Maintenance Information Volvo 780 I

MODEL IDENTIFICATION

Note. In 1991 the Coupe model was offered, it is the same as the 1990 780 Coupe, and is only equipped with the turbo engine.

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN CODE ID EXPLANATION. Scheme 2

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Normal Service

1. Driven More Than 10 Miles Daily
2. No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

1. Extended Idling Or Low Speed Operation
2. Frequent Short Trips Of Less Than 7 Miles
3. Extended Operation In Dusty Or Sandy Conditions
4. Trailer Towing Operations
5. Driving In Mountainous Conditions

CAMSHAFT TIMING BELT (1989-91 TURBO MODELS)

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist

1. Cracks Or Tears In Belt Surface
2. Missing, Damaged, Cracked Or Rounded Teeth
3. Oil Contamination
4. Damaged Or Faulty Tensioners
5. Incorrect Tension Adjustment

Volvo recommends replacement of the camshaft timing belt at specified intervals. See CAMSHAFT TIMING BELT REPLACEMENT INTERVALS table.

CAMSHAFT TIMING BELT REPLACEMENT INTERVALS

Scheme 3

Scheme 4

Scheme 5

1. With gear selector in Park, depress brake pedal.
2. Move gear selector to desired position.
3. If gear selector DOES NOT MOVE, check fuse #12.
4. TO MANUALLY RELEASE gear selector, push finger between brushes at base of shifter and push catch forward. (Scheme 5)
5. Select a gear.

Scheme 6

Scheme 7

Note. For more information regarding valve adjustment procedures refer to the 2.8L V6 article in the ENGINE MECHANICAL section.

Scheme 8

Note. For more information regarding valve adjustment procedures refer to the 2.3L 4-CYL article in the ENGINE MECHANICAL section.

Scheme 9

Note. For more information regarding camshaft timing belt service refer to the 2.3L 4-CYL article in the ENGINE MECHANICAL section.

MODELS 780 with B230F-T TIMING BELT REPLACEMENT

Scheme 10

Note. For more information regarding kickdown cable service refer to the ADJUSTMENTS article in the ENGINE PERFORMANCE section.

Scheme 11

Note. For more information regarding manual transmission service refer to the TRANSMISSION SERVICING - A/T article in the TRANSMISSION/TRANSAXLE section.

Scheme 12

Scheme 13

Scheme 14

Note. For more information regarding lifting and hoisting refer to the JACKING & HOISTING article in the WHEEL ALIGNMENT section.

Scheme 15

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

TIRE INFLATION

Tire specification label is located on the right front door.

WHEEL TIGHTENING

Tighten all wheel lug nuts to 63 ft. lbs. (85 N.m) using pattern shown in Fig. (Scheme 16).

Scheme 16

BATTERY SPECIFICATIONS

All vehicles use batteries with a 66 amp hour rating.

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

Note. See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAR WARNING

Note. For information on air bag DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

REPLACING BLOWN FUSES

Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE SYSTEM

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

ENGINE OIL

When driving in conditions that would raise oil temperature, it is recommended that SAE 15W/40 oil be used. DO NOT use SAE 15W/40 oil in extremely low ambient temperatures.

FUEL SYSTEM SERVICE

HALOGEN BULBS

Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

RADIATOR FAN

TURBOCHARGED MODELS

WHEELS & TIRES

Only wheels tested and approved by the manufacturer should be used on models equipped with Air Dam aerodynamic components.

When driving in conditions that would raise oil temperature, it is recommended that SAE 15W/40 oil be used. DO NOT use SAE 15W/40 oil in extremely low ambient temperatures.

WARRANTY INFORMATION

BASIC WARRANTY

The manufacturer warrants that repairs due to defects in material or workmanship, occurring under normal use, will be performed at no charge to the vehicle owner during period covered by the appropriate warranty. During the warranty period the warranty is fully transferable to subsequent owners. The warranty period is divided into 3 periods (1, 3 & 5 year). All periods begin the day the vehicle is delivered to the first retail customer or put into service, which ever comes first. The Basic Warranty covers the entire vehicle, with the exception of expendable items such as tires, for a period of 12 months with unlimited mileage.

MAJOR ASSEMBLY COVERAGE

Covers the following items and components for a period of 36 months with unlimited mileage from warranty start date

1. Engine And Cooling System
2. Transmission And Driveshaft
3. Rear Axle And Axle Shafts
4. Brakes (Excluding Brake Pads)
5. Steering
6. Suspension (Excluding Shock Absorbers)
7. Air Conditioning
8. Computerized Engine Control Systems
9. Electrical Components

CORROSION PROTECTION WARRANTY

Painted body panels are warranted against perforation for a period of 5 years. Structural damage due to rust or corrosion is warranted for 8 years.

SEAT BELTS & SUPPLEMENTAL RESTRAINT SYSTEMS

Factory installed seat belts or restraint systems are warranted for a period of 5 years.

EMISSION SYSTEM WARRANTIES

Manufacturer warrants that the vehicle emission control system was designed and installed to conform, at the time of sale, to all applicable U.S. emission standards. The warranty covers repairs resulting from any defect in material or workmanship which could cause the vehicle not to meet emission standards during the warranty period. The following items are not warranted

1. Normal Scheduled Maintenance Of Emission Components
2. Regular Maintenance Items
3. Damage To Components Due To Accidents
4. Damage Due To Contaminated Or Incorrect Fuels
5. Any Component On A Vehicle With An Altered Odometer
6. Damage Caused By The Use Of Non-Genuine Parts

The following components are covered Emission System or Emission Performance warranties

1. Ignition Cables
2. Distributor Components
3. Ignition Coil
4. Ignition Control Unit
5. Spark Plugs
6. Knock Sensor
7. Engine RPM Sensor
8. Fuel Pressure Regulator
9. Mass Airflow Meter
10. Fuel Injection Control Unit
11. Fuel Injectors
12. Idle Air Valve
13. Coolant Temperature Sensor
14. Throttle Position Sensor
15. Series Resistor
16. Oxygen Sensor
17. Cold Start Injector
18. Temperature Sensor
19. Manifold Pressure Sensor
20. Evaporative Emission System
21. PCV System
22. Air Intake System
23. Catalytic Converter
24. Exhaust Manifold
25. Exhaust Pipe (Manifold-To-Catalyst)
26. EGR System
27. Miscellaneous Items Used In Above System

FUSE PANEL LOCATION

Note. The fuse panel is located in the center console behind the ashtray. To gain access to the panel, remove the ashtray and retainer.

Scheme 17

Fuse & Circuit Breaker Identification

1. 1 - 25 Amp - Fuel Pump, Fuel Injection System
2. 2 - 25 Amp - Central Locking System, Hazard Warning Lights, Headlight Flashers, ABS System
3. 3 - 15 Amp - Fog Lamps, Watch-Dog Alarm System
4. 4 - 15 Amp - Brake Lights, Trunk Lid Switch
5. 5 - 15 Amp - Glove Box Light, Clock, Radio, Engine Compartment Light, Interior Lighting, Trunk Light, Electric Antenna, Door Courtesy Lights, Vanity Mirror
6. 6 - 15 Amp - Electrically-Heated Front Seat (Passenger)
7. 7 - 30 Amp - Electronic Climate Cooling Fan
8. 8 - 30 Amp - Power Windows
9. 9 - 15 Amp - Seat Belt Reminder, Turn Signal Indicators, Air Conditioning, Electrically-Heated Front Seat (Driver), Power Windows
10. 10 - 30 Amp - Heated Rear Window, Heated Door Mirrors, Power Moonroof
11. 11 - 15 Amp - Fuel Tank Pump, Heated Oxygen Sensor (Lambda-sond)
12. 12 - 15 Amp - Back-Up Lights, Cruise Control, Ignition On, Overdrive (4th Gear), SRS (Air Bag), ABS System
13. 13 - 15 Amp - Spare
14. 14 - 15 Amp - Power Door Mirrors, Cigar Lighter, Radio, Fuel Door Lid
15. 15 - 25 Amp - Horn, Windshield Washer/Wiper, SRS (Primary Side of Fuse)
16. 16 - 30 Amp - Heater Blower, Air Conditioning
17. 17 - 15 Amp - Left High Beam
18. 18 - 15 Amp - Right High Beam, Supplementary High Beam
19. 19 - 15 Amp - Left Low Beam
20. 20 - 15 Amp - Right Low Beam
21. 21 - 15 Amp - Left Parking Lights (Front & Rear), License Plate Lights, Ashtray Light, Heated Rear Window Switch Light, Sunroof, Instrument Lighting, Switch Lighting (Left Of Steering Wheel) Watch-Dog Alarm System
22. 22 - 15 Amp - Seat Belt Lock Illumination, Center Storage Box Light Right Parking Lights (Front & Rear), Fog Lamps
23. 23 - 15 Amp - Power Front Seat Relay
24. 24 - 30 Amp - Power Passenger Seat
25. 25 - 15 Amp - Rear Fog Lamps
26. 26 - 30 Amp - Power Driver's Seat

Scheme 18

Relay Identification

1. A - Headlight Relay with Bulb Malfunction Indicator
2. B - Fasten Seat Belt Relay
3. C - Intermittent Windshield Wiper Relay
4. D - Not Used
5. E - LH-Jetronic 2.2 Fuel Injection Relay (B230F-T Engines)
6. F - Headlamp Hi-Beam Relay
7. G - Flasher Relay
8. H - Fuel Tank Door Relay
9. I - Overdrive Relay
10. J - Power Windows and Electric Cooling Fan Relay
11. K - Automatic Cut-Out Headlights Relay
12. L - Central Locking System Relay
13. M - Rear Fog Lamps Relay
14. N - Front Fog Lamps Relay
15. O - Not Used
16. P - Not Used
17. R - Alarm (Watch Dog) Relay
18. S - Starter Inhibitor (Watch Dog) Relay

ABS FUSE PANEL IDENTIFICATION

Note. On vehicles equipped with Anti-Lock Brakes (ABS), the system is protected by (2) additional fuses. (1) 10 Amp fuse located in the trunk compartment on the right side, and (1) 80 Amp fuse located on the left inner fender. (Scheme 19)

Scheme 19

ABS RELAY IDENTIFICATION

Note. On vehicles equipped with Anti-Lock Brakes (ABS), the ABS pump motor, solenoids and relays are located in the trunk compartment on the right side. (Scheme 20)

Scheme 20

FUSE PANEL IDENTIFICATION (1988-91)

Note. Models with front and rear radio amplifiers have (2) 30 Amp fuses next to the battery.

Note. On 1989-91 B230F-T engine models, a high output 10 Amp fuse is mounted on the left suspension tower.

Fuse & Circuit Breaker Identification

1. 1 - 25 Amp - Fuel Pump, Fuel Injection System
2. 2 - 25 Amp - Central Locking System, Hazard Warning Lights, Headlight Flashers, ABS System
3. 3 - 15 Amp - Fog Lamps, Watch-Dog Alarm System
4. 4 - 15 Amp - Brake Lights, Trunk Lid Switch
5. 5 - 15 Amp - Glove Box Light, Clock, Radio, Engine Compartment Light, Interior Lighting, Trunk Light, Electric Antenna, Door Courtesy Lights, Vanity Mirror
6. 6 - 15 Amp - Electrically-Heated Front Seat (Passenger)
7. 7 - 30 Amp - Electronic Climate Cooling Fan, Heater Blower
8. 8 - 30 Amp - Power Windows
9. 9 - 15 Amp - Seat Belt Reminder, Turn Signal Indicators, Air Conditioning, Electrically-Heated Front Seat (Driver), Power Windows
10. 10 - 30 Amp - Heated Rear Window, Heated Door Mirrors, Power Sunroof
11. 11 - 15 Amp - Fuel Tank Pump, Heated Oxygen Sensor (Lambda-sond)
12. 12 - 15 Amp - Back-Up Lights, Cruise Control, Ignition On, Overdrive (4th Gear), SRS (Air Bag), ABS System
13. 13 - 15 Amp (1988-89) - Cooling Fan Relay, Constant Idle Speed System 15 Amp (1990-91) - Cooling Fan Relay, Turbo Plus
14. 14 - 15 Amp - Power Door Mirrors, Cigar Lighter, Radio, Fuel Door Lid
15. 15 - 25 Amp - Horn, Windshield Washer/Wiper, SRS (Primary Side of Fuse)
16. 16 - 30 Amp - Spare
17. 17 - 15 Amp - Left High Beam
18. 18 - 15 Amp - Right High Beam, Supplementary High Beam
19. 19 - 15 Amp - Left Low Beam
20. 20 - 15 Amp - Right Low Beam
21. 21 - 15 Amp - Left Parking Lights (Front & Rear), License Plate Lights, Ashtray Light, Heated Rear Window Switch Light, Sunroof, Instrument Lighting, Switch Lighting (Left Of Steering Wheel) Watch-Dog Alarm System
22. 22 - 15 Amp - Seat Belt Lock Illumination, Center Storage Box Light Right Parking Lights (Front & Rear), Front Fog Lamps
23. 23 - 15 Amp - Power Front Seat Relay
24. 24 - 30 Amp - Power Passenger Seat
25. 25 - 15 Amp - Rear Fog Lamps
26. 26 - 30 Amp - Power Driver's Seat

Relay Identification

1. A - Headlight Relay with Bulb Malfunction Indicator
2. B - Fasten Seat Belt Relay
3. C - Intermittent Windshield Wiper Relay
4. D - Not Used
5. E - LH-Jetronic 2.2 Fuel Injection Relay (B230F-T Engines)
6. F - Headlamp Hi-Beam Relay
7. G - Flasher Relay
8. H - Fuel Tank Door Relay
9. I - Overdrive Relay
10. J - Power Windows and Electric Cooling Fan Relay
11. K - Automatic Cut-Out Headlights Relay
12. L - Central Locking System Relay
13. M - Rear Fog Lamps Relay
14. N - Front Fog Lamps Relay
15. O - Not Used
16. P - Not Used
17. R - Alarm (Watch Dog) Relay
18. S - Starter Inhibitor (Watch Dog) Relay

ABS FUSE PANEL IDENTIFICATION (1988-91)

Note. On vehicles equipped with Anti-Lock Brakes (ABS), the system is protected by an additional 10 Amp fuse located to the left of the steering column. (Scheme 21)

Scheme 21

Note. The ABS system is protected by an additional 10 AMP fuse which is incorporated in the surge protector at the brake pedal mounting.

ABS RELAY IDENTIFICATION (1988-91)

Note. On vehicles equipped with Anti-Lock Brakes (ABS), the ABS pump motor, solenoids and relays are located under the hood, on the right side. (Scheme 20)

See also:
• CAMSHAFT TIMING BELT REPLACEMENT INTERVALS