cross-member
6.
Side member
7.
Spare wheel well
8.
Cross-member
9.
Attachment for rear axle
support arms
10.
Cross-member
11.
Front floor plate
8-S
P 120
Fig. 10.
Roof section, Station Wagon
Fig. 11.
Catch device for rear seat, Station Wagon
1.
Eccentric
2.
Pull rods
3.
Catch sleeve
4.
Handle
The roof section (Fig. 10) consists of the roof
plate,
windscreen member, two roof arches and
rear member.
Doors and openings
The doors on the Station Wagon are similar to those
on the 4-door model. The tailgate consists of an
upper and lower part. The hinges of the upper
tailgate are attached to the rear edge of the roof
section and those of the lower tailgate are bolted
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n the rear cross-member. The inside of the lower
tailgate is provided with a cover plate and mat
which are attached by means of screws. Both tail-
gate sections are locked by means of a common
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ock which is bolted on to the lower tailgate. Each
of the tailgate sections is provided with a support
for holding it in the open position. Opening of the
upper tailgate is facilitated by means of a gas
spring, i.e. a piston which runs in an enclosed gasfilled
cylinder. There are four different opening
positions.
Interior fittings and upholstery
FRONT SEATS
See the corresponding section for the 4-door
model.
REAR SEAT
The rear seat is built up of springs on a frame and
has foam plastic padding which is covered with
vinyl. The seat cushion is provided with two hinges
at the lower front edge and can if necessary be
tipped up against the front seats. It is covered with
a
mat underneath and forms the front limit of the
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oading space when in the tipped-up position.
The backrest consists of a back plate fitted with
rubber bands. The padding consists of foam plastic
and the upholstery of fabric-backed vinyl. The rear
side of the back plate is provided with a mat and
when folded down forms an extension of the floor
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n the loading space. The backrest is locked in the
normal position by a spring-loaded catch device,
see Fig. 11, the handle (4) of which operates the
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atches through an eccentric (1) and pull rods (2).
The lower corners of the backrest rest partly on a
fixed catch and partly (on the left-hand side) on a
sprung catch.
Bumpers
The bumpers are the same as on the 4-door model
except that the rear overriders serve as footsteps,
the upper sides of which are rubber-covered.
P 120
REPAIR INSTRUCTIONS
FRONT END
Front mudguards
The front mudguard is removed by taking out the
following screws: the screw between the mudguard
and stay at the lower side member, the screw bet-
ween the mudguard and body side behind the
above-mentioned stay, the screws in the front side
section and the screws in the upper side member.
I
n addition, the headlamp with leads must be removed. Concerning removing the headlamp, see
Part 3. Fitting is done in the reverse order.
Front section
The front section is attached to the front mudguards,
wheel arch plates and the upper and lower crossmembers.
When removing, take out the headlamps, the screws
between the front section and splash guard under
the headlamp, the screws in the upper and lower
cross-members and the screws in the wheel arch
plates.
Bonnet and bonnet lock
The bonnet is attached by means of screws in each
hinge. The bonnet is removed by taking out the
screws between the hinges and bonnet. The hinges
are attached to the body with four screws each.
All the holes in the hinges are oval in order to
permit the bonnet to be adjusted.
There are two types of bonnet lock. The early production lock (up to chassis number about 10 000)
i
s illustrated in Fig. 12. The bonnet lock is adjusted
as follows.
When the bonnet is locked the U-shaped catch
should lie right inside the lock catch groove and
the measurement B, Fig. 12 must not exceed 3 mm
(0.12").
Any adjustment should be made on the
catch itself. It should be adjusted vertically so that
the gap between the bonnet and the front section
Fig. 13.
Bonnet lock, late production
of the body is 4.5 ± 1 mm (0.18 ± 0.04"). The tension
of the safety catch spring should be at least 0.1 kg
(0.22 lb.) measured at D, Fig. 12, in order to move
it from its rest position.
8--
7
P 120
8-8
Fig. 14.
Door check
When the bonnet is closed, the U-shaped catch
should meet the safety catch as close to the top as
possible, but not so high as to cause the hook
to be pushed forwards, measurement C, Fig. 12.
A small adjustment of 1-2 mm (0.04-0.08") can
be made by bending the safety catch. If a larger
adjustment is found to be necessary, this means
that the whole locking device has been displaced.
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n this case the complete bonnet lock must be reset.
The late production lock, with effect from chassis
number about 10000, is illustrated in Fig. 13.
The lock can be adjusted laterally and longitudinal-
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y since the
holes in the front section are larger than
the diameter of the attaching screws. The length
of the latch is adjustable by means of nuts. The
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atch and spring are lubricated with grease.
DOORS
Removing front door
1.
Remove the door check, see Fig. 14. The
attaching bolts for this are accessible after
the side insulation material on the body has
been removed. The door check can also be
removed by unscrewing the guide roller and
pulling it off. In order to get at the guide
roller, the door upholstery must be removed
see under "Removing the door handle and
upholstery".
2.
Unscrew the four countersunk screws which
hold the door to the upper and lower hinges.
The door sealing strip must be moved in order
to get at the hinge screws. This is done by
releasing the two plates over the hinges
to which the strip is glued and carefully pulling
to one side, see Fig. 15. When doing this,
make sure that the rubber strip does not come
away from the plate or door.
Fig. 16.
Removing armrest
VOLVO
25255
Fig. 15.
Plate over hinge
Fitting the door is done in the reverse order
to removing. Since the holes in the door are
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arger than the diameter of the bolt, and the
nut plates are movable, the hinge attachment
can be adjusted both vertically and laterally.
The door is adjusted longitudinally at the
hinge attachments in the body.
Removing rear door
(See also under "Removing front door")
1.
Remove the door check. The attaching bolt
for this is accessible after the rubber plug in
the centre pillar has been removed.
2.
Remove the plates over the hinges.
VOLVO
23235
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