TWO- AND FOUR-DOOR CARS ( 121/122 S M) DESCRIPTION DRIVING SERVICING
BEFORE YOU START DRIVING YOUR NEW VOLVO PLEASE READ THROUGH THIS INSTRUCTION BOOK CAREFULLY. IT CONTAINS ALL THE INFORMATION YOU NEED TO BE ABLE TO DRIVE AND SERVICE YOUR VEHICLE IN THE BEST POSSIBLE WAY. BY FOLLOWING THE INSTRUCTIONS GIVEN IN THIS BOOK, YOU WILL FIND THAT YOUR VOLVO WILL COME UP TO ALL THE EXPECTATIONS CONCERNING ECONOMICAL OPERATION AND EXCELLENT PERFORMANCE THAT YOU HAVE EVERY RIGHT TO EXPECT OF A TOP-QUALITY VEHICLE.
DO NOT WAIT UNTIL SOMETHING GOES WRONG BEFORE YOU START READING THIS BOOK. READ IT NOW. THE SHORT TIME THIS TAKES WILL MORE THAN REPAY YOU IN THE LONG RUN. THE BETTER YOU KNOW YOUR VOLVO, THE BETTER SERVICE IT CAN GIVE YOU. THIS BOOK CAN CONTAIN SOME VALUABLE INFORMATION EVEN FOR AN EXPERIENCED MOTORIST FINALLY, WE WOULD LIKE TO EXPRESS OUR APPRECIATION FOR THE CONFIDENCE YOU HAVE SHOWN IN THE NAME OF VOLVO BY CHOOSING A VOLVO VEHICLE.
CONTENTS 4
CONTENTS
VOLVO SERVICE Volvo Service Organization In order to get the most out of the invested capital represented by a car, it must be looked after and serviced rationally. Volvo has gone to a great amount of trouble in the design and selection of material to ensure that the car in question only requires a minimum of servicing. All this work will be in vain unless we can count on your co-operation - that is to say, that you make sure that your vehicle gets the regular 'servicing it needs.
VOLVO SERVICE Warranty and Service Booklet A warranty and service booklet accompanies each vehicle when it is delivered. This book contains a coupon entitling you to a cost-free service inspection after 2 500 km (1 500 miles) running. If possible, let the dealer who supplied the vehicle carry out this service inspection. If necessary, however, any of our dealers can do this.
DESCRIPTION General The Volvo 121/122 S is a two- or four-door, five-seater car. Many colours are available and in each particular case the colour of the internal fittings and upholstery harmonizes with the external finish of the car.
Type designations This instruction book deals with vehicles having the following type designations: Type designation 121341 121361 122341 122351 122461 131211 131341 131361 132341 132461 M M M M M M M M M M or or or or or or or or or or 121342 121362 122342 122352 122462 131212 131342 131362 132342 132462 M M M M M M M M M M Engine B 18 A B 18 A B 18 D B 18 D B 18 D B 18 A B 18 A B 18 A B 18 D B 18 D Gearbox M 40 BW 35* M 40 M 41 BW 35* M 30 M 40 BW 35* M 40 BW 35* On the USA market, 12234 and 13
DESCRIPTION The engine is a four-cylinder carburettor unit with overhead valves. The pistons are made of light-alloy and the upper compression ring on each piston is chromed. The main bearings and connecting rod bearings are replaceable. The crankshaft is statically and dynamically balanced. Engine type B 18 A has an output of 85 h.p. (SAE) and is equipped with Zenith-Stromberg horizontal carburettor. Engine type B 18 D has an output of 100 h.p. ( SAE ) and is equipped with twin SU horizontal carburettors.
1. Carburettor (B 18 D) 2. Float chamber (B 18 D) 3. Air cleaner (B 18 D) 4. Expansion tank with filler cap for coolant 5. Charging control 6. Dynamo 7. Oil filler cap 8. Air cleaner (B 18 A) 9. Carburettor (B 18 A) 10. Battery 11. Hoses for heater system 12. Oil dipstick 13. Distributor 14. 15. 16. 17. 19. 18. 20. 21. Relay for back-up light 22. Relay for headlight Heater flasher Starter motor 23. Motor for windscreen Ignition coil washers Plate with type desig- 24.
DESCRIPTION Electrical system The electrical system is of the 12-volt type and is fitted with a voltage control dynamo. The starter motor is controlled from the instrument panel by means of the ignition key. This key also forms the main switch for the rest of the electrical system. The cables to the headlights, parking lights and internal lighting, however, are not taken over the ignition switch but can be switched on and off without the ignition key being in position.
DESCRIPTION Power transmission Clutch The function of the clutch is to transmit the power from the engine to the gearbox. The clutch is of the single dry plate type with diaphragm spring. The diaphragm spring 'functions partly as a lever when declutching and partly as a pressure spring when engaging. Gearbox The gearbox is used to regulate the speed ratio between the engine and the rear axle so that the engine always operates in its most favourable speed range.
Gearbox 15
DESCRIPTION Body Bonnet The bonnet is fitted with a catch which is operated from the driving seat through a handle located to the left under the instrument panel. The bonnet catch is released by pulling the handle out. When the bonnet catch handle has been released inside the car, the bonnet is still retained by a safety catch. After this is pressed in as shown, the bonnet can be lifted up.
Doors and locks There is a lock with a keyhole on each of the front doors. All the doors can be locked from inside the car by pressing down the lock buttons on the window ledge. On the rear doors, this button must first be pulled up before the doors can be opened from the inside. This is an important safety factor if children are alone in the back. All the doors can be locked by pressing down the internal lock button and then closing the doors.
DESCRIPTION Front seats The front seats can be slid backwards or forwards after the knob on the outside of the seat is pressed down. Exert leverage with your feet on the floor and slide the seat to the desired position. If necessary, the seats can be moved 25 mm (1") further to the rear than permitted by the slide rails by using the extra holes in the seat frames.
Safety belts Standard on this vehicle includes safety belts for both the front seats. Utilize this simple but effective safety device. Even when driving slowly, for example, in town traffic, a sudden, unexpected stop can cause serious injury. For this reason, the safety belt should always be on when driving. The length of the belt can be adjusted at the outer, lower attachment.
DESCRIPTION I nstruments and operating controls Before you start the engine, sit behind the wheel and carefully check through all the instruments and controls. The location of these is shown in the illustration. The instruments and operating controls are described in more detail on the following pages with reference to the numbers in the illustration.
DESCRIPTION I Temperature gauge The temperature gauge shows the temperature of the cooling system and thus indicates the working temperature of the engine. The indicator on this gauge should remain within the green marking. If it should show an excessively high temperature for a long time, this can depend upon the fact that the channels in the cooling system are blocked and circulation is thus being hindered. In such cases the cooling system should be cleaned (see page 40).
DESCRIPTION 10 Control for windscreen wipers and washers The control for the windscreen wipers and washers has four positions. When pressed in, the control is shut. When pulled out one step, the windscreen wipers operate at normal speed. When pulled out two steps, the windscreen wipers move more quickly. When pulled out fully, the windscreen washers are also operated. (Not standard on USA cars.) When the control is pressed in again, the wiper blades stop when they have reached their normal position.
DESCRIPTION 14 Heater and ventilation system Switch for fresh-air fan Air-flow Sliding control for air temp. Pushed right in - closed Interco. pos. - full output Fully out - half output AIR _ Air to front seat floor DEFR = Air to windscreen and to rear seat floor This control is used to regulate the temperature of the incoming air. The heating and ventilation system of the car is operated as shown above.
DESCRIPTION 20 Lighting switch Parking lights (Lighting switch pulled out one notch) Dipped headlights (Lighting switch fully out and foot dipper switch in dipped position) Full headlights (Lighting switch fully out and foot dipper switch in full position) The headlights are switched from full to dipped and vice versa by depressing the dipper switch with your foot. Instrument lighting The instrument lighting is regulated by turning the lighting switch knob.
DRIVING Starting i n a garage If you start your vehicle in a garage, always open the garage doors before starting the engine. The exhaust gases from the engine contain the poisonous gas carbon monoxide which is particularly dangerous since it is both invisible and odourless.
SERVICING General Before the vehicle was delivered from the factory it was subjected to a very thorough inspection. Your dealer, in his turn, carried out a further delivery inspection in accordance with the specifications of the Volvo factory. In addition to this there is the cost free service inspection after 2 500 km (1 500 miles).
SERVICING Maintenance scheme In the maintenance scheme below the servicing procedures have been given certain numbers which refer to the detailed descriptions on the following pages. Some of the work must be carried out by skilled mechanics or requires the use of special tools and these have been marked in colour.
SERVICING In addition to the servicing procedures mentioned in this scheme you should also regularly check the following from the point of view of traffic safety: a) lighting, including brake warning lights b) direction indicator flashers c) horn Operation 33
SERVICING Lubrication Lubrication is the most important procedure in servicing a vehicle. The cost of lubricant is insignificant compared with the cost of repairs caused by neglected lubrication. All metallic surfaces, no matter how finely ground they are, consist of extremely small uneven points. If two ground surfaces are pressed together and rubbed, the uneven surfaces will engage in each other and result in friction and wear.
SERVICING 1 Body lubrication In order to avoid squeaks and unnecessary wear, the body should be lubricated about every 10 000 km (6 000 miles) or at least once a year. During the winter season the door locks and luggage compartment lock should be treated with a suitable anti-freeze agent to prevent them from freezing up. No.
SERVICING 2 Check the oil level in the engine The oil level in the engine should be checked each time the fuel tank is filled. Carry out the check with the engine switched off by using the oil dipstick which is on the left-hand side of the engine. The oil level should be between the two marks on the dipstick. It must never be permitted to go down below the lower mark, but on the other hand the oil level should not be above the upper mark since oil consumption will then be abnormally high.
SERVICING 4 Gearbox 6 Rear axle 8 Steering box 5 7 The oil in the gearbox should be checked after every 5 000 km (3 000 miles). The oil level should be up to the filler hole. If necessary top up with new oil. The oil in the gearbox should be changed after every 40 000 km (25 000 miles). In the case of a new or reconditioned gearbox the oil should also be changed after the first 5 000 km (3 000 miles). The old oil should be drained off immediately after the vehicle has been run.
SERVICING 9 10 Brake fluid Clutch control fluid The fluid level in the brake and clutch control hydraulic systems should be checked after every 5 000 km (3 000 miles). The fluid should be up to the level marks in the containers. Use brake fluid for both systems. Engine 11 Oil filler cap The oil filler cap is fitted with a filter. If this filter becomes blocked there will be excessive pressure in the crankcase and this can lead to 12 oil leakage.
14 Fuel filter 15 Air cleaner (B 18 A) The fuel filter should be cleaned after every 10 000 km (6 000 miles). Loosen the screw and remove the cover and strainer and clean these. When refitting the cover make sure that the gasket seals properly. The air cleaner should be replaced with a new one after every 40 000 km (25 000 miles). With continuous driving in dusty conditions replacement must be carried out more fre- quently.
SERVICING 20 Check the coolant level To be able to function with maximum efficiency, the cooling system must be well filled and must not leak. Check the coolant level when tanking. The level should be between the "Max" and "Min" marks on the expansion tank. When the engine is new or the cooling system has been emptied, this check should be carried out with particular thoroughness. Topping up the coolant.
SERVICING 22 23 Check, replace the sparking plugs The sparking plugs should be removed after every 10 000 km (6 000 miles) and the electrode gap checked. The gap should be 0.7-0.8 mm (0.028-0.032"). After 20 000 km (12 500 miles) the plugs should be replaced. This replacement should preferably be carried out at a Volvo workshop where the sparking plugs are tightened with a torque wrench to about 3.5 kgm (25 lb.ft.). When fitting new sparking plugs, be sure to fit the right type (see page 56).
SERVICING Electrical system 27 Check the battery electrolyte level The electrolyte level should be checked when the fuel tank is being filled. The electrolyte level should be 5-10 mm ( 3/16- 3 /8") over the top of the cell plates. Top up with distilled water if necessary. Never add too much distilled water since this can cause the acid to splash over and result in corrosion on the parts of the engine around the battery. Never check the electrolyte level by lighting a match.
Replacing the headlight bulbs Loosen the screw on the underside of the rim with a screwdriver. Pull out the bottom part of the rim slightly and then lift upwards so that the retainer catch releases its grip. (Do not pull the headlight rim so far forwards that the catch at the top becomes bent, otherwise water can penetrate and damage the reflector.) Loosen the three screws retaining the insert. It is not necessary to remove these screws completely.
SERVICING Replacing the bulbs in the front parking lights/flashers Unscrew the two screws by means of a Philips screwdriver and lift off the glass and the metal frame. The bulbs can now be removed by pushing in and twisting anticlockwise. The larger one is the flasher and the smaller one the parking light. See that the glass seats properly on the gasket. Replacing the bulbs in the rear flashers, stop/tail lights and back-up lights Unscrew the two screws, one at the.
SERVICING Power transmission 30 Checking the free travel of the clutch yoke 31 Check the propeller shaft In order to prevent the clutch from slipping, the free travel of the clutch yoke must be checked regularly and adjusted if necessary after 10 000 km (6 000 miles) of operation. If the clutch does not disengage in a satisfactory way, the free travel of the clutch pedal must be checked. See the data on page 57.
SERVICING Wheels and tyres 35 Air pressure Make a habit of checking the air pressure in the tyres regularly. The best way to do this is to check the pressures every time you fill the fuel tank. See page 58 for the correct air pressures. Do not forget the spare wheel when you check the air pressure. Even if this wheel is not used, the air pressure can go down and you may find that the tyre is flat just when you need it.
Changing a wheel Before the vehicle is jacked up, the handbrake should be applied and one of the gears engaged to make sure that the vehicle stands still. Lay a couple of stones or chocks i n front of and behind the wheels that remain on the ground. Removing 1 Lever off the hub cap with the help of the spade-shaped lever. 2 Loosen the wheel nuts slightly with the help of the box spanner and tommy bar.
SERVICING Body 36 Washing 37 Polishing (waxing) When the vehicle is new it should be washed often to harden the surface finish. If dust and dirt are allowed to remain in contact with the surface finish for any length of time, damage can result. Washing and polishing are also important from the viewpoint of rust protection. Special care should be taken particularly during the wintertime that all residues of road-salt are washed off as soon as possible otherwise corrosion can easily occur.
Touching-up damage on the surface finish The touching-up of any extensive damage to the synthetic finish requires the use of special equipment and skill, so that the repairing of any such damage should be entrusted to a Volvo workshop. Any minor damage caused by flying stones, etc. and small scratches can, however, be attended to by the owner himself. Damage caused by flying stones requires immediate treatment.
SERVICING Chromed parts The chromed parts should be washed with clean water as soon as they are dirty. This is particularly important if you drive a lot on gravel roads which are treated with chemicals to keep the dust down and during the wintertime when salt is used on the roads to melt the snow or if you drive near the sea. After washing you can apply wax or antirust preparation. 38 Anti-rust treatment 39 Cleaning The Volvo 121/122 S is anti-rust treated at the factory.
SERVICING Servicing before long-distance driving If you're thinking of travelling abroad with your vehicle or making any other long journey, you should have your vehicle thoroughly checked at a Volvo workshop. You will enjoy your journey better if you know that your vehicle is in perfect trim. You drive in a more relaxed way if you're certain that everything is functioning perfectly. You thus avoid irritating incidents and expensive and time-making stoppages.
SERVICING Procedure in cold weather When cold weather is in the offing, it is time to think of the winter servicing of your vehicle. The first heavy night frosts can come as an unpleasant surprise unless preventive precautions have been taken. Engine cooling system Genuine Volvo coolant should be used all the year round. Therefore the coolant should not comprise only of water plus a rust-proofing agent, not even during the summertime.
SERVICING Engine lubricating system During the winter multigrade oil SAE 10 W-30 or engine oil with a viscosity of SAE 10 W should be used for the engine lubricating system. These oils reach the lubricating points in the engine more easily at low temperatures and also facilitate cold starting. If you drive mainly short distances during the winter, the engine oil should be changed more often than usual, for example after every 2 500 km (1 500 miles). See page 36.
FAULT TRACING The information given below is only intended to serve as a guide in localizing and temporarily correcting minor faults. After having carried out any such measures, have them checked and adjusted by an expert mechanic. The engine does start although the starter motor turns it round at normal speed 1 Check that there is fuel in the tank. 2 If the engine is warm, starting should be done with the accelerator pedal slowly depressed as far as it will go.
SPECIFICATIONS Dimensions and weights 55
SPECIFICATIONS Engine Fuel system Cooling system I gnition system 56
57
SPECIFICATIONS 58
Symbols Brake fluid See page 38 Rear axle oil Grade : Hypoid oil Viscosity : See page 37 Lubricant see notes Light engine oil Engine oil Grade : For Service MS Viscosity : Multigrade SAE 10 W-30 See page 36. Gearbox oil Viscosity : See page 37 Notes for lubricating chart Note 1 Check that the oil reaches up to the filling plug.
Steering box Note I Wheel bearings Note 2 Dynamo (B 18 A) Note 8 Wheel bearings Note 2 Clutch fluid Note 3 Carburettor Note 9 Brake fluid Note 3 Oil filter Note 10 Distributor Note 4 Gearbox Note 7 Engine Note 5 Handbrake cable Note 6 Handbrake cable Note 6 Rear axle Note 7 Wheel bearings Note 2 Wheel berings Note 2
