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Volvo 740 1982-1988 Workshop Service Repair Manual

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The Volvo 740, produced from 1982 to 1988, represents the first generation of Volvo's robust executive sedan and wagon. Renowned for its exceptional safety focus, solid construction, and long-term durability,...
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Volvo 740 1982-1988 Workshop Service Repair ManualVolvo 740 1982-1988 Workshop Service Repair ManualVolvo 740 1982-1988 Workshop Service Repair ManualVolvo 740 1982-1988 Workshop Service Repair Manual
The Volvo 740, produced from 1982 to 1988, represents the first generation of Volvo's robust executive sedan and wagon. Renowned for its exceptional safety focus, solid construction, and long-term durability, the 740 was engineered to provide a reliable and secure driving experience, competing effectively with established European luxury brands. Its mechanical design is also noted for its relative straightforwardness, making it accessible for home maintenance when equipped with proper documentation. This model is a testament to Volvo's enduring commitment to safety and longevity, offering a blend of comfort, space, and dependable performance. This comprehensive factory service repair manual provides complete workshop service and repair information for all styles of the Volvo 740. It covers a vast array of systems, including detailed engine and transmission service, brake and electrical system diagnostics, suspension and steering, cooling, fuel, and emission systems, as well as heating and air conditioning. The manual includes step-by-step repair procedures, diagnostic guides, maintenance schedules, and hundreds of illustrations to assist owners and technicians. Its detailed substeps, notes, cautions, and warnings ensure that all maintenance and repair tasks are performed correctly and safely, preserving the vehicle's integrity and performance.
🏷️ Basic Information
Identification
Make:
Volvo
Model:
740
Model Code:
P740
Production Years Covered By Manual:
1982, 1983, 1984, 1985, 1986, 1987, 1988
Generation
Generation Identifier:
First Generation
Codes
Chassis Codes:
P740 (Sedan), P745 (Wagon)
👋 Introduction
Market Position
Positioning:
A robust and reliable executive sedan and wagon known for safety and durability, popular in North America and Europe.
Competitive Analysis
Key Competitors:
Competed against vehicles like the Mercedes-Benz W124 series, BMW 5 Series (E28/E34), Audi 100, and upper trims of American sedans like Ford Taurus and Chevrolet Caprice during its production run.
Key Features
Longevity And Durability:
The 740 is renowned for its solid construction and long-term durability, making it a favored choice for those seeking a reliable classic vehicle.
Safety Focus:
Volvo's inherent commitment to safety is evident in the 740's design, featuring strong chassis, crumple zones, and safety cage construction.
Diy Friendliness:
The mechanical design of the 740 is relatively straightforward, making it accessible for home mechanics with the right documentation, like this manual.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service and Repair
Style Coverage:
All Styles Covered
Page Count
Estimated Page Count:
Hundreds (specific count not provided but implied to be extensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service And Repair:
Comprehensive engine diagnostics, repair, and overhaul procedures for applicable engine variants.
Transmission Service And Repair:
Detailed procedures for manual and automatic transmissions, including removal, installation, and internal repairs.
Brake System:
In-depth coverage of brake system components, maintenance, troubleshooting, and repair, including ABS if equipped on later models within the range.
Electrical System:
Detailed diagnostics, troubleshooting, and repair procedures for the entire electrical system.
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems, crucial for troubleshooting.
Suspension:
Maintenance and repair of front and rear suspension components, including alignment specifications.
Steering:
Service and repair procedures for the power steering system and steering linkage.
Cooling System:
Radiator, thermostat, water pump, hoses, and cooling fan service and repair.
Fuel System:
Comprehensive coverage of fuel tank, pump, lines, filters, and fuel injection systems.
Fuel Injection:
Detailed information on Bosch and other fuel injection systems used, including component testing and calibration.
Emission System:
Information on emission control components, diagnosis, and repair to meet regulatory standards.
Heating Air Conditioning:
Service and repair of HVAC systems, including refrigerant handling (where applicable), component diagnosis, and cabin comfort.
Engine Control System:
Diagnosis and repair of the Engine Control Unit (ECU) and associated sensors and actuators.
Chassis Body:
Information on chassis components, body panels, adjustments, and related repairs.
Restraint System:
Information on seat belts and airbags (if equipped on later models within the range) and their related systems.
Interior:
Procedures for interior trim removal, installation, and component repair.
Differential Drive:
Service and repair of the rear differential and driveshaft components.
Axle:
Information on front and rear axles, including CV joints and wheel bearings.
General Maintenance:
Routine maintenance procedures and schedules.
Periodic Lubrication:
Detailed lubrication points and recommended lubricant specifications.
Troubleshooting:
Systematic troubleshooting guides for common and complex vehicle issues.
Procedures Included
Repair Procedures:
Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components.
Diagnostic Procedures:
Detailed diagnostic trees and testing methods for identifying faults.
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements, spark plug service, and brake fluid flushes.
Electrical Troubleshooting And Repair:
Combined troubleshooting and repair for electrical system faults, supported by wiring diagrams.
Technical Depth
Depth:
Complete Factory Service Information (suitable for DIY and professional mechanics)
Detail Level:
Detailed substeps, notes, cautions, and warnings for critical information.
Illustration Quality:
Hundreds of photos, illustrations, drawings, and enlarged insets for detailed part examination.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Compatible with all PC-based Windows operating systems and Mac.
Digital Options:
Downloadable, storable on hard drive, burnable to CD-ROM.
Print Quality
Printability:
Fully printable without restriction (entire manual or selected pages).
Binding Type
Binding:
N/A (Digital Download - printable for self-binding)
Paper Type
Paper Type:
N/A (Digital Download - user's choice for printing)
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Family:
Volvo B230 (Redblock)
Engine Variants
Common Engines:
2.3L (2316cc) Inline-4
Performance
Horsepower Range:
Approximately 114-130 hp (naturally aspirated), up to 162 hp (turbocharged variants like the 740 Turbo).
Torque Range:
Approximately 130-150 lb-ft (naturally aspirated), up to 180-200 lb-ft (turbocharged).
Fuel System
Injection Systems:
Bosch LE-Jetronic, Bosch LH-Jetronic (with EZK ignition control), and Motronic for turbocharged models.
Fuel Requirements
Octane Rating:
Typically requires unleaded gasoline with an octane rating of 87 or higher (check specific vehicle for exact requirements).
Engine Design
Bore X Stroke:
96.0 mm x 80.0 mm (2.3L)
Compression Ratio:
Typically 9.0:1 to 10.1:1 depending on engine variant.
🔧 Transmission
Standard
Transmission Type:
4-speed Manual (M46 Overdrive) or 5-speed Manual (M47)
Optional
Transmission Type:
AW70/71 (3-speed Automatic) or AW70/71E (4-speed Automatic with electronic control).
Features
Overdrive:
M46 manual transmission features an electrically activated overdrive gear (OD).
Fluid Specifications
Automatic Transmission Fluid:
Dexron II or equivalent (check manual for exact specification).
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.
📐 Dimensions
Exterior
Length:
Approximately 189.1 inches (480 cm) for sedan, 190.7 inches (484 cm) for wagon.
Width:
Approximately 68.5 inches (174 cm).
Height:
Approximately 55.1 inches (140 cm) for sedan, 57.7 inches (147 cm) for wagon.
Weights
Curb Weight:
Approximately 3,000-3,300 lbs (1360-1497 kg) depending on configuration.
Wheel Specifications
Bolt Pattern:
5x108
Lug Nut Torque:
103 lb-ft (140 Nm)
🛡️ Safety Features
Ratings
General Perception:
Volvo vehicles of this era were highly regarded for their safety performance and robust construction.
Active Features
Braking System:
Power-assisted disc front brakes, drum rear brakes. Some later models may offer optional ABS.
Passive Features
Seat Belts:
Three-point seat belts for all occupants, with pre-tensioners on front seats in later models.
Structural Integrity:
Reinforced passenger cage, side-impact beams, and energy-absorbing crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player. Amplified systems were available on higher trims.
Driver Assistance
Cruise Control:
Standard on most models for its era, providing highway driving comfort.
Antilock Brakes:
Optional ABS available on later models within the production range.
Connectivity
Early Features:
Limited by the era, connectivity primarily revolved around the radio and speaker system.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000 to 7,500 miles or 6-12 months, depending on driving conditions and oil type used.
Transmission Fluid Change:
Every 30,000 to 50,000 miles for automatic transmissions. Manual transmission fluid may not have a scheduled interval but is recommended to check and replace if contaminated.
Timing Belt Replacement:
For B230 engines, timing belt replacement is crucial and typically recommended every 60,000 miles or 4-5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 is common. Check owner's manual for specific viscosity based on climate.
Coolant:
Volvo coolant or a 50/50 mixture of ethylene glycol antifreeze and distilled water. Ensure proper corrosion inhibitors are present.
Brake Fluid:
DOT 3 or DOT 4 (check manual for exact specification), change every 2-3 years to prevent moisture absorption.
Known Issues
Oil Leaks:
Common areas for oil leaks include the front and rear crankshaft seals, valve cover gasket, and oil cooler lines.
Wiring Harness Issues:
Age-related degradation of wiring insulation, especially in the engine bay, can lead to electrical gremlins.
Fuel Pump Reliability:
Fuel pumps can become less reliable with age, often exhibiting symptoms like difficulty starting or stalling.
Idle Control Valve:
The idle control valve can become clogged or fail, leading to rough idling or stalling.
📚 Vehicle History
Brand Heritage
Volvo Philosophy:
Founded in 1927, Volvo has a long-standing reputation for engineering safety, reliability, and durability into its vehicles.
Model Evolution
700 Series Introduction:
The 700 series debuted in 1982 with the 760, followed by the more mainstream 740 in 1984, offering a blend of comfort, space, and Volvo's signature engineering.
740 Positioning:
The 740 was positioned as a more accessible version of the luxury 760, sharing many mechanicals but with simpler trim and fewer luxury features.
Production
Manufacturing Locations:
Primarily manufactured in Sweden (Torslanda) and Belgium (Ghent).
🏆 Awards & Recognition
Recognitions
General Reputation:
Consistently ranked among the safest vehicles of its time. Known for its longevity and value retention.
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