Segment:
Compact Executive/Premium Compact Car
Target Audience:
DIY enthusiasts, independent repair shops, Volvo owners seeking in-depth knowledge
Competitors:
BMW 3 Series (E36), Mercedes-Benz C-Class (W202), Audi 80/A4 (B4/B5), Saab 900 (NG900)
Design Philosophy:
Safety, durability, comfort, distinctive Scandinavian design
Powertrain Innovation:
Introduction of the inline 5-cylinder engine, front-wheel drive (later AWD)
Primary Coverage:
Comprehensive Service and Repair
Additional Coverage:
Diagnostics, Troubleshooting, Maintenance, Electrical Schematics, Specifications
Type:
Factory Service Manual (FSM)
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine management (ECU), turbocharging (where applicable), transmission (manual and automatic)
Chassis:
Suspension (front and rear), steering, brakes (front and rear, ABS), wheels and tires
Electrical:
Complete wiring diagrams, lighting, instruments, engine control module (ECM), body control modules (BCM), power windows, locks, mirrors, climate control, audio system, security system
Body:
Exterior body panels, interior trim, seats, doors, windows, glass, bumpers, body sealing, rust prevention and repair
Maintenance:
Oil changes, filter replacements, fluid checks and changes, belt inspections and replacement, spark plug replacement, air filter replacement
Repair:
Engine internal repairs, transmission overhaul, brake caliper and rotor replacement, suspension component replacement, steering rack replacement, starter motor and alternator replacement, radiator and cooling fan replacement
Diagnostics:
OBD-I diagnostic codes, symptom-based troubleshooting guides, component testing procedures, electrical circuit tracing
Depth:
Detailed step-by-step repair instructions, torque specifications, special tool requirements, diagnostic flowcharts, component removal and installation procedures, overhaul procedures
Engine Code Gasoline:
B5204F (2.0L), B5234F (2.3L), B5234FT (2.3L Turbo), B5254F (2.5L)
Engine Configuration:
Inline 5-cylinder
Engine Displacement:
1984 cc (2.0L), 2316 cc (2.3L), 2435 cc (2.5L)
Bore X Stroke:
81.0 mm x 77.0 mm (2.0L), 81.0 mm x 90.0 mm (2.3L), 81.0 mm x 90.0 mm (2.5L)
Horsepower 2.0L:
126 hp @ 5700 rpm
Horsepower 2.3L:
170 hp @ 6200 rpm
Horsepower 2.3L Turbo:
222 hp @ 5200 rpm (GLT/T5)
Horsepower 2.5L:
170 hp @ 6200 rpm
Torque 2.0L:
170 Nm @ 4500 rpm
Torque 2.3L:
205 Nm @ 4200 rpm
Torque 2.3L Turbo:
300 Nm @ 2000 rpm (GLT/T5)
Torque 2.5L:
217 Nm @ 4200 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) with coil-on-plug
Type:
5-speed Manual (M56H)
Type:
4-speed Automatic (AW30-43)
Automatic Modes:
Economy (E) and Sport (S) modes
Manual Transmission Gear Ratios:
Detailed ratios provided in manual (e.g., 1st: 3.77, 2nd: 2.10, 3rd: 1.37, 4th: 1.00, 5th: 0.79)
Manual Fluid:
Volvo Manual Transmission Fluid (part # 1161681)
Automatic Fluid:
JWS 3309 (ATF Type T-IV equivalent)
Length:
4785 mm (188.4 in)
Height:
1410 mm (55.5 in)
Wheelbase:
2649 mm (104.3 in)
Front Track:
1470 mm (57.9 in)
Rear Track:
1460 mm (57.5 in)
Curb Weight:
Approx. 1450-1550 kg (3200-3400 lbs)
Gross Vehicle Weight Rating Gvwr:
Approx. 1900-2000 kg (4189-4409 lbs)
Sedan Trunk Volume:
Approx. 0.45 m³ (16 cu ft)
Wagon Cargo Volume Seats Up:
Approx. 0.48 m³ (17 cu ft)
Wagon Cargo Volume Seats Down:
Approx. 1.55 m³ (54.7 cu ft)
NHTSA Frontal Impact Driver:
5-star rating (for models equipped with side airbags, if applicable to specific year/variant)
IIHS Side Impact:
Acceptable (for models with side airbags)
ABS:
Standard on most models
Traction Control:
Optional on some models (TRACS)
Airbags:
Driver and front passenger airbags standard. Side airbags became optional/standard in later years.
Seatbelts:
Three-point inertia-reel seatbelts front and rear, whiplash protection system (WHIPS) introduced late in production.
Body Structure:
Integrated safety cage, crumple zones, reinforced roof and side pillars.
Audio System:
Factory cassette or CD players with optional premium sound systems (e.g., Harman Kardon).
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) with cabin air filter.
Cruise Control:
Standard on most models.
Headlights:
Halogen headlamps with manual leveling.
Internal Diagnostics:
OBD-I diagnostic port, requiring specific Volvo diagnostic tools or knowledge to interpret codes.
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months (synthetic oil recommended)
Timing Belt Replacement:
Every 70,000-100,000 miles (critical maintenance item)
Spark Plug Replacement:
Every 60,000 miles (platinum or iridium)
Coolant Flush:
Every 2-3 years or 30,000 miles
Engine Oil Type:
API SG, ACEA A2-96, or approved synthetic (e.g., 5W-30, 10W-30, 10W-40 depending on climate)
Engine Oil Capacity:
Approx. 5.2 liters (5.5 US quarts)
Coolant Type:
Volvo VCS coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)
Brake Fluid Type:
DOT 3 or DOT 4
Common Wear Items:
Suspension bushings (control arms, sway bar links), front strut mounts, mass airflow sensor (MAF), idle air control valve (IACV), ignition coils, turbocharger hoses (for turbo models), ABS sensor rings.
Electrical Gremlins:
Dashboard warning lights (ABS, SRS), window regulators, central locking issues due to module failure or wiring.
Engine Management Issues:
Vacuum leaks, clogged PCV system causing oil leaks, fuel pump failure.
Volvo Safety Focus:
Volvo's long-standing commitment to safety and innovation.
Introduction Year:
1990 (Europe), 1992 (North America)
Design Influence:
Designed by Jan Wilsgaard, based on the Volvo ECC (Environmental Concept Car).
Key Variants:
Base, GL, GLT (turbocharged), T5 (high-output turbocharged), AWD variants.
Manufacturing Locations:
Uddevalla and Ghent
Production End Year:
1998
