Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide



See Figures 1, 2, 3, 3, 4, 5, 6, 7, 8 and 9

Having the right tools for the job is essential. Without the proper tools and equipment it is impossible, or at least unnecessarily frustrating, to properly service your vehicle. It would be impossible to catalog each and every tool needed to perform every procedure in this guide. It would also be unwise for the amateur to rush out and buy an expensive set of tools on the theory that he may need one or more of them sometime.

The best approach is to proceed slowly, gathering together a good quality set of those tools that are used most frequently. Don't be misled by the low cost of bargain tools. It is far better to spend a little more for quality. Forged wrenches, 6 or 12-point sockets and fine tooth ratchets are by far preferable to their less expensive counterparts. As any good mechanic can tell you, there are few worse experiences than trying to work on a car with bad tools. Your monetary savings will not be worth the consequent cost of frustration and mangled knuckles.

Certain tools, plus a basic ability to handle tools, are required to get started. A basic mechanic's tool set, a torque wrench, and a Torx® bit set. Torx® bits are hex lobular drivers which fit both inside and outside on special Torx® head fasteners used in various places on Volvo vehicles.

Begin accumulating those tools that are used most frequently: those associated with routine maintenance and tune-up.

In addition to the normal assortment of screwdrivers and pliers, you should have the following tools for routine maintenance jobs (your Volvo uses metric fasteners):

Metric wrenches, sockets and combination open end/box end wrenches in sizes from 3mm to 19mm; and a spark plug socket. If possible, buy various length socket drive extensions. One break in this department is that the metric sockets available in the U.S. will all fit the ratchet handles and extensions you may already have ( 1 / 4 in., 3 / 8 in., and 1 / 2 in. drive).
Jackstands for support.
Oil filter wrench.
Funnel for pouring oil.
Grease gun for chassis lubrication.
Hydrometer for checking the (non-sealed free) battery.
A container for draining oil.
Many rags for wiping up the inevitable mess.

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Fig. Fig. 1: All but the most basic procedure will require an assortment of ratchets and sockets

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Fig. Fig. 2: In addition to ratchets, a good set of wrenches and hex keys will be needed

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Fig. Fig. 3: A hydraulic floor jack and a set of jackstands are essential for lifting and supporting your Volvo

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Fig. Fig. 4: A few inexpensive lubrication tools will make regular service easier

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Fig. Fig. 5: An assortment of pliers will be handy, especially for old rusted parts and stripped bolt heads

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Fig. Fig. 6: Various screwdrivers, a hammer, chisels and prybars are necessary to have in your toolbox

In addition to the above items there are several others that are not absolutely necessary but handy to have around. These include oil-absorbing material in case of spills, a long funnel for filling the transmission and the usual supply of lubricants, antifreeze and fluids. This is a basic list for routine maintenance, but only your personal needs and desires can accurately determine your list of necessary tools.

The second list of tools is for tune-ups. While the tools involved here are slightly more sophisticated, they need not be outrageously expensive. There are several inexpensive tach/dwell meters on the market that work every bit as well for the average mechanic as an expensive professional model. Just be sure that the tachometer scale reads to at least 1200 rpm (preferably 1500 rpm), and that it works on 4 cylinder engines.

A basic list of tune-up equipment could include:

Tach/dwell meter.
Spark plug wrench or socket.
Timing light (a DC light that is powered by the Volvo's battery is best, although an AC light that plugs into 110V house current will suffice at some sacrifice in brightness).
Wire-type spark plug gauge and plug adjusting tools.
Set of feeler blades.

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Fig. Fig. 7: A common dwell/tachometer

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Fig. Fig. 8: An inductive-type timing light

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Fig. Fig. 9: A variety of tools and gauges are needed for spark plug service

In addition to these basic tools, there are several other tools and gauges you may find useful. These include:

A compression gauge. The screw-in type takes longer to use, but eliminates the possibility of a faulty reading due to escaping pressure.
A manifold vacuum gauge.
A test light.
An induction meter. This is used for determining whether or not there is current in a wire. These are handy for use if a wire is broken somewhere in a wiring harness.

As a final note, you will probably find a torque wrench necessary for all but the most basic work. The beam type models are perfectly adequate, although the newer click (breakaway) type are more precise and you don't have to crane your neck to see a torque reading in awkward situations. Breakaway torque wrenches are more expensive and will need to be recalibrated periodically.

A torque specification for each fastener will be given in the procedure in any case that a specific torque value is required. If no torque specifications are given, use the following values as a guide, based upon fastener size:

Bolts marked 6T

6mm bolt/nut: 5-7 ft. lbs. (7-10 Nm)
8mm bolt/nut: 12-17 ft. lbs. (16-23 Nm)
10mm bolt/nut: 23-34 ft. lbs. (31-46 Nm)
12mm bolt/nut: 41-59 ft. lbs. (56-80 Nm)
14mm bolt/nut: 56-76 ft. lbs. (76-103 Nm)

Bolts marked 8T

6mm bolt/nut: 6-9 ft. lbs. (8-12 Nm)
8mm bolt/nut: 13-20 ft. lbs. (18-27 Nm)
10mm bolt/nut: 27-40 ft. lbs. (37-54 Nm)
12mm bolt/nut: 46-69 ft. lbs. (62-94 Nm)
14mm bolt/nut: 75-101 ft. lbs. (102-137 Nm)

See Figure 10

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Fig. Fig. 10: Many repairs will require the use of a torque wrench to assure the components are properly fastened

Special tools are occasionally necessary to perform a specific job or are recommended to make a job easier. Recommendation for their use has been kept to a minimum. When a special tool is indicated, it will be referred to by a manufacturer's part number, and, where possible, an illustration of the tool will be provided so that an equivalent tool may be used.