1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ19292 Date: 081007

A/C - Climate Control System Cleaning

Retailer Technical Journal 19292

Climate control system, cleaning

Date: 10-07-2008

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 81

Reference:

VIDA, Special Tools Bulletin 163

Retailer Technical Journal 17865

Note!

If using a printed copy of this Retailer Technical Journal, first check for the latest online version.

NOTE!

THIS DOCUMENT SUPERSEDES THE PREVIOUS RETAILER TECHNICAL JOURNAL (RTJ) 19292, DATED 6-23-2008. THE

OPERATION TIME FOR C30, S40, V50 AND C70 HAS BEEN INCREASED TO 0.4 HRS; ALSO ADDED, IS INFORMATION

CONCERNING THE REMOVAL / REINSTALLATION OF THE ACCELERATOR PEDAL ON C30, S40, V50, AND C70. PLEASE

UPDATE YOUR FILES.

AFFECTED VEHICLES:

DESCRIPTION:

A new tool and cleaning treatment designed to disinfect the climate system has been introduced. Should a customer report a climate system odor,

the following should be treated, checked, and replaced. Included in this document is information related to the tool, treatment, and how to locate the

instructions for use.

- Ensure the odor is not from some other source and all other A/C system checks have been completed. (No water standing underneath the floor

carpets.)

- There are no refrigerant leakages (not PAG oil causing the odor).

- Climate housing drain hose is installed correctly, not clogged - drains sufficiently.

- Aircomatic treatment; tool and treatment agent listed.

- After the treatment is completed; replace the climate system (pollen) filter.

- Engage the Afterblow function on applicable vehicles, instructions for afterblow engagement can be found in RTJ 17865.

NOTE:

At the time of this writing, afterblow is applicable to these vehicles:

MATERIAL:

TOOLS:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 82

SERVICE:

To complete the treatment with the Aircomatic unit and cleaning agent, see VIDA instructions.

IMPORTANT:

See Accelerator Pedal Removal / Installation; C30, S40, and C70 for information specific to C30, S40, V50, and C70.

NOTE:

At the time of this writing, not all vehicles / model years are included in VIDA 2008 C. Additional vehicles will be added with new versions of

VIDA. The general instructions apply to all vehicles.

- Vehicle Profile / choose the appropriate vehicle - select OK

- Information

- Cleaning, Inspection and Adjustment

- 8 Body and Interior

- 87 Climate units

- 870 general

- Climate control system, general

- Climate control system, cleaning

IMPORTANT:

This treatment is designed to last 6 - 12 months, and may need to be completed again sometime in the future.

As noted in VIDA: "An odor is present for a few days after cleaning, which is usual". The odor is of a perfume type and be sure to advise the

customer of this.

Accelerator pedal Removal / Installation; C30, S40, V50, and C70

In order to remove / replace the climate system (pollen) filter on C30, S40, V50, and C70 vehicles, the accelerator pedal needs to be removed /

reinstalled. While removing the pedal, the bolts (studs) used to hold the accelerator pedal assembly in place may become loose when the

"compressed nuts" are removed by the technician. The installation process of the bolts (studs) was modified to reduce the possibility of this from

the following chassis numbers; S40-92141 / V50-91193. The nuts holding the accelerator pedal changed from compressed nuts to "regular" M6

nuts from the following chassis numbers; 544-276806 / 545-291234 / 542-14430.

IMPORTANT NOTE:

Many of the bolts (studs) loosened from their mounts have been caused by the use of pneumatic tools (i.e. air ratchets). Regardless of the

chassis number or production modifications, pneumatic tools should never be used to remove / install the accelerator pedal mounting nuts!

During accelerator pedal reinstallation, any previously installed compressed nuts should be replaced with regular M6 nuts, P/N 985919 (x3).

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 83

WARRANTY CLAIM INFORMATION

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB8930 Date: 891001

A/T - Math Part II

TSB: 89-30 (Oct)

SUBJECT: TRANSMISSION MATH - Part II

Planetary Gear Sets:

Knowing the gear ratios of an automatic transmission can come in handy at times -- especially when you're swapping transmission types or

differentials. The problem is in trying to find a manual with the ratios listed. What do you do?

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 66

BREAK OUT THE CALCULATOR, AND FIGURE IT OUT.

When you figure the gear ratios for planetary gear sets, it is just like any other gear set. You divide the output gear by the input. Also, don't count

the idler gear; planetaries are considered idler gears. Set them aside, their tooth count doesn't matter.

Now for the tricky part -- which gear do you consider the input, and which one the output? Figure 1 shows a planetary gear set with 34 teeth on the

ring gear and 20 teeth on the Sun gear.

FOR GEAR REDUCTION, one of the gears is held stationary, and the other is used for the INPUT. THE TOOTH COUNT FOR THE OUTPUT

GEAR IS THE SUM OF THE SUN GEAR AND THE RING GEAR, so if you are using the Sun gear for the input, then the ring gear + the Sun

gear divided by the Sun gear = Ratio.

EXAMPLE: 34 + 20 divided by 20 = 2.7:1 This is how 1st gear on a THM 700 R4 is calculated. (See figure)

When the ring gear is used as the input, then the ring gear + the Sun gear divided by the ring gear = Ratio.

EXAMPLE: 34 + 20 divided by 34 = 1.58 This is now 2nd gear on a THM 350 is calculated. (See figure)

FOR OVERDRIVE, the sum of the ring gear + Sun gear is used for the input tooth count.

So, IF THE SUN GEAR IS HELD, then the ring gear divided by (ring gear + Sun gear) = Ratio

EXAMPLE: 34 divided by (34 + 20) = .63:1 Look familiar?

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 67

The A4LD, the THM 200-4R, the A-140E, the A-40D, the THM 325-4L are some of the units that use this method of getting overdrive. (See

figure)

If the ring gear is held, then the Sun gear divided by (ring gear = Sun gear) = Ratio

EXAMPLE: 20 divided by (34 + 20) = .37:1 (See figure)

REVERSE IS THE EASIEST - THE PLANET IS HELD.

The Sun gear is the input, and the ring gear is the output. The formula for this is: The ring gear divided by the Sun gear = Ratio.

EXAMPLE: 34 divided by 20 = 1.7 (See figure)

Occasionally, the ring gear is used as the input, and the Sun gear as the output.

The formula for this is: The Sun gear divided by the ring gear = Ratio.

EXAMPLE: 20 divided by 34 = .59

(See figure)

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 68

Notice that the output is overdriven.

A transmission using this method must use another planetary gear set to reduce the output. The Mercedes W3A-040 is a good example of this

To get more than one gear forward and a reverse, requires multiple, or compound planetary gear sets.

Two of the most common of these are the SIMPSON GEAR SET, used in transmissions like the THM 350, the Ford C-4, and the TF 6 & 8, and the

RAVIGNEAUX GEAR SET, found in transmissions such as the FMX, the AOD, and the T-35.

Figuring out all the ratios for these transmissions is a little tricky, so I'll give you the formulas, and let you figure out how these formulas were

derived.

THE SIMPSON GEAR SET:

For this example I'll use a THM 200, which has 74 TEETH ON THE FRONT RING GEAR, 42 TEETH ON THE FRONT SUN GEAR, 30

TEETH ON THE REAR SUN GEAR, AND 62 TEETH ON THE REAR RING GEAR.

The formula for 1ST GEAR is: rear ring divided by rear Sun x front Sun plus front Sun + front ring divided by front ring.

EXAMPLE: On the THM 200, it would be:

62 divided by 30 x 42 + 42 + 74 divided by 74 = 2.74:1

SECOND GEAR is easy: Front Sun + front ring divided by front ring.

EXAMPLE: 42 + 74 divided by 74 = 1.57:1

THIRD GEAR is Direct Drive, or 1:1

REVERSE is rear ring divided by rear Sun

EXAMPLE: 62 divided by 30 = 2.06

THM 440-T4 (BACKWARDS SIMPSON):

The THM 440 T4 is sort of a backwards version of a Simpson gear set, and although it looks complicated, it really is very simple.

The front Sun gear has 26 teeth, while the rear Sun gear has 42. The front ring gear has 62 teeth, but keep in mind that it is part of the rear carrier,

just as the rear ring gear is part of the front carrier, with a tooth count of 74.

As I said earlier, the THM 440 T4 is sort of a backwards version of a Simpson gear set, so in figuring the ratio for 1ST GEAR -- it is identical,

except you substitute the words "front" and "rear" in the appropriate places. Front ring divided by front sun x rear Sun + rear Sun + rear ring

divided by rear ring = Ratio

EXAMPLE: 62 divided by 26 x 42 + 42 + 74 divided by 74 = 2.92:1

2ND GEAR: Rear Sun + rear ring divided by rear ring

Example: 42 + 74 divided by 74 = 1.57:1

3RD GEAR: Direct Drive, or 1:1

4TH GEAR: Front ring divided by (front Sun + front ring = Ratio

EXAMPLE: 62 divided by (26 + 62) = .74:1

RAVIGNEAUX GEAR SET:

This is considered a compound gear set, and for this example I'll use an AOD, which has:

36 teeth on the front Sun gear

30 teeth on the rear Sun gear, and

72 teeth on the ring gear

The formula for first gear is: Ring gear divided by rear Sun gear = Ratio

EXAMPLE: 72 divided by 30 = 2.4:1

SECOND GEAR formula is: Rear Sun + front Sun divided by rear Sun x Ring divided by (Ring + front Sun)

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 69

EXAMPLE: (30 + 36) divided by 30 x 72 divided by (72 + 36) = Ratio 66 divided by 30 x 72 divided by 108 = 1.47

THIRD GEAR is Direct, or 1:1

FOURTH GEAR is: Ring gear divided by (ring gear + front Sun gear) = Ratio

EXAMPLE: 72 divided by (72 + 36) = .67:1

REVERSE on a Ford AOD is: Ring gear divided by front Sun gear.

EXAMPLE: 72 divided by 36 = 2:1

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ24461 Date: 110414

Fuel System - E10 Petrol Fuel Requirements

Title E10 Petro Fuel Requirements

Ref No US24461.1.0 en-GB

Issuer -

Partner 3 US 7510 Volvo Cars North America

Func Group 2300 Func Desc fuel system, exclusive gas propulsion

Status Released

Status Date 2011-05-17

Issue date 2011-04-14

Reference VIDA

Attachment

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 28

Vehicle Type

CSC

DTC

Text

Note!

If using a printed copy of this Technical Journal, first check for the latest online version.

DESCRIPTION:

Today's petrol engines are very sensitive to fuel quality and contaminations.

Fuel not fulfilling the demands according to Volvo's recommendation will cause increased engine wear engine damages and engines not performing

as specified.

Petrol with 10% ethanol (E10) is cleared for use in all Volvo cars with petrol engines introduced to the market since 1976 based upon servicing and

other conditions according to the equipment and material with which the vehicle was originally equipped.

There is a test in VIDA used to determine the amount of ethanol in the fuel. See VIDA:

INFORMATION> Fault Tracing> General Diagnostics and tests> Engine with mounting and equipment> Ignition and control systems> Control

system fuel supply> Measuring the ethanol content.

NOTE!

No after market additives are allowed.

that the vehicle is not used for extended periods.1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # SB77-006 Date: 111103

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 26

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 27

S161982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ19495 Date: 090911

A/T - Cooler/Line Flushing Information

Retailer Technical Journal 19495

Automatic transmission

cooler/lines flushing

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 92

Date 09-11-2009

Reference: VIDA, VSTG, RTJ 16724

Note!

If using a printed copy of this Retailer Technical Journal, first check for the latest online version.

NOTE!

THIS RTJ SUPERSEDES THE PREVIOUS VERSION OF RTJ 19495 RELEASED 10-8-2008. A LABOR OPERATION HAS BEEN

REMOVED. THE DESCRIPTION OF BURNT OIL HAS BEEN EDITED. PLEASE UPDATE YOUR FILES.

AFFECTED VEHICLES:

DESCRIPTION:

The purpose of this RTJ is to work as a guideline for technicians when an automatic transmission is being replaced. In order for modern automatic

transmissions to properly adapt to transmission wear while maintaining comfortable shift quality, the pressure control is closely monitored. For this

reason, the automatic transmission fluid (ATF) must meet the transmission manufacturer's specifications.

A faulty transmission often has debris in the ATF, the coolers, the lines, and throughout the transmission. This debris must be properly flushed out

before a new transmission is installed. Flushing the ATF using the transmission oil pump of the newly installed transmission will not suffice and

can possibly cause damage to the new unit. Depending on the condition of the ATF, the transmission coolers and lines may need to be replaced.

The information below is copied directly from VIDA.

SERVICE:

Once a transmission is properly diagnosed to be faulty and needs to be replaced, it is important that the proper procedures are followed for flushing

out the used ATF from the ATF coolers and lines. Note that some vehicles have two coolers; the cooler in the side of the radiator and the auxiliary

cooler.

When an automatic transmission is replaced, follow VIDA to reset adaptive memory. Simply disconnecting the TCM (Transmission Control

Module) or power from the TCM does not reset adaptive memory!

On all vehicles, always flush the radiator, coolers, and lines before installing the new transmission. The guidelines and procedures for flushing vary

with each model.

There is a procedure for flushing coolers and lines found in a hyperlink in the VIDA transmission/gearbox installation procedure called

Transmission, preparations before installing for AW (Aisin Warner) 5- and 6- speed automatics and in the VIDA transmission replacement

procedure for the AW 4-speed automatic.

The guidelines for flushing coolers on a GM 4T65 4-speed automatic are in VIDA/Information/Repair/Transmission, removing and there is a

hyperlink in VIDA/Information/Repair/Transmission, installing for a flushing procedure called Oil cooler, flush cleaning. The guidelines for the

1999-2005 S80 will be updated to match the XC90.

More details about these guidelines can be found below.

On a GM 4T65 (2003-2005 XC90 T6 and 1999-2005 580 6-cyl), if there is:

^ glycol in the transmission fluid (refer to RTJ 16724 for more information on checking for glycol contamination), this would indicate an internal

leak in the radiator requiring complete replacement of the ATF cooling system (radiator, auxiliary cooler [if applicable*], and cooler lines).

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 93

^ metal in the transmission fluid, this would indicate an internal transmission problem. Note! Metal in the ATF is nearly impossible to flush out

completely. In order to be rid of all metal particles, complete replacement of the ATF cooling system (radiator, auxiliary cooler [if applicable*],

and cooler lines) is required. See photo.

^ fine black sediment in the pan or on the pan magnet, this is normal. This can be flushed out according to VIDA. See photo.

^ dirty oil or burnt oil, this would indicate friction component (band or clutch disc) breakdown and in order to be sure all of the debris is out of

the ATF cooling system, complete replacement of the ATF cooling system (radiator, auxiliary cooler [if applicable*], and cooler lines) is

required. See photo.

*Note! All 2003-2005 XC90 T6 vehicles have an auxiliary automatic transmission fluid cooler.

Labor operation code 49115 should be used when the ATF cooling system is flushed, not replaced.

WARRANTY CLAIM INFORMATION

1984 VOLVO GLT1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 881A Date: 000701

Seat Belt - Extensions

GROUP:

88

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 73

NO:

1A

ISSUING DEPARTMENT:

Parts Support

CAR MARKET:

U.S. and Canada

DATE:

July 2000

TITLE:

SEAT BELT EXTENDER

200, 700/900, 850, S/V/C70, S/V90, S80, S/V40

REFERENCE BULLETINS:

Supersedes: SMB 88-1A, Jan. 2000

A front seat belt extender is available for owners who require one.

Seat Belt Extender forms must be faxed to Parts Support. In the U.S., fax to (201) 784-4551. In Canada, fax to (416) 493-8754. The original signed

order form should be kept in the retailer's file.

WARNING:

Seat belt extenders MUST NOT BE USED FOR THE REAR SEATS.

NOTE:

This is not a comfort item. It is intended only for persons who are physically unable to use the standard seat belt assembly. The extender is

strictly for use by these persons only, and can be ordered only by using the special ordering form attached.

Before ordering, please be certain that all seat adjustment possibilities have been considered. Also check for proper operation of the retractor and

latch before and after installing the extender.

Three seat belt and extender combinations are available.

APPLICATION:

240

From 1975 MY to 1987 MY (244 chassis No. ->257599, chassis No. ->750769), use Extender Type A. NOTICE: Seatbelt and catch must be

changed to:

240

From MY 1987 and up (244 chassis No.257600->, 245 chassis No. 750770->), use Extender Type A.

740/760

From 1983 MY to 1990 MY, (744 chassis No.-> 396999, 745 chassis No.-> 242699, 764 chassis No.->76899 and 765 chassis No.-> 31199) use

Extender Type A or B. (see part number below).

NOTE:

If the car has a single-retractor belt, a dual-retractor seat belt system must be installed according to instructions found on page 338 of Service

Manual TP 31127/1; Body, Interior, Climate.

From 1990 MY (744, Chassis No.397000->, 745 Chassis No.242700->, 764 Chassis No. 76900->, 765 Chassis No. 31200->)and up, use Type D.

780

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 74

From 1987 MY, up to and including part of 1990 MY (780 Chassis No.-> 9964), use Extender Type A.

From part of 1990 MY (780 Chassis No.9965->) and up, use Extender Type D.

900

From 1991 and up, use Extender Type D.

850

From 1993 and up, use Extender Type D.

Note: For MY93 850 cars with Chassis Nos. below 44448, where an extender is needed, belt catches must be changed. Pivot type catch P/N

9136184 (driver's side) and P/N 9136185 (passenger's side) must always be used in combination with the extender. New catches will be provided

with the extender if the Chassis No. is below 44448.

S/V40, S/V/C70, S/V90, S80

From 1998 and up, use Extender Type D.

Extender Type A can be used in conjunction with the seat belts shown.

Extender Type B can be used in conjunction with the belts shown.

Extender Type D can be used in conjunction with the seat belts shown.

Extender Type D can also be used in conjunction with all front seat belts in the following models: S/V/C7O, S80, S/V90

Seat Belt P/N Labeling:

Part numbers of seat belts are on labels sewn onto the belt webbing (see illustration). At the time of installation, the retailer is responsible for testing

the extender in the customer's vehicle to be sure that the correct extender/seat belt combination is used.

ORDERING PROCEDURES:

1. The retailer should complete the attached order form and secure the customer's signature, then FAX the form to Parts Support. Hand or mail a

photocopy of the completed form to the customer. You must retain the original form for the retailer file for legal purposes.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 75

Note:

No extenders will be shipped without a completed order form, properly signed by the customer.

2. Parts Support will enter the order, which will then be sent to the retailer on a "drop ship" basis from the distribution center.

SEAT BELT EXTENDER ORDER FORM

SEAT BELT EXTENDER SAFETY WARNINGS

NOTICE!

The Volvo front seat belt extender is intended for use only by persons who are physically unable to use the standard seat belt assembly. Even

when the seat belt extender is properly installed and in use, the vehicle's safety restraint system may provide the user with less protection than

when the standard seat belt assembly alone is used.

RULES FOR USE OF A VOLVO FRONT SEAT BELT EXTENDER

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 76

The Volvo front seat belt extender must be used only as described below:

^ The seat belt extender may be used only for the vehicle and seat for which the extender was purchased.

The extender is not designed to work in any other make or model of vehicle or with any other seat.

^ The seat belt extender may be used only by the intended user. Use by other persons may result in decreased protection to them in the event of a

collision.

^ The seat belt extender must not be used for rear seats. Extenders are not designed to work with rear seats or seat belts.

^ When the extender is installed, the intended user seated in that position must buckle his or her seat belt, whether required by local law or not.

^ When not in use by the intended user, the seat belt extender must be removed from the seat belt buckle.

SEAT BELTS, SEAT BELT EXTENDERS, AND THE VOLVO SUPPLEMENTAL SAFETY RESTRAINT SYSTEM

From model year 1998 and up, the Volvo Supplemental Safety Restraint System (SRS) uses a two-threshold airbag deployment system that relies

upon information provided by sensors linked to the front seat belt buckles. These sensors tell the SRS whether or not the seat belt is buckled. In a

frontal collision, the airbag of an unbuckled seat position may deploy even if the airbag of a buckled seat position does not.

If either a seat belt or seat belt extender tab is inserted into the the seat belt buckle, the SRS will believe that a seat belt is in proper use. Therefore,

in a frontal collision, if the extender is installed and the seat belt is not properly used, the affected airbag may not deploy or may not deploy with

appropriate force!

VOLVO STRONGLY URGES YOU AND ALL ADULT OCCUPANTS OF YOUR CAR TO PROPERLY WEAR SEAT BELTS AND TO

ENSURE THAT CHILDREN ARE PROPERLY RESTRAINED IN THE REAR SEAT.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ24188 Date: 110121

Electrical - Lead Acid Battery Handling Precautions

Title Safety Precautions When Working With Lead Acid Batteries

Ref No US24188.1.1 en-GB

Issuer -

Partner 3 US 7510 Volvo Cars North America

Func Group 3110 Func Desc battery

Status Released

Status Date 2011-01-21

Issue Date 2011-01-19

Reference

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 29

Attachment

Vehicle Type

CSC

DTC

Text

DESCRIPTION:

Lead acid batteries that are in common use in most automotive applications can be dangerous it net handled properly in the workshop. Charging a

Lead acid battery either from the vehicle's charging system or an external charger will produce Oxygen and Hydrogen gas. Oxygen is formed at the

positive plate and hydrogen at the negative plate. Hydrogen gas when mixed with oxygen in the right concentration will produce an extremely

explosive mixture. Battery explosions can be violent and may cause serious burns from the sulfuric acid mixture contained within the cells if the

case bursts.

See TJ24188 attachment. pdf for an example of a battery that has exploded.

All batteries are equipped with ventilation systems to minimize the hydrogen concentration around the battery but there is still a risk of these

explosive gases concentrating around the battery when servicing the vehicle. Therefore if a battery's ventilation system is blocked improperly

installed or if the battery case is cracked there is a possibility that the hydrogen/oxygen mixture may be concentrated around the top of the battery

case. It is important to note that Hydrogen is lighter than air. This mixture can therefore be ignited from the resultant spark of a disconnected

battery terminal or any other ignition source.

SERVICE:

To avoid serious injury always observe the following precautions when working around lead acid batteries:

^ ALWAYS wear safety goggles and protective gloves when working around batteries

^ Know where the closest eye station is located in your shop

^ Always provide for proper ventilation in the battery containment area

^ Keep metal tools and jewelry away from an exposed battery to avoid short circuiting the terminals.

^ Inspect for defective cables, loose connections, corroded cable connectors or battery terminals, cracked cases or covers, loose hold-down clamps

and deformed or loose terminal post before a disconnection occurs.

^ Always ensure that the vehicle ignition is OFF and the car is in Sleep mode on later model Volvo products or the current drain is as small as

possible before making any disconnection. Disconnecting circuits where there is current flow will cause a spark.

^ If a case is cracked or there is excessive corrosion around the terminal, make the disconnection as far away from the battery as possible. If

necessary, first disconnect the ground from the chassis and engine termination and not the battery end. This will keep the spark as far as possible

from a gassing battery.

^ When connecting a battery charger or an external power supply, always make the positive connection at the battery B+ terminal first and then the

negative connection at the chassis or engine ground as far away from the battery as possible.

^ If acid gets into your eyes, flush immediately with water for 15 minutes, and then promptly seek medical attention.

^ If acid gets on your skin, rinse the affected area immediately with large amounts of water. Seek medical attention if the chemical burns appear to

be a second degree or greater.

Please also see VIDA/Information/Product specifications/Design and Function/Battery for more detailed information on battery design.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 30

NOTES

1. Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

2. In case of leak spill ignition or explosion refer to the material data safety sheet (MSDS) and follow appropriate workplace safety procedures.

3. If you need to dispose of lead acid or any other type of batteries please ensure that they are disposed of in an environmentally safe manner or in

accordance with your local town municipally recycling procedures.

INFORMATION FOR NELCO GLY-TEK KIT1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ21507 Date: 090930

Engine - Pressure Washing Precautions

Retailer Technical Journal 21507

Pressure washing engines

Date 09-30-2009

Reference: VIDA

Note!

If using a printed copy of this Retailer Technical Journal, first check for the latest online version.

AFFECTED VEHICLES:

DESCRIPTION:

VCNA suggests that in general engines and engine compartments not be washed with high pressure water due to the following points:

^ Increased amount of electronic equipment installed in the compartment.

^ Run off water could be contaminated with toxic fluids if there are leaks present.

The components are protected from road water spray with various devices such as the lower splash shield and weather proof seals on the protective

covers, but are not designed to prevent high pressure water from getting in.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 91

The areas circled are very sensitive to direct water pressure and should be avoided.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TNN88-41 Date: 060712

Air Bag System - System Life Expectancy

No: 88-41

DATE: 7-12-2006

MODEL:

All Models with Supplemental Restraint System (SRS)

MODEL YEAR:

All Model Years with Supplemental Restraint System (SRS)

SUBJECT:

Extended Supplemental Restraint System (SRS) Lifetime

REFERENCE: SMB 88-0017

DESCRIPTION:

BACKGROUND:

Based on testing and experience since the 1980's, Volvo has extended the lifetime of the Supplemental Restraint System (SRS) components to be

the same as the lifetime of the car.

This lifetime extension supersedes all previous publications concerning Supplemental Restraint System (SRS) component lifetime. Periodic

inspections and servicing of the Supplemental Restraint System (SRS) components, based solely on the age of the vehicle, are no longer required.

The lifetime extension applies to all pyrotechnic components in vehicles equipped with Supplemental Restraint System (SRS):

^ Driver airbag module

^ Passenger airbag module

^ Seat belts with pyrotechnic seat belt pretensioners

^ SIPS (Side Impact Protection System) airbag module

^ IC (Inflatable Curtain) airbag module

^ Adaptive Steering Column (ASC)

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 77

^ Adaptive Load Limiter (ADLL)

Note:

Equipment is different for different car models.

SERVICE:

Note!

If the vehicle has been involved in a collision, regardless of crash severity, or if the SRS warning lamp is lit, immediately contact an authorized

Volvo dealer for further action and inspection.

TEMPORARY SOLUTION:

For customers who want to make an appointment for an inspection, explain the situation using this Tech Net Note.

For customers who still want to have an inspection, carry out the inspection and remove the SRS Airbag Service Decal from the vehicle according

to the SRS Airbag Service Decal Removal Instruction below. Explain that no further inspection is necessary.

In case replacement of components is required, remove the SRS Airbag Service Decal from the vehicle according to the SRS Airbag Service Decal

Removal Instruction below and explain that no further inspection is necessary after the replacement.

FINAL SOLUTION:

VIDA will be updated with information about the service life of pyrotechnic components on a running basis. All vehicles equipped with

Supplemental Restraint System (SRS) are affected.

Path for general information in VIDA:

Information / Repair / General information / 8 Body and interior / 88 Interior equipment / General / Service life pyrotechnic components

VIDA will be updated regarding Supplemental Restraint System (SRS) components in the service programs on a running basis. All vehicles

equipped with Supplemental Restraint System (SRS) are affected.

Path for service and maintenance in VIDA:

Information / Repair / 1 Service programs / 17 Standard parts, service and maintenance material / Service and maintenance / Maintenance service /

Service program A + B

VIDA will be updated regarding repair methods from MY 2007 onward.

Path for repair methods in VIDA:

Information / Repair / Removal, replacement and installation / 8 Body and interior / 88 Interior equipment / Seat belts and other retention systems

Note!

From MY 2007, the SRS Airbag Service Decal on the B or C pillar will no longer be fitted at Volvo (concerns all models/variants).

SRS Airbag Service Decal Removal Instruction

General

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 78

Note!

Since the illustrations are used for different model years and/or model variants, there may be certain deviations. However, the essential

information in the illustrations is always correct.

The SRS Airbag Service Decal is found on either the B or the C pillar, depending on model/variant.

Removal

Warm the SRS Airbag Service Decal carefully using a hot air gun.

Scrape up a corner using a plastic scraper and pull off the SRS Airbag Service Decal.

Cleaning

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 79

Clean the area using a mixture of 50% isopropanol and 50% water.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB8754 Date: 870901

A/T - Front Bushing Wear

TSB 87-54 (Sept)

SUBJECT: ALL AUTOMATICS

PROBLEM: Front Bushing Wear

CAUSE:

When diagnosing front pump bushing wear, the cause may be:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 62

1. Excessive CONVERTER HUB RUN-OUT. This may, or may not be due to a faulty torque converter.

The torque converter can be checked visually, and with a dial indicator. (See Figure 1) Hub run-out should not exceed .010".

2. BROKEN, BENT OR CRACKED FLYWHEELS can also cause run-out. If the torque-converter-to-flywheel bolts have been loose, the

flywheel holes can become egg-shaped, or the torque converter pads may wear into the flywheel, causing run-out.

3. Another possibility is WEAR IN THE CRANKSHAFT, where it supports the torque converter pilot.(See Figure 2)

Often the crankshaft is only worn in a small area where the torque converter pilot has been against it.

If only a portion of the crankshaft is worn, rotate the crankshaft until the worn area is at 12:00 o'clock.

When the torque converter is pushed forward into the crankshaft, the torque converter pilot will bottom on a good portion, and should center

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 23132 Date: 860601

Fuel Pump - Noise, Hesitation and Lack of Power

Subject: Product

NEW PRE-PUMP CARS

1979 -

WITH FUEL Group

INJECTION

ENGINES 23

Date: No.

JUNE 1986 132

THIS BULLETIN APPLIES TO THE U.S. AND CANADA; AND SUPERCEDES P20 SB 23-132 ISSUED MAY 1986.

NOTE: New information is highlighted in the margin.

Foam formation in the fuel tank can affect fuel supply causing fuel pump noise and, in extreme cases, hesitation and lack of power. Vehicles

operated in areas of high ambient temperature and/or high altitude are more subject to this condition.

To improve fuel supply, a new pre-pump with higher fuel delivery capacity is now available.

New Pre-Pump Specifications:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 35

Current consumption 3-5 Amp

Min. fuel pressure (at 12V and

delivery of 140 1/hr) 30kPa (4.4 psi)

REQUIRED Description Part Number Quantity

PARTS:

(all models) pre-pump 1389436-5 1

O-ring 949276-0 1

rubber hose 1389440-7 1

nut 150205-3 2

filter 1274817-4 1

Additional parts for:

(1979-1983 models) hose clamp 945650-0 2

screw 947279-6 2

spring nut 942866-5 1

spring nut 967770-9 1

spring bracket 1312388-0 1

bracket 1312390-6 1

hook 1389437-3 1

SPECIAL TOOL: wrench 9995169-1

New Pre-Pump, Installing

Work sequence

WARNING:

Disconnect battery ground cable before starting work on fuel/electrical system.

1979-1983 models

Remove:

- screw 5

- nuts (11) and washers 10

- pre-pump (9) with bracket (8) and filter 7

- rubber hose 4

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 36

Cut 30 mm (1-3/16 in.) off the pressure pipe (arrow).

Grind off any sharp edges.

CAUTION:

Flush pipe with mineral spirits after machining to prevent metal shavings from damaging (seizing) the main fuel pump.

Install:

- spring bracket, P/N 1312388-0, to pump mounting bracket, P/N 1312390-6, using spring nut, P/N 967770-9, and screw, P/N 947279-6.

- pump mounting bracket to pre-pump, P/N 1389436-5, with hook, P/N 1389437-3, positioned between bracket and pump to secure pump.

Install:

- rubber hose (2), P/N 1389440-7, with hose clamps (3), P/N 945650-0, to pressure pipe and pre-pump assembly (1).

- nuts (4), P/N 150205-3, and washers.

- pre-pump assembly (1) to sender using spring nut, P/N 942866-5, and screw, P/N 947279-6.

- filter (5), P/N 1274817-4.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 37

NOTE: Position pre-pump so it is free from contact with the sender.

Install fuel gauge sender in fuel tank using wrench 5169 and new O-ring, P/N 949276-0.

1984 - models

Remove:

- filter 7

- pre-pump bracket assembly 8

- nuts and washers 11

- hose clamps 3 pre-pump 9

Cut 30 mm (1-3/16 in.) off the pressure pipe.

Grind off any sharp edges.

CAUTION:

Flush pipe with mineral spirits after machining to prevent metal shavings from damaging (seizing) the main fuel pump.

Install :

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 38

- pump mounting bracket assembly to new pre-pump, P/N 1389436-5, with hook, P/N 1389437-3, positioned between bracket and pump to

secure pump.

Install:

- rubber hose (2), P/N 1389440-7, with hose clamps (3) to pressure pipe and pre-pump.

- nuts (4), P/N 150205-3, and washers

- pre-pump assembly (1) to sender

- filter (5), P/N 1274817-4.

NOTE: Position pre-pump so it is free from contact with the sender.

Install fuel gauge sender in fuel tank using wrench 5169 and new o-ring, P/N 949276-0.

Warranty Info.

During the New Car Warranty, claims must be submitted as follows:

Operation No. Labor Description Time Allowance

233133 Pre-pump, replace 0.7 hr.

Includes: remove sender

87426-2 Replacing magnetic clutch 1.2 hr1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 228206 Date: 961001

Engine Management Systems - Parts, Information

SECTION

2

GROUP

28

NO.

206

DATE

Oct. 1996

RE:

Fuel injection/ignition systems and control modules

200, 4 cyl. F engines

REFERENCE: TP 30869/1, SECTION 2 (20-22), ENGINE B230F; 240 1985-19..

Engine management systems and control modules for 200, 4cyl. F engines

The number of engine management systems and variants has increased over the years.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 48

The tables contain the type of fuel injection system, ignition system and control module P/N for each engine type and model year.

The P/Ns apply to factory installed control modules. Replacement part numbers may vary depending on whether the control module is a

replacement unit or not. If necessary compare with the cross-list.

Note that some systems are only available in certain markets and may not be available in your market.

1982 VOLVO GL1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 665203 Date: 970101

Tools - Replacing Trailing Arm Bushing

SECTION

6

GROUP

65

NO.

203

DATE

Jan. 1997

RE:

Replacing trailing and bushing

200

REFERENCE:

TP 30125/2, SECTION 6 (65) REAR WHEEL SUSPENSION; 240/260 1975-

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 49

Replacing trailing arm bushing

Background:

A new press tool to suit air/hydraulic presses for removing and installing trailing arm bushing on the rear axle. This Service Bulletin covers

replacing the trailing arm bushing with these press tools.

Materials: Screw 947564-1

Nut 971085-6

Bushing 1229165-4

Shop Equipment required: Underhoist utility stand or transmission jack.

Tool: Hydraulic pump, air-driven 9512615-7 or 9512564-7

alternative Hydraulic pump 9995576-7

Puller cylinder (included in hydraulic pump

kits identified above) 9995575.9

Puller rod (included in hydraulic pump

kits identified above) 9995592-4

Spacer sleeve 9995079-2

Press tool (5568, 5568-1 and 5568-2) 9995568-4

The tools are further described in Special Tool Bulletin no. 96

Removing trailing arm bushing

Removing screw for trailing arm

Raise the car:

- use a 2 pillar hoist.

Lift rear axle:

- position the mobile jack under the rear axle and apply slight pressure.

Remove:

- the screw from trailing arm mounting to rear axle.

Removing trailing arm bushing

Lift rear axle:

- press up rear axle so that trailing arm bushing is accessible.

Take out:

- hydraulic pump 9512564-7 or 2615-7 or 5576-7.

- puller cylinder (puller tool) 5575-9.

Install:

- spacer sleeve 5079-2 (B) between mountings on the rear axle. (Hammer the spacer sleeve with a drift to fix it securely against the bushing.)

Install:

- puller rod 5592-4 in the pulling tool.

- counterhold 5568 (A) on the puller tool. (Turn the counterhold so that the bushing can be pushed in with it.)

- puller tool and counterhold (A) to rear axle inner trailing arm mounting according to upper illustration.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 50

- drift 5568-1(C) against bushing according to upper illustration.

Press:

- trailing arm bushing out of rear axle mounting to position E, according to lower illustration.

Installing trailing arm bushing

Install:

- counterhold 5568 (A) on the puller tool. (Turn counterhold so that the bushing cannot be pressed into it).

- a new trailing arm bushing on pulling tool. NOTE! The center hole in the bushing is displaced and bushing is installed with sockets (1)

horizontal and with arrow (2) downwards.

- the bushing (E) loosely in the rear axle mounting.

- drift 5568-2 (D) as illustrated, against rear axle outer trailing arm mounting.

Press:

- the bushing (E) into rear axle mounting until the counterhold 5568 (A) is tight to the mounting.

Removing tools

Remove:

- press tools.

- spacer sleeve 5079-2.

Installing screw

Operations:

- lower rear axle so that the holes in the bushing and the trailing arm are aligned.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 51

- install a new screw (P/N 947564-1).

- install a new nut (P/N 971085-6).

NOTE!

Do not tighten screw.

- lower the car.

- move the car to a ramp.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB9002006 Date: 900201

A/T - Choosing the Right ATF

TRANSMISSION: ALL

BULLETIN: # 9002006

SUBJECT: Automatic Transmission Fluid

DATE: Feb 1990

AUTOMATIC TRANSMISSION FLUID

CHOOSING YOUR ATF

Different ATF's (Automatic Transmission Fluid) can have different frictional properties which can produce different shift characteristics. You may

have already experienced problems like lock-up shudder, or squawks on shifts and have corrected them by changing the fluid. This alone tells, you

that friction material and fluids are critical in today's cars.

MEETING THE O.E.M. SPECIFICATIONS

The first thing to consider when choosing an ATF is "Does it meet the O.E.M. specification?" ATF's wishing to be labeled as DEXRON II and/or

MERCON must first meet the respective minimum requirements. It's important to note that even though the specification for DEXRON II and

MERCON are currently very similar, THEY ARE NOT IDENTICAL. Also note, even fluids which meet the same specification may not be

identical. One fluid may just meet a specification and, another may far surpass it. You should know what your fluids properties are! You can get

that information from your fluid supplier.

EVALUATING YOUR FLUID

Ask your supplier to prove (certify) that the fluid meets O.E.M. specifications (MERCON OR DEXRON II). He will do that by supplying you with

the license (certification) number issued to him by the O.E.M.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 70

A DEXRON-II license number (sometimes referred to as a "D" number) will always start D-2. A typical DEXRON license number can be seen in

Figure 2.

MERCON license numbers will be six digits starting with M as shown in Figure 3..

TRY TO MEET SEVERAL SPECIFICATIONS!

DEXRON II and MERCON have different minimum specifications, so a product that meets BOTH specifications may be better then those meeting

only one spec. Meeting other specs, in addition to the first two can be an added benefit. If a fluid is licensed as DEXRON II AND MERCON as

well as others like Allison C-4, or Caterpillar TO-2/TO-4, it means the fluid had to pass more tests and may be a better fluid.

Lastly, demand that the license numbers be placed on all your invoices especially if you buy in bulk. If your supplier is unwilling, it is very likely

that they are supplying you an unlicensed fluid. Licensed suppliers are required to supply the license numbers to their customers as part of their

agreement with the O.E.M.

OTHER THINGS TO CHECK

So now you've narrowed your choices down to a few suppliers that have O.E.M. license numbers. How do you compare two fluids that meet the

same O.E.M. Spec.? Ask your supplier to give you the viscometrics on the fluid you buy.

An excellent "bench mark of the overall quality of a fluid is its viscosity at -40 degrees. This is measured in "centipoise" or "cPs". DEXRON II

specification says viscosity will be no more then 50,000 cPs @ - 40 degrees. (Some poor fluids have tested at over 1,000,000 cPs) In general, the

lower the number, the better the fluid.

Keep in mind that as the number goes down the price of the fluid usually goes up. (You get what you pay for) Most good fluids will average around

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 71

35,000 cPs. Hydrotreated (or Hydrocracked) fluids average around 20,000 cPs or less. (Hydrotreating is a refining process done to the base oil to

clean out contaminants or impurities) Synthetic ATF's average 10,000 cPs or less, and some are as low as 5000 cPs. Viscosity at -40 degrees is a

function of the base stock from which the ATF is made. A low number indicates a premium base oil OR an expensive refining process.

(Hydrotreating)

FOR ADDITIONAL INFORMATION:

Transmission Digest August '89

Page 91 December '89 Page 51

BULLETIN RECAP

^ Only use fluids with O.E.M. approvals.

^ Try to get a fluid that meets more than one spec (e.g DEXRON II AND MERCON)

^ Check the viscosity at -40 degrees. The lower the number the better.

^ Avoid bargain basement fluids with no license numbers.

81911-2 Modifying in windshield frame 0.2 hr.1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB028 Date: 901001

A/T - Engine Vacuum Testing

BULLETIN: # 028

DATE: October 1990

SUBJECT: Engine Testing With A Vacuum Gauge

TRANSMISSION: All

Engine Testing With A Vacuum Gauge

ENGINE/TRANSMISSION RELATIONS

An important part of transmission diagnosis is to make certain the engine operates properly. If the engine performance is incorrect, the transmission

will receive the wrong information.

The engine sends signals to the transmission through a vacuum line, throttle cable or both. These signals basically synchronize torque with

transmission line pressure, shift feel and shift timing.

Malfunctions in items like the air filter, spark plugs, EGR valves and other parts of the fuel, electrical and emission systems could result in

improper transmission performance.

VACUUM GAUGE ENGINE PERFORMANCE TESTING

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 57

A vacuum gauge shows the difference between outside atmospheric pressure and the amount of vacuum present in the intake manifold.

The pistons in the engine serve as suction pumps and the amount of vacuum they create is affected by the related actions of:

^ Piston rings

^ Valves

^ Ignition system

^ Fuel control system

^ Other parts affecting the combustion process (emission devices, etc.).

Each has a characteristic effect on vacuum and you judge their performance by watching variations from normal.

It is important to judge engine performance by the general location and action of the needle on a vacuum gauge, rather than just by a vacuum

reading. Gauge readings which may be found are as follows:

NORMAL ENGINE OPERATION

At idling speed, an engine at sea level should show a steady vacuum reading between 14" and 22" HG. A quick opening and closing of the throttle

should cause vacuum to drop below 5" then rebound to 23" or more. See figure 1.

GENERAL IGNITION TROUBLES OR STICKING VALVES

With the engine idling, continued fluctuation of 1 to 2 inches may indicate an ignition problem. Check the spark plugs, spark plug gap, primary

ignition circuit, high tension cables, distributor cap or ignition coil. Fluctuations of 3 to 4 inches may be sticking valves. See figure 2.

INTAKE SYSTEM LEAKAGE, VALVE TIMING, OR LOW COMPRESSION

A vacuum reading at idle much lower than normal can indicate leakage through intake manifold gaskets, manifold-to-carburetor gaskets, vacuum

brakes or the vacuum modulator. Low readings could also be very late valve timing or worn piston rings. See figure 3.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 58

EXHAUST BACK PRESSURE

Starting with the engine at idle, slowly increase engine speed to 3000 RPM, engine vacuum should be equal to or higher than idle vacuum at 3000

RPM.

If vacuum decreases at higher engine RPM's, an excessive exhaust back pressure is probably present.

CYLINDER HEAD GASKET LEAKAGE

With the engine Idling, the vacuum gauge pointer will drop sharply, every time the leak occurs. The drop will be from the steady reading shown by

the pointer to a reading of 10" to 12" Hg or less. If the leak Is between two cylinders, the drop will be much greater. You can determine the location

of the leak by compression tests. See figure 4.

FUEL CONTROL SYSTEM TROUBLES

All other systems in an engine must be functioning properly before you check the fuel control system as a cause for poor engine performance. If the

pointer has a slow floating motion of 4 to 5 inches - you should check the fuel control.

BULLETIN RECAP

^ Engine problems can affect transmission performance.

^ If you suspect an engine problem, connect a vacuum gauge to the intake manifold.

^ Note the location and action of the vacuum gauge needle.

^ Use the information in the bulletin to determine the engine problem.

^ Correct the engine problem before doing extensive calibration work on the transmission.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB8927 Date: 890901

A/T - Twenty Steps To Successful Repairs

TSB 89-27 (Sept)

SUBJECT: TWENTY STEPS TO SUCCESSFUL TRANSMISSION REPAIR

1. As you start work on a transmission, read your ATRA bulletins pertaining to that transmission. (If you do this every time, before you know it

you'll have the bulletins memorized.)

2. Clean the entire transmission, including the valve body.

3. Check pumps, valve bodies, and cases for warpage.

4. Flat file pumps, valve bodies, and cases. (Just a few strokes with the file to knock off high spots and handle burrs.)

5. Check all pump gear clearances.

6. Check planet pinion endplay and side to side motion.

7. Soak all planet assemblies.

8. Soak all friction material for 15-30 minutes.

9. Sand, tumble, or replace all steel plates.

10. Re-surface all drums on which a band rides.

11. Replace all rotating oi1 control rings.

12. Check all oil control rings, and rubber products in their bores for proper fit.

13. Replace all major support bushings and bushings that control lube oil.

14. Pre-lubricate all bushings and thrust washers.

15. Pre-lube pumps.

16. Pre-fill torque converters.

17. Use available manuals to find specifications.

18. Set correct clutch and band clearances

19. Take the time to set total unit endplay

20. Use a torque wrench on all pumps and valve bodies.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # PB77-017 Date: 120127

Wheels - Wheel Cross Reference

No.

017

GROUP

77

MARKET

United States, Canada

DATE

YEAR MONTH DAY

2012 01 27

SUBJECT

Wheel Cross Reference

Updated in this bulletin: Stamping number: 31280139, Part Number: 31269420, Size: 7.5 x 18, Name: Zepherus.

This list is provided as a cross reference for most wheels offered by Volvo Since the names and designs of the wheels are sometimes difficult to

describe, we recommend obtaining the stamping number off the wheel before trying to order.

Generally this stamping number will be a seven-digit number, found behind the center cap or on the inside rear of the wheel Before ordering wheels

, it is a good idea to ask for the stamping number.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 20

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 21

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 22

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 23

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 24

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # SB77-007 Date: 120226

Tires/Wheels - Tire Rotation Recommendations

NO:

007

GROUP:

177

ISSUING DEPARTMENT:

Service Business

CAR MARKET:

United States, Canada

DATE:

YEAR MONTH DAY

2012 01 26

TITLE:

Tire Rotation

As suspensions and drive trains evolve, so do vehicle manufacturer recommendations for tire rotation. Volvo's recommendations have always had a

technical basis, while leaving some latitude for customer preference. Presently, for current models, Volvo has no recommended tire rotation.

Customers may need the guidance of a Volvo service advisor to help them understand the performance and handling tradeoffs that come with tire

rotation. Tire wear is affected by a number of factors such as tire inflation, ambient temperature, driving style etc.

Benefits of Not Rotating Tires Braking Stability Performance

During hard braking, braking on a slippery road, or braking in a curve, good rear tire tread may help you avoid oversteer. Oversteer is when a

turning vehicle wants to keep turning because of momentum and dynamic forces on the vehicle suspension. Volvo stability systems are all designed

toward reducing or helping a driver avoid oversteer. Still, all things being equal, having more rear tire tread can contribute to reduced oversteer.

Without rotation, the rear tires will naturally wear more slowly and have more tread.

Tread Set

As tires age, the tread adopts an angular set, based on its angle to the road surface. For vehicle handling reasons, front and rear tread angle is not the

same. If tires are rotated, the tread will eventually set at an angle somewhere between what is optimal for a front or rear tire. Although vehicle ride,

handling, and road noise may still be acceptable, they may not be optimal. Additionally, an infrequently or irregularly rotated tire may result in tire

noise, faster tire wear, and unpleasant changes in steering feel and vehicle handling.

Driving Performance

A tire that can actually adapt to its position will generally provide better steering feel, lower tire noise, and better fad economy.

Suspension Wear Diagnostics

Every vehicles suspension needs periodic inspection and maintenance. A tire's tread wear pattern can be an aid in detecting and diagnosing a

suspension problem. Each tire, if left in place, tells a story about its place in the suspension. Tire rotation, on the other hand, can mask a developing

problem. Early detection is very important, because suspension problem can worsen tire wear, and reduce vehicle performance, handling, stability,

and fad economy.

Tire Rotation

If the tires are rotated, they should only be moved from front to rear or visa versa. They should never be rotated left to right/right to left.

Ideally, tire rotation should be done the first time after approximately 3,000 miles/5,000 km and thereafter at 6,000 mile/10,000 km intervals. Some

customers find that tire rotation may help to get extra mileage from tire life.

Tire rotation should only be performed if front/rear tire wear is fairly even and tread height is above 1/16" (1.6 mm).

However, with all current Volvo models, Volvo believes that numerous technical, performance, and handling benefits outweigh any perceived

benefit of tire rotation.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F9

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # NHTSA84V017000 Date: 840217

Recall 84V017000: Alternator to Starter Wire Rerouted

A WIRE LOCATED BETWEEN THE STARTER AND THE ALTERNATOR MAY RUB AGAINST THE HEAT SHIELD AT THE TURBO

CHARGER. THE WIRE WILL BE RELOCATED AND SECURED, AND DAMAGE TO THE WIRE WILL BE REPAIRED,OR THE WIRING

WILL BE REPLACED.

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH TURBO CHARGED ENGINES.

SYSTEM: ELECTRICAL; ALTERNATOR WIRING HARNESS.

CONSEQUENCES OF DEFECT: THE CHAFING MAY LEAD TO A SHORT CIRCUIT THAT CAN CAUSE PREMATURE BATTERY

DRAIN, MELTING AND BURNING OF THE WIRING HARNESS, OR AN ENGINE COMPARTMENT FIRE. INJURY TO VEHICLE

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 887214 Date: 980101

A/C Compressor Pulley And Clutch - Replacing

SECTION

8

GROUP

87

NO.

214

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 39

DATE

Jan. 1998

RE:

Supplement to Service Manual Section 8(87) Replacing pulley and magnetic clutch 200 1975-1993

REFERENCE:

TP 31120/1, SECTION 8(82-88) BODY FITTINGS, INTERIOR, HEATING AND AC; 200 1975-19..

SPECIAL TOOL BULLETIN NO. 103.

Replacing pulley and magnetic clutch on A/C compressors Supplement to Service Manual Section 8(87)

This Service Bulletin describes the method for replacing the pulley and magnetic clutch on compressors. The tools used in this method are new.

Tools: P/N:

Torque wrench

Circlip ring pliers

Puller (compressor pulley/clutch) 9995598-1

Socket with ring (compressor pulley/clutch) 9995599-9

Socket with ring (compressor pulley/clutch) 9995600-5

Socket (compressor clutch plate) 9995601-3

Tool kit for replacing shaft seal 9995602-1

Socket with ring (compressor pulley/clutch) 9995618-7

Socket with ring (compressor pulley/clutch) 9995619-5

The above tools can be found in:

Special Tool Bulletin no. 103

Preparations/Method

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 40

- Make note of radio code.

- Disconnect battery lead.

- Remove air cleaner assembly (see illustration).

- Fold back preheating hose.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 41

Slacken off the bell tensioner nuts.

Remove:

- drive belt

- diode nut and screw (3).

Separate switch (2).

Only applies to diesel engines

Remove compressor mounting screws.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 42

Remove the lower radiator hose from the mounting on the member.

Lift off the compressor and carefully hang it from the radiator hose mounting.

Applies to gasoline and diesel engines

Raise the car.

Remove splash guard under engine.

Replacing Pulley/Clutch

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 43

Removing clutch plate.

Remove screw and washer.

Use counterhold 999 5596-5.

Remove the clutch plate.

Use puller 999 5597-3.

Note position of the tool.

Keep the shims.

Removing pulley.

Remove circlip.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 44

Remove pulley.

Use puller 999 5598-1 and sleeve 999 5599-3 (or 999 5618-7).

Note position of the tools.

Removing magnet coil.

Remove:

- circlip

- magnet coil.

Installing magnet coil

Install:

- magnet coil

- circlip.

Installing pulley

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 45

Install:

- pulley loosely

- pulley using the tools: puller 999 5598-1 and sleeve 999 5599-3 (or 999 5618-7).

Note position of the tools.

Reinstall circlip.

Installing clutch plate

Install:

- shims. Ensure that the shims are reinstalled on the shaft in the same order as they were removed.

- clutch plate on compressor shaft, if necessary use puller 999 5598-1 ans sleeve 9995601-3.

- screw and washer or nut.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 46

Tighten to 15 Nm (11 ft. lbs).

Use counterhold 999 5596-5.

Check Clearance/Finishing Work

Run a feeler gauge all the way around in the gap. Clearance should be between 0.3 and 0.5 mm. 0.3 mm should pass all around the gap.

If the clearance is not between the given values, use shims to adjust clearance until it does.

Shims are available in the following dimensions:

^ 0.2 mm

^ 0.3 mm

^ 1.0 mm

Work after checking clearance

Install diode.

Connect connector.

Install:

- compressor (diesel)

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 47

- splash guard under engine

Lower the car.

Reinstall drive belt.

Tension drive belt and tighten the compressor.

Install:

- air cleaner (ACL) assembly

- preheating hose

- battery lead

Reset the clock and enter anti-theft radio code.

Function check

Operation No. Labor description Time

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ19245 Date: 100727

Vehicle - Platform Identification

TIE - Technical Journal

Title Vehicle type and platform identification

Ref No US19245.1.5 en-GB

Issure -

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 31

Partner 3US7501 Volvo Cars North Amercia

Func Group 0100 Func Desc

Status Released

Status Date 2010-07-27

Issue Date 2010-07-27

Reference

Attachment

Vehicle Type

CSC

DTC

Text

CSC* = Customer Symptom Code

NOTE!

This document supersedes the previous "RTJ 19245 - Vehicle type and platform" dated 7-01-2010. Correction to C70 (873) to include 2005 Model

Year. PLEASE UPDATE YOUR FILES.

Background:

In our Service Literature, a vehicle is often referred to by its "type" not its "model". For example the 1999 - 2006 Model Year S80 is type "184".

You may also see the designation, for example "P2X". This is referring to a platform type or vehicle family.

NOTE:

If a document states "P1X" or "5XX" as an example, it will apply to all models within the platform type. "54X" will apply to the "544", "545" and

"542" models. "X" represents variable data.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 32

The table above will clarify the vehicle type and platform designations:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 33

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # ATRATB8748 Date: 870801

A/T - Slipping or No-Shift/Metal Sealing Rings

TSB 87-48 (Aug)

SUBJECT: Metal sealing rings

Various Units

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 60

PROBLEM: Slipping, or sometimes no-shift

POSSIBLE SOLUTION: Sealing rings could be under-size.

1. Always inspect rings as outlined in SIL 84-29

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 61

2. Place ring in bore of drum where they will be running. (See Figures 1 & 2)

3. Sealing rings should be snug in bore; rings should fit all around the drum. (drum could be out-of-round)

4. Air check all drums. (Use 30 PSI air pressure only.) If air escapes you have leaks -- better find now, than later. This represents lost clutch

pressure, and could result in soft application and burned friction material.

5. Following these steps will help you save money, plus help you build better units.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ27220 Date: 121221

Engine/Drive Train - Best Before Date Use For Gasket Sealants

Technical Journal

TITLE:

Chemical gasket. Best before-date very important

CAR MARKET:

United States

ISSUING DEPARTMENT:

Technical Service

REF NO:

TJ 27220

ISSUE DATE:

YEAR

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 94

2012

MONTH

12

DAY

21

PARTNER:

3 US 7510 Volvo Cars North America

FUNC DESC:

adhesive; tape; sealant;

locking fluid

FUNC GROUP:

1870

"Fixed Right - First Time"

Attachment

Vehicle Type

CSC Customer Symptom Codes

DTC Diagnostic Trouble Codes

Text

Note!

If using a printed copy of this Technical Journal, first check for the latest online version.

DESCRIPTION:

The use of too old sealant when repairing powertrain components may cause an oil leak/high oil consumption. E.g. when resealing cam cover on 6

cylinder engines.

Always check the best before date. The product must be scrapped if the best before date is expired or is missing. Otherwise, there is a risk for

extended hardening time. The hardening will stop at temperatures

below +15 degC (59 degF), but continues when the temperature rises.

The use of too old chemical gasket may ruin an otherwise perfect job.

Photo 1 in the attachment shows the best before date, e.g. 4/13 means April 2013.

SERVICE:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 95

Never use chemical gasket with an expired or missing best before date.

Continue to view TJ attachment

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # NHTSA82V134000 Date: 821221

Recall 82V134000: Increased Wiring Connector Resistance

INCREASED RESISTANCE IN THE SYSTEM WIRING CONNECTORS DUE TO THE POSSIBLE PRESENCE OF LACQUER, PLASTIC

RESIDUE ON THE PINS AND IMPERFECT PIN DIAMETERS, MAY CAUSE IGNITION MISFIRING AND, IN EXTREME CASES,

INTERMITTENT STALLING. DEALER WILL INSPECT AND INSERT CONTACT PIN SLEEVES DESIGNED TO SCRAPE ANY

LACQUER OR UNWANTED RESIDUE AWAY. THIS WILL PRODUCE HIGHER CONTACT PRESSURE WITHIN THE CONNECTOR

AND IMPROVE THE ELECTRICAL CONNECTION.

VEHICLE DESCRIPTION: PASSENGER VEHICLES.

SYSTEM: ELECTRICAL; IGNITION, WIRING CONNECTORS. CONSEQUENCES OF DEFECT: A STALLED VEHICLE IN THE MIDST

OF TRAFFIC WOULD PRESENT A SAFETY HAZARD THAT COULD LEAD TO A VEHICLE ACCIDENT.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TNN77-18 Date: 070515

Tires - Pressure Requirements/Recommendations

NO: 77-18

DATE: 5-15-2007

MODEL:

All

MODEL YEAR:

All

SUBJECT:

Tire Pressures, Requirements and Recommendations

REFERENCE:

VIDA, SMB 17-006, owners' manuals

Description

Tire pressure is a critical element of vehicle performance. Correct tire pressure is important for:

^ achieving good fuel economy

^ achieving optimum comfort and good driving characteristics

^ helping to prevent flat-spotted tires due to low tire pressures

As stated in the Model Year 2007 owners' manuals:

^ Under-inflation is the most common cause of tire failure and may result in severe tire cracking, tread separation, or 'blow-out,' with unexpected

loss of vehicle control and increased risk of injury.

^ Under-inflated tires reduce the load carrying capacity of your vehicle.

Over-inflation is also undesirable. Over-inflated tires can be stiff and unyielding, and will cause the vehicle to ride more harshly and loudly.

Under-inflation or over-inflation may cause uneven treadwear patterns.

There are many opportunities for the Volvo retailer to check and maintain proper tire pressure, from new vehicle storage, to delivery, through the

service life of the vehicle. This TNN is designed to summarize and highlight Volvo's requirements and recommendations regarding tire pressures.

Service

GENERAL:

Tire pressures should always be checked cold. Tires are considered to be cold when they have the same temperature as the surrounding (ambient)

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 80

air. This temperature is normally reached after the vehicle has been parked for at least 3 hours.

After driving a distance of approximately 1 mile (1.6 km), tires are considered to be hot.

When the weather temperature changes, tire inflation pressures also change. A 10-degree F (5-degree C) temperature drop causes a corresponding

drop of 1 psi (7 kPa) in inflation pressure.

TRANSPORT PRESSURE:

All new Volvo vehicles are delivered from the port to the retail facility with tires at 'transport pressure', which is 43 psi (300 kPa). As indicated in

Service Manager Bulletin 17-006, Retail Car Delivery Process, Stock Maintenance checks require that tire pressure be checked every 60 days, and

be maintained at 43 psi (300 kPa). This is also true for vehicles on static display, such as the showroom or outside display areas. This transport

pressure must be maintained until just before retail delivery.

Note!

Failure to maintain transport pressure in tires may result in tire damage not covered by the tire manufacturer's warranty.

CPS (CUSTOMER PREPARATION SERVICE):

SMB 17-006 also gives detailed information regarding operations to conduct during the CPS (Customer Preparation Service).

Note!

CPS should only be completed just prior to actual retail delivery of the vehicle to the customer.

Model Year 2007 U.S. specification vehicles have only one recommended tire pressure. This is the case whether the vehicle is equipped with a Tire

Pressure Monitoring System (TPMS) or not. It is critical during CPS (and whenever tire pressures are checked and set) that all 4 tires be set exactly

to the tire pressure indicated on the tire pressure label. This will assure that the customer has the best combination of ride, handling, and tire life.

Canadian specification vehicles continue to use labels with both a cold tire pressure and an optional tire pressure.

In all cases:

Use the recommended cold inflation pressure for optimum tire performance and wear.

NITROGEN:

There have been reports in the industry regarding the use of nitrogen for inflating tires. Volvo's position is that nitrogen is not required when

servicing tires. While it is not harmful to use, it is also not necessary. This is true even for vehicles with TPMS.

CALIBRATION OF TIRE PRESSURE MEASURING EQUIPMENT:

VIDA can be used to check a vehicle's tire pressures.

This is the path in VIDA to follow:

Diagnostics > Vehicle communication > UEM> Advanced > Quick Test

As the tire pressure displayed in VIDA is extremely accurate, this display can be used to 'calibrate' tire pressure measuring equipment in the service

workshop. Compare the VIDA reading with a tire pressure gauge, and compensate accordingly.

TPMS (TIRE PRESSURE MONITORING SYSTEM):

TPMS (Tire Pressure Monitoring System) was optional on certain Model Year 2005 and 2006 vehicles fitted with SST (self-supporting tires).

TPMS is standard equipment on all U.S. specification Model Year 2007 S60 (except S60R), V70 (except V70R), XC70, XC90, and S80 vehicles. It

is planned to be standard equipment on 100% of the U.S. specification Model Year 2008 vehicles. TPMS is optional on Model Year 2007 Canadian

specification vehicles.

The system must be regarded as a driver aid to maintain the correct tire pressure. TPMS does not take the place of good vehicle maintenance which

requires that tire pressure be checked on a regular basis. The owners' manual recommends to the owner that tire pressures be checked monthly.

When inflating the tire with air, you must, as much as possible, ensure that the tires are at same temperature as the outside temperature. When

inflating with air, the tires must be filled to the pressure stated on the decal located on the car body. These pressures MUST be followed.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TJ16724 Date: 081008

A/T - Coolant Contamination Information

Retailer Technical Journal 16724

Coolant contamination in automatic transmissions

Date: 10-8-2008

Reference: VIDA

Note!

If using a printed copy of this Retailer Technical Journal, first check for the latest online version.

NOTE!

THIS DOCUMENT SUPERSEDES THE PREVIOUS VERSION OF RTJ 16724 (TNN 43-48) DATED 4-18-2007. Changes have been made

to the cooler and hose replacement guidelines. PLEASE UPDATE YOUR FILES.

AFFECTED VEHICLES:

BACKGROUND:

The root cause for some automatic transmission failures is glycol contamination from the engine/transmission cooling system. Severe cases of

contamination are easy to detect by a visual inspection. The transmission fluid will have a milky appearance and there may be signs of transmission

fluid in the coolant reservoir. Less severe cases are impossible to detect without doing a chemical analysis of the transmission fluid. This slight

contamination is easy to overlook and will result in a repeat transmission failure.

A small leak from the cooling system into the transmission can cause driveability problems long before there are any visual signs of contamination.

SYMPTOMS OF COOLANT CONTAMINATION:

The most common symptom of coolant contamination is shudder; a high frequency vibration.

^ On AW55 transmissions, the shudder normally occurs while in torque converter slipping lock-up mode. It is most easily reproduced by driving

slightly uphill at about 40 MPH (65KPH) in 4th or 5th gear with light pedal at 122?158鐧?(50-70鐧? transmission oil temperature.

^ On the GM4T65 transmission, the shudder normally occurs during upshifts.

^ On all transmissions, other symptoms such as harsh shifts, slipping, flare, loss of drive, other DTCs, etc... are possible but not likely.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 84

The Volvo test kit, PN 30783360, will accurately detect even very low levels of glycol contamination in transmission oil. One test kit contains

materials to perform 25 tests.

1. Start with a clean test tube. Wash it with a soap solution and the brush which is supplied in the kit.

Use the large pipette to put 5 ml (2 x 2.5 ml) of Volvo A (clear fluid) into the test tube.

2. Add 0.5 ml of the oil to be tested using the small pipette.

3. Add one packet of reagent B (white powder) to the test tube.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 85

4. Screw on the cap & shake the tube until all the powder has dissolved.

5. Place the test tube in hot tap water for 5 minutes.

(A coffee cup full of tap water which has been microwaved for 2 minutes is suitable.)

6. Unscrew the cap and add one packet of reagent C (purple powder) to the test tube.

7. Screw on the cap & shake the tube until all the powder has dissolved.

8. Place the test tube in hot tap water for 20 minutes.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 86

9. A clear (no color) result indicates no glycol contamination.

A purple result indicates glycol contamination.

SERVICE:

If the sample tests positive for glycol, the transmission and cooler will need to be replaced. The cooler hoses will need to be flushed with clean

transmission fluid or replaced. For 1999- 2006 S80s and 2003-2005 XC90s with the GM4T65 transmission, replace the radiator, auxiliary cooler (if

applicable), and all three cooler hoses in the case of glycol contamination.

In the event of needing to test for coolant contamination as part of a warranty repair, the labor and part description shown above can be used.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 87

Note:

The following kit is also available as an alternative, but not via a Volvo part or tool number. It can be purchased directly from the manufacturer.

Each kit includes material to test 10 transmissions.

Nelco Company LLC, Glyt-Tek Test Kit

1047 McKnight Rd S, Saint Paul, MN 55119

Phone: 651.738.2014 Fax: 651.738.9447

E-mail: Cvnelco@aol.com

www.aviceda.com/nelco/index.htm

TESTING FOR GLYCOL CONTAMINATION WITH NELCO GLY-TEK KIT:

1. Let the vehicle sit for several minutes. Using a clean bottle, take a small sample of oil from the sump via the drain plug.

2. Open one vial. Twist the cap while removing it. Do not use the one with the red cap (it is a sample already containing glycol).

3. Using a new syringe, add oil to the vial. The vial should now have about 50% oil, 50% clear liquid.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 88

4. Cap the vial and shake it vigorously for 20 seconds.

5. Remove the cap and let the vial sit until the liquids separate.

6. Remove the red caps from both ends of one glass tube. Note that for the remaining steps (7-12), care must be taken not to allow the crystals

or felt plugs from coming out of the tube.

7. Protect your eyes and hands from any small pieces of glass by wrapping the tube in a paper towel. While holding the tube horizontally, break

off both ends at the score marks.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 89

8. While holding the tube horizontally, install the rubber bulb onto one end. Twist it while pushing it on.

9. While holding the tube horizontally, slowly squeeze the bulb to remove the majority of the liquid from the crystals.

10. With the bulb squeezed, insert the open end of the tube into the bottom of the vial (through the oil, into the clear liquid).

11. Slowly release the bulb to draw liquid into the tube. Stop when the liquid is just past the top felt plug and remove the bulb. Do not draw

liquid into the rubber bulb, as it will need to be kept clean for future tests.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 90

12. Immediately lay the tube down flat and let it sit for exactly 15 minutes.

ANALYZING THE RESULTS:

After the tube has been laying flat for 15 minutes a brown band will have formed in the crystals above the bottom felt plug. A large pink/purple

area above this brown band indicates the presence of glycol. A very thin pink/purple band or no color above this brown band shows that the oil is

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # TNN40-04 Date: 051013

A/T, M/T, AWD - Approved Lubricants

NO: 40-04

DATE: 10-13-2005

MODEL/YEAR: All Models

SUBJECT:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 72

Transmission and AWD Lubricants

REFERENCE: Owners Manual and VIDA

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # SB39-009 Date: 120330

Memory Systems - Restoring Customer Preferred Settings

NO:

009

GROUP:

39

TITLE:

Restoring Customers

Preferred Settings

ISSUING DEPARTMENT:

Service Satisfaction

CAR MARKET:

United States and Canada

DATE:

YEAR

2012

MONTH

03

DAY

30

It should always be our goal to meet or exceed customers expectations. When a customer leaves their vehicle in our care, they expect to get that

vehicle back in the same or better condition than when they dropped off the vehicle. In particular they expect that all of the personalized vehicle

settings and pre-set selections they have made to personalize their vehicle should be found as they were when they dropped off the vehicle.

This bulletin includes the following forms for your use in recoding customer settings and resetting prior to scheduled pick up time.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 2

^ P2 Customer Settings

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 3

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 4

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 5

^ P1 Customer Settings

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 6

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 7

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 8

^ XC90 Customer Settings

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 9

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F0

^ P3 Non Sensus Customer Settings

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F1

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F2

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F3

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F4

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F5

^ P3 Sensus Customer Settings

The procedure shall be as follows:

1) Read out and record the customer settings and block offset values. A checklist for each platform type has been provided.

2) Download the appropriate Software Product.

3) Restore the customer settings and block offset values read out in step 1 above.

4) Perform any initializations as normally required after a Software Download such as windows, sunroof, etc... VIDA will typically provide a "pop

up" message when these are required.

- tighten nut (P/N 971085-6) with the car resting on its wheels. Tighten to 130 Nm (96 ft.lbs).1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # 881210 Date:

961201

Body - Template for Modifying Windshield Frame

SECTION

8

Group

81

NO.

210

DATE

Dec. 1996

RE:

Template for modifying

windshield frame

200

REFERENCE: TP 31120/1, SECTION 8(82-88), BODY FITTINGS, INTERIOR HEATING AND A/C 200 1975-19..

Template for modifying windshield frame

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 52

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 53

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 54

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 55

The replacement part windshield frame is supplied without windshield wiper holes. This Service Bulletin contains templates for marking up holes

and instructions on how to position them correctly

Templates for marking up holes.

Copy templates onto transparent or overhead film.

No. 1: No. 2:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 56

Left windshield wiper -1985 flight windshield wiper -1985

No. 3: No. 4:

Left windshield wiper 1985- flight windshield wiper 1985-

Note!

The old windshield frame can be used instead of foil templates.

Warning!

When drilling, protective eyewear should be worn.

Drilling holes with a conical drill

- Position the transparent template (or old windshield

frame) on the new windshield frame.

- Mark out the holes

- Drill guide holes.

- Ream holes to (diameter) 30 mm (1-3/16") using a conical drill.

Do not use a hole saw!

- File off holes before painting.

WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim

type: O1

Operation no. Labor description Defect code

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Technical Service Bulletin # SB39-004 Date: 120418

Audio System - CD's Stuck In Audio Units

NO:

004

GROUP:

39

TITLE:

Stuck CDs in Audio Units

ISSUING DEPARTMENT:

Warranty

CAR MARKET:

United States, Canada

REFERENCE BULLETINS:

SMB 00-170

DATE:

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F6

YEAR

2012

MONTH

04

DAY

18

This SMB supersedes SMB 39-004 dated 10-21-2009 and TNN 39-51 dated 04-16-2008.

Description:

This document describes the process for returning audio units diagnosed with stuck CDs. Below are two basic procedures to use as applicable.

IMPORTANT:

IF A COMPACT DISC UNIT HAS BEEN DIAGNOSED WITH A DEFECT OTHER THAN

STUCK CDs, PLEASE BE SURE TO EJECT THE CDs FROM THE UNIT WHILE IT IS

STILL CONNECTED TO THE VEHICLE BEFORE RETURNING TO TMA OR YOUR

LOCAL DC. PLEASE ENSURE THAT THE CDS ARE PROMPTLY RETURNED TO THE

OWNER.

IT IS EXTREMELY IMPORTANT THAT YOU INDICATE ON THE OUTSIDE OF THE

AUDIO BOX THAT AUDIO CDs ARE INSIDE.

Procedure # 1: TMA WARRANTY RETURNS

For All Audio units that are requested to be returned to TMA for Testing and Analysis.

Compact Discs may get stuck in the CD-Changer drive. If this occurs, DO NOT ATTEMPT to remove them.

Please fill out the attached CD Return Form completely and legibly.

The form must be visible inside the audio box.

It is mandatory that you fill in the owner's full name and complete address on the CD Return Form.

Return the CD return form and the audio unit to TMA per established shipping instructions as detailed in SMB 00-170.

Upon removal, owner's CDs will be mailed to the Owner per the information on the CD Return Form within 2-3 weeks of receipt.

IMPORTANT NOTE!

IT IS IMPORTANT THAT YOU INCLUDE THE CD RETURN FORM WITH THE DEFECTIVE

UNIT. IF THE CD RETURN FORM IS NOT INCLUDED WITH AN AUDIO UNIT DIAGNOSED

WITH STUCK CDs, AND YOU DO NOT INCLUDE THE OWNER'S RETURN ADDRESS,

YOU WILL BE RESPONSIBLE FOR REIMBURSING THE OWNER FOR THEIR CDs. VOLVO

WILL ONLY OPEN AND REMOVE CDs FROM CHANGERS THAT ARE RETURNED WITH

THE CD REMOVAL FORM.

Note:

Audio units tampered with or opened, or damaged from foreign objects inserted into mechanism drives (e.g., coins, business cards or visibly

evident peeling CD-R labels) will not be covered under warranty.

IMPORTANT

Please wait for the TMA Parts Return Request before returning these units. Please ensure that all TMA Warranty claims, TMA Warranty Core

reports and the CD Form are included with the unit. IT IS EXTREMELY IMPORTANT THAT YOU INDICATE ON THE OUTSIDE OF

THE AUDIO BOX THAT AUDIO CDs ARE INSIDE.

Procedure # 2: STRAIGHT CORE RETURNS

For returning a non requested or non-warranty audio core unit to your local Distribution Center with a CD Changer diagnosed with stuck CDs.

Please fill out the attached CD Return Form completely and legibly.

The form must be visible inside the audio box.

It is mandatory that you fill in the owner's full name and complete address on the CD Return Form.

Continue to include all applicable Core Reports with the units. Return the unit to your local Distribution Center.

The local Distribution Center will process the units and forward the units to the refurbishment facility. CDs will be removed by the refurbishment

facility. The CDs will be returned to the owner per the information on the CD Return Form. This process may require more than 3 weeks,

depending upon the audio unit type and the refurbishment facility.

In order for this process to be successful, the attached CD Return form must be filled out and visible inside of the audio box with the audio unit and

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F7

the owner's name and complete address filled out.

IT IS EXTREMELY IMPORTANT THAT YOU INDICATE ON THE OUTSIDE OF THE AUDIO BOX THAT AUDIO CDs ARE INSIDE.

IMPORTANT NOTE!

IT IS IMPORTANT THAT YOU INCLUDE THE CD RETURN FORM WITH THE DEFECTIVE UNIT.

IF THE CD RETURN FORM IS NOT INCLUDED WITH AN AUDIO UNIT DIAGNOSED WITH STUCK CDs, AND YOU DO NOT

INCLUDE THE OWNER'S RETURN ADDRESS, YOU WILL BE RESPONSIBLE FOR REIMBURSING THE OWNER FOR THE COST OF

THEIR CDs. VOLVO WILL ONLY OPEN AND REMOVE CDs FROM CHANGERS THAT ARE RETURNED WITH THE CD REMOVAL

FORM.

Note:

Audio units damaged from foreign objects inserted into mechanism drives (e.g., coins, business cards or visibly evident peeling CD-R labels)

may result in a loss of core credit.

1982 Volvo 240 L4-2127cc 2.1L SOHC B21F8