TSB 82: Repair and Diagnosis: Technical Service Bulletins

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Expand All (for easy ctrl-f) Collapse All How to Find Technical Service Bulletins by Category/Symptom Recalls Generals Campaign - Rerouting of Seat Cable Harnesses Overview Rerouting of Seat Cable Harnesses - 780 Inspection Repair Protection of Seat Backrest Wiring Protection for Seat Belt Buckle Cable Rerouting of Seat Cable Harnesses - 940SE Inspection Repair Protection for Seat Belt Buckle Cable Protection of Seat Heater Wiring Safety Recall - Follow Up to Bulletin Number 82 Overview Owner Letter Recall 97V166000: Chafing Accessory Wiring Recall 91V010000: Fuel Sending Unit Leak at Top of Tank Customer Interest Brakes - Resonance In Steering Wheel During Braking Overview Parts Information Tightening Torques and Tools Required Procedure Troubleshooting Hub Unit - Model Year 1988 and Up A/C - Odor Elimination Overview Equipment: Method: Vehicles Equipped With AC or ACC: 780 Equipped With ECC: 760 Equipped With ECC: Cleaning Procedure: A/C - Center Dash Air Vent Repair Overview Removal Procedure 1 - Early Version Removal Procedure 2 - Later Version Vane Repair - Both Versions Air Recirculation Intake Grille - Small Debris Entering A/C - Unpleasent Odor On Startup Overview Installing Control Module and Cables/740 MCC 1988-90 Installing Control Module/Cables/740/940 w/MCC year 1991 Installing Control Module/Cables/740/940 W/MCC 1991-95 Install. Control Module/Cables 760/960 W/MCC-ECC 1988-94 Installing Control Module/Cables 780 ECC 1988 Install. Control Module/Cable 960-S90-V90 MCC/ECC 95-97 Installing Control Module/Cable 940 W/ECC 1996- Diagram Wiring Images Description of Components Warranty Statement Volvo Documentation Text Steering Column - Revised Clicking Noise Elimination Overview Steering Column - Clicking Noise Steering Column Lock, Replacement Brake Caliper - Rattling Sound Front Brake Caliper - Revised Overview New Parts and Improvements Concern: Lubrication and Installation Operation, Labor and Time Allowance Radio - Noise Interference Radio - Interference On AM Band ABS - Warning Lamp ON Body - Whistle/Wiper Well Cover Panel Sealing strip Windshield Washer Jets - New Filter M/T - Slips Out of 1st Gear Power Antenna - Malfunction Overview Inspection and Cleaning Antenna Inspection Inspection 4-Door Models Inspection 5-Door Models Checking and Replacing Control Module Engine - Hard Cold Starting and Performance Mirror - Popping Noise in Audio System Drive Shaft - Take-Off Vibration at Low Speed M/T - Improved Reverse Shift Quality Seat Belt - Extensions A/C - Climate Control System Cleaning A/T - Coolant Contamination Information Brakes - Front Brake Noise Labor/Parts Updates Power Steering Pressure Hose - Revised Clamp Required Manual Updates Body Fittings - Service Manual Change Superceded Bulletins SB39-004 - 04/16/08 SB77-006 - 01/13/11 TJ19245 - 03/22/10 TJ16773 - 01/16/09 TNN43-48 - 04/18/07 517 - 05/01/87 881 - 07/01/88 51111 - 06/01/89 87120 - 08/01/89 59101 - 08/01/89 37702 - 12/01/89 37701 - 01/01/90 514 - 03/01/90 87713 - 04/01/90 514900401 - 04/01/90 87713 - 05/01/90 36109 - 05/01/90 39113 - 04/01/91 887955 - 02/01/96 88-1A - 01/01/99 888002 - 09/01/97 28102 - 08/01/93 23137 - 11/01/90 2112 - 05/01/87 Interior - Front Seat Wiring Power Antenna - Cleaning Seat Belt - Extender Seat Belt Extender - Front Seat Only SRS Airbag - Extended Service Life A/C - Cleaning for System Odors A/C - Odor From Ventilation System A/C - Odor Emitted From Evaporator A/C - Odor from Evaporator Heater Motor - Replacement A/C - Replacement of Blower Motor/New Kit Available A/T - Cooler/Line Flushing Guidelines A/T - Cooler/Line Flushing When Replacing A/T Fuel Control Unit - Updated to Improve Cold Starting Throttle Housing, Switch and Mechanism - Fault Tracing Engine Oils - Updated Recommendations A/T - Engine Coolant Contamination Detection Transmission/Drivetrain - Lubricants And Fluids Engine - Required Engine Oils And Maintenance Intervals All Technical Service Bulletins Memory Systems - Restoring Customer Preferred Settings Audio System - CD's Stuck In Audio Units Tires/Wheels - Tire Rotation Recommendations Wheels - Wheel Cross Reference Electrical - Battery Current Consumption And RDAR Wheels - Winter Wheel Applications (USA, Canada) Fuel System - E10 Petrol Fuel Requirements Electrical - Lead Acid Battery Handling Precautions Vehicle - Platform Identification Vehicle - Type and Platform Identification Campaign - Rerouting of Seat Cable Harnesses Overview Rerouting of Seat Cable Harnesses - 780 Inspection Repair Protection of Seat Backrest Wiring Protection for Seat Belt Buckle Cable Rerouting of Seat Cable Harnesses - 940SE Inspection Repair Protection for Seat Belt Buckle Cable Protection of Seat Heater Wiring Body - Replacement Parts Modifications A/C - Supplement to Service Bulletin 8-87-217 Tools - New Address For Mono Tester Repairs Safety Instructions - Fluoroelastomer Seals Scan Tool - Usage During Trouble Code Diagnostics Overview List of Abbreviations Key Functions Connection of Vst Diagnostic Unit Connections Scan Tool Display Information Test Modes Mode 1 - Displaying DTCS Mode 2 - Testing Input Signals From System Sensors Mode 3 - Cyclic Activation of Components Mode 4 - Individual Activation of Components & Setting of Code Mode 5 - Displays Control Module Data Mode 6 - Enters Data In Control Module Operation and Labor Information Tools - Volvo Multifunction Tester Updates Tools - Volvo Multifunction Tester Tools - Bulletin Indexes Tools - Replacement Parts or Repairs Made By Motometer Canadian Warranty Poster U.S. Warranty Poster Warranty - Authorization For Goodwill Spending Overview I.Goodwill Philosophy II. Goodwill Authorization Policy III. Rationale For Goodwill Spending IV. Goodwill Guidelines V.Goodwill Claims Procedures Warranty - Coverage In New York Warranty - Claim Resubmission Tools - Measuring Brake Disc and Hub Runout Brakes - Resonance In Steering Wheel During Braking Overview Parts Information Tightening Torques and Tools Required Procedure Troubleshooting Hub Unit - Model Year 1988 and Up Instrument Panel - New Design Wood Paneling Tools - R12 Recycling Equipment Overview List of Ul Listed RF-12 Recycling Equipment Volvo Shop Equipment Program Test Results For Recycled CFC/R-12 VS. Recycling Standards Features and Benefits of the 17300 and 17350 How to Use Specifications Other Available Equipment Model Rrc-750 Supplement Tools - Charging Station/R-12 Recycling Units Available Tools - Light Duty R12 Recovery/Recycling Unit Available A/C - Odor Elimination Overview Equipment: Method: Vehicles Equipped With AC or ACC: 780 Equipped With ECC: 760 Equipped With ECC: Cleaning Procedure: A/C - Check for Chafing Hoses And Pipes A/C - Center Dash Air Vent Repair Overview Removal Procedure 1 - Early Version Removal Procedure 2 - Later Version Vane Repair - Both Versions A/C - Conversion, R12 to R134a Overview Equipment and Materials For Conversion Verification of A/C System Tables - Basic Kit # 1 and # 2 Contents of Conversion Kits Conversion of A/C System - Retrofit Shaft Seal Replacement Overview Shaft Seal on Sanden 709 Compressor, Replace Shaft Seal on Sanden 508/510 Compressors, Replace Tightening Torques For Hoses and Pipe Connections CU And AC Dash Controls - New Indicating Panel A/C - Control Panel Modification to Fit Earlier Models A/C - Improved Recirculation Function Power Steering Pressure Hose - Revised Clamp Required Safety Precaution - Fluoroelastomer (Viton) Seals Front, Rear Brake Pad - Parts List Overview Front Brakes Anti-Squeal Shims, Front - DBA/Bendix Rear Brakes, ATE Remedies For Brake Noise Brake Discs, Thickness (In mm), New and Absolute Minimum: Vented Front Brake Disc Replacement Chart Tools - New and Modified Air Recirculation Intake Grille - Small Debris Entering A/C - Replacement of Blower Motor Heater - New Design Fan Housing A/C - Fan Motor Whining/Humming at Low Speed A/C - Evaporator Condensate Drainage A/C - Unpleasent Odor On Startup Overview Installing Control Module and Cables/740 MCC 1988-90 Installing Control Module/Cables/740/940 w/MCC year 1991 Installing Control Module/Cables/740/940 W/MCC 1991-95 Install. Control Module/Cables 760/960 W/MCC-ECC 1988-94 Installing Control Module/Cables 780 ECC 1988 Install. Control Module/Cable 960-S90-V90 MCC/ECC 95-97 Installing Control Module/Cable 940 W/ECC 1996- Diagram Wiring Images Description of Components Warranty Statement Volvo Documentation Text Tools - Special Tool (5407) Must Be Checked Tools - New Special Tools Available Tools - Rear Crankshaft Seal Installer Modification A/C - Condenser/Pressure Pipe Connections Changed Suspension - Tips For Installation of Nivomat Shocks Suspension - Self-Levelling Shock Absorber Operation Suspension - Installing Rear Shock Absorber Bearing Gislaved and Nord Frost Tires - Warranty Information Overview 1.Eligibility 2.Adjustment Policy 3.Calculation of Pro-Rata Credits 4.Additional Important Terms and Conditions 5.Gislaved's Obligations 6.Owner's Obligations Safety Warning Power Seat - Height Adjuster Interior - Noise From Seats and Panels Overview Parts/Materials: Procedures Warranty Information Interior - Front Seat Height Recall - Follow Up to Bulletin Number 82 Overview Owner Letter Steering Column - Revised Clicking Noise Elimination Overview Steering Column - Clicking Noise Steering Column Lock, Replacement Steering Column - Reference Bulletin for Popping Noise Steering Column - Popping Noise Reference Bulletin Final Drive - Revisions, Identification and Repair Overview General Information Specifications, Final Drive New Special Tools Drive Shaft, Removal/Repair Drive Shaft, Installation Propeller Shaft, Removal Replacement of Seal/Pinion Propeller Shaft, Installation Warranty Information Tools - Installing Clutch and Pressure Plate ATF Filter - Cleaning Deleted LH Fuel Injection Control Unit - Exchange Tools - Engine, Oxygen Sensor, Temp Sensor Wheel Hub Assembly - Check/Replace Update Rear Axle Toothed Wheel/Inductive Pickup - Clearance ABS Wheel Sensor - Installation Tool Brake Caliper - Rattling Sound Front Brake Caliper - Revised Overview New Parts and Improvements Concern: Lubrication and Installation Operation, Labor and Time Allowance Battery - Charging Voltage Battery Ground Cable - New Routing Fuel Tank Sender Ground Lead - Modification Tank Sending Unit - Replacement For Tanks W/Metal Flange Catalytic Converter - Replacement On EGR Equipped Cars Recall 97V166000: Chafing Accessory Wiring Door Switch - Revised Radio - Buzzing Noise Radio - Noise Interference Radio - Interference On AM Band Interior - Extended Airbag Service Life SRS Crash Sensor - Manual Revision Overview Warning:Do Not Remove Crash Sensor From Bracket. Do Not Disconnect Crash Sensor Connector. Cancel Fault Code As Follows: Warranty Information SRS - Replacing Crash Sensor, Labor Revision SRS Collision Sensor - Revised Airbag Sensor - Modifying Overview Modifying Airbag Sensor (SRS), 780 Modifying Cable Harness Opening Casing Installing Protective Strips Cable Routing to Seat Belt Tensioner Preparations Right Seat Belt Tensioner Left Seat Belt Tensioner DTC Table EVAP Carbon Filter - Revised Connecting Rod Bushings - Replacement MTBE - Oxygenated Fuel Description Fuel And Ignition Systems - Fault Tracing Recall 91V010000: Fuel Sending Unit Leak at Top of Tank Speedometer Connector - Sealing After Repairs Cylinder Head Gaskets and Bolts - Revised Parking Brake Cable Bracket - Replacement ABS - Troubleshooting Tips ABS - Warning Lamp ON Tools - Replacing Control Arm Bushing Differential Housing - Revised Upper Bushing Replacement Differential Housing - Upper Bushing Service Correction Body - New Adhesive Body - New Repair Equipment and Chemicals Overview Parts and Chemicals Use of Sealant Bonding of Sheet Metal Bonding of Glass Cleaning Tips Body Fittings - Service Manual Change Warranty - Corrosion Inspection Claim Body - Whistle/Wiper Well Cover Panel Sealing strip Body - Changes in Service Manual Section 8 Body - Using Surge Protectors While Arc Welding Welding Precautions for Electrical Components SRS - Deployment/Handling/Ordering/Replacement SRS - Identification Number Recording SRS Tool - Resistance Measurement Antitheft Alarm - Fault Tracing (Watchdog 2) Overview Fault-Tracing Procedure 1, 2, 3, & 4 Fault-Tracing Procedure 5, 6, 7, 8 & 9 Fault-Tracing Procedure 10 & 11 Windshield Washer Jets - New Filter Windshield Moulding - Noise Window - Replacement, Manual Supplement Outside Mirror Glass - Replacement Oil - Abnormal Consumption Engine Oils - Suggested Usage Engine Oil - Viscosity Recommendation Cooling System - Recycled Antifreeze A/T - ZF 4HP-22 Pressure Tap Locations A/T - ZF4HP22 Pressure Fitting Modification A/T - Engine Vacuum Testing A/T - ZF4HP22 Clutch A (Foward) Failure A/T - How To Use A Pressure Gauge A/T - ZF Orifice Placement A/T - ZF 4HP 22 Valve Body Identification A/T - Intermittent Electrical Problems A/T - ZF 4 HP-22 Slipping/No Reverse/3-4 Shuttle Shift A/T - Failsafe Modes A/T - Slipping or No-Shift/Metal Sealing Rings A/T - Front Bushing Wear A/T - ZF 4HP-22 Clutch A (Foward) Failure A/T - Math Formulas Part I Overview Shift Speed and Pressure Speedometer Ratios A/T - Twenty Steps To Successful Repairs A/T - Math Part II A/T - ZF4HP22 Clutch Application Chart A/T - ZF4HP22 Check Ball and Orifice Locations A/T - ZF4HP22 Burning A (Foward) Clutch A/T - Choosing the Right ATF First Gear/Needle Bearings - Revised M/T - Slips Out of 1st Gear M/T - Revised Hydraulic Pistons and O-Rings Overview Replacement of Hydraulic Pistons Clutch Plate Replacement/Service Kit Installation M/T - Replacing Short Dog Keys With Long Dog Keys Power Antenna - Malfunction Overview Inspection and Cleaning Antenna Inspection Inspection 4-Door Models Inspection 5-Door Models Checking and Replacing Control Module A/T Fluid - Correct Applications A/T, M/T, AWD - Approved Lubricants Throttle Switch/Mechanism - Adjustment CIS Valve - Checking Procedures I/P, Knee Bolster Member - Modification Odometer - Information Sticker Used After Replacing Engine Oil - Recommended Electrical - Ground Test By Voltage Drop Sealed Crimping Sleeve - New Engine - Hard Cold Starting and Performance Cruise Control - Correction to Fault Tracing Tools - P70 Wheel Nut Torque Alignment - New Wheel Angle Tolerances Alignment - Camber And Caster Adjustment M/T - New Driven Plates and Release Bearing Mirror - Popping Noise in Audio System Seat Belt - Extender Available Overview Ordering Procedures; Seatbelt Extender Order Form Seat Belt - Extender Availability For Front Seats Glass - Replacement Audio - Diagnostic Check List Paint - New Supplier Paint - Approved Products Drive Shaft - Take-Off Vibration at Low Speed ABS Hydraulic Modulator - Revised Warranty - Allowance For Federal Tax On Freon Jack - New Type, Mounting A/C - Evaporator Condensate Drainage Modification Unleaded Fuel - Usage In Earlier Models M/T - Improved Reverse Shift Quality Seat Belt - Extensions Tools - Installation of Pinion Seal Air Bag System - System Life Expectancy Tires - Pressure Requirements/Recommendations Cam Gear P/S Racks - Bleeding A/C - Climate Control System Cleaning A/T - Coolant Contamination Information Engine - Pressure Washing Precautions Brakes - Front Brake Noise A/T - Cooler/Line Flushing Information