🏷️ Basic Information

Make:

Volvo

Model:

850

Year:

1996

Chassis Code:

LS

Engine Codes:

B5252S, B5254S, B5254FS

👋 Introduction

Positioning:

The Volvo 850 was positioned as a premium, safe, and comfortable compact executive car, a significant departure for Volvo with its transverse engine and front-wheel-drive layout, directly competing with German luxury sedans.

Competitors:

BMW 3 Series, Mercedes-Benz C-Class, Audi 80/90, Saab 900.

Design Philosophy:

'The Car of the Nineties' emphasized safety, comfort, distinctive Scandinavian design, and a refined driving experience, breaking from Volvo's more utilitarian past.

Platform Innovation:

Introduced Volvo's first transverse inline-five engine and front-wheel-drive platform, a major engineering shift.

📋 Manual Details

Coverage Scope:

Comprehensive service and repair for the 1996 Volvo 850, including all major systems and components.

Page Count:

Approx. 1500+

Manual Type:

Factory Service Manual (FSM)

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, valve train, pistons, crankshaft, timing belt replacement, lubrication system.

Engine Management:

Fuel injection system (Motronic), ignition system, emissions control, sensors, actuators, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch, gearbox overhaul, synchronizers, shift linkage, fluid specifications.

Transmission Automatic:

AW50-42LE automatic transmission overhaul, hydraulic system, valve body, torque converter, electronic controls.

Drivetrain:

Front-wheel drive (FWD), Constant Velocity (CV) joints, axle shafts, differential.

Suspension:

Front MacPherson struts, rear multi-link independent suspension, springs, shock absorbers, bushings, alignment specifications.

Steering:

Power steering system, steering rack, pump, fluid specifications, alignment.

Brakes:

Front vented discs, rear solid discs, ABS (Anti-lock Braking System) components and diagnostics, hydraulic system, brake fluid specifications.

Electrical System:

12V battery system, alternator, starter motor, wiring diagrams, fuse box locations and functions, lighting system, horn, wipers.

Climate Control:

HVAC system (heating, ventilation, and air conditioning), blower motor, A/C compressor, refrigerant, climate control unit diagnostics.

Body And Interior:

Body panel removal and installation, interior trim, seats, door panels, glass replacement, body repair procedures.

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, coolant flushes, belt inspections and replacement (timing belt crucial).

Troubleshooting:

System-specific diagnostic flowcharts, symptom-based troubleshooting guides for common problems.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation, including torque specifications.

Diagnostics:

OBD-I/OBD-II diagnostic codes, live data interpretation, sensor testing.

Specifications And Tolerances:

Detailed technical data, torque values, clearances, and performance specifications for all components.

Depth:

Expert Level: Covers everything from routine maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair.

📊 Manual Specifications

File Type:

Searchable PDF

Resolution:

High-resolution for clear text and diagrams

Printability:

Printable pages for workshop use

Binding:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Family:

Volvo Modular Engine

Engine Configuration:

Inline-5 Cylinder

Displacement 1:

2.5 Liters (2435 cc)

Engine Code 1:

B5252S

Horsepower 1:

140 hp @ 5200 rpm

Torque 1:

162 lb-ft @ 3700 rpm

Displacement 2:

2.5 Liters (2435 cc) - 20v

Engine Code 2:

B5254S (Non-Turbo)

Horsepower 2:

168 hp @ 6000 rpm

Torque 2:

166 lb-ft @ 4300 rpm

Displacement 3:

2.5 Liters (2435 cc) - 20v Turbo

Engine Code 3:

B5254FS (T5/R)

Horsepower 3:

222 hp @ 5200 rpm (T5) / 240 hp @ 5200 rpm (R)

Torque 3:

221 lb-ft @ 2000 rpm (T5) / 240 lb-ft @ 2000 rpm (R)

Induction:

Naturally aspirated and turbocharged (Bosch LH-Jetronic fuel injection, Garrett turbochargers).

Fuel Type:

Unleaded gasoline

Fuel Octane Rating:

91 AKI (95 RON) recommended for turbo models, 87 AKI (91 RON) acceptable for naturally aspirated.

Engine Management System:

Bosch Motronic LH-Jetronic 2.4 (N.A.) / Bosch Motronic 4.3 (Turbo)

🔧 Transmission

Transmission Type Std:

5-speed Manual (M56)

Transmission Type Opt:

4-speed Automatic (AW50-42LE)

Automatic Modes:

Sport/Economy (S/E) mode selection.

Manual Gear Ratios:

Provided within the manual for specific gearsets.

Automatic Fluid Type:

Volvo Dexron III (or equivalent)

📐 Dimensions

Length:

187.1 inches (4753 mm)

Width:

68.9 inches (1750 mm)

Height:

55.3 inches (1405 mm)

Wheelbase:

104.3 inches (2649 mm)

Front Track:

59.3 inches (1506 mm)

Rear Track:

58.5 inches (1486 mm)

Curb Weight Est:

3200-3400 lbs (1450-1542 kg), varies by model and equipment.

Gross Vehicle Weight Rating:

Approximately 4400 lbs (1996 kg)

🛡️ Safety Features

NHTSA Driver Front 1996:

5-star

NHTSA Passenger Front 1996:

5-star

ABS:

Standard on all models.

Traction Control:

Optional on some higher trims.

Airbags:

Driver and front passenger airbags standard.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners, side-impact protection (SIPS).

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Audio System:

Factory premium audio systems often included cassette players, AM/FM radios, and CD changers (optional).

Climate Control Features:

Manual or optional automatic climate control with cabin air filter.

Cruise Control:

Standard on most models.

Memory Seats:

Optional on some higher trims.

OBD Standard:

OBD-I (early 1996 models) and transitioning to OBD-II for later 1996 production runs, with specific diagnostic protocols for Volvo systems.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first, using synthetic or high-mileage oil.

Timing Belt Replacement:

Every 70,000 - 90,000 miles (112,000 - 145,000 km) or 5 years. CRITICAL: Failure can cause catastrophic engine damage.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs, 60,000 miles (96,000 km) for platinum-tipped plugs.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Engine Oil Spec:

API SJ or SL, SAE 5W-30 or 5W-40 (check owner's manual for specific climate recommendations).

Coolant Spec:

Volvo Green Coolant (or G48 equivalent), 50/50 mix with distilled water.

Brake Fluid Spec:

DOT 3 or DOT 4.

Power Steering Fluid Spec:

Volvo Power Steering Fluid (or ATF Dexron III equivalent).

Common Problems:

Timing belt tensioner failure, coolant leaks (especially at thermostat housing and hose connections), mass airflow sensor (MAF) issues, ABS sensor failures, rear axle trailing arm bushings wear, ignition coil failure, sticky throttle body.

Maintenance Tips:

Regularly inspect the timing belt and related components. Use high-quality parts. Keep the MAF sensor clean. Check for vacuum leaks.

📚 Vehicle History

Heritage:

Volvo's reputation for safety and reliability, established with models like the Amazon and 240 series.

Introduction:

The 850 was launched for the 1992 model year in Europe and 1993 in North America, representing a significant modernization and departure from previous Volvo designs.

Platform Design:

Front-wheel drive platform with transverse-mounted inline-five engine, designed for improved packaging and handling.

Body Styles:

Available as a 4-door Sedan and a 5-door Station Wagon.

Production Years:

1992-1997

Manufacturing Location:

मुख्य रूप से जेंट, बेल्जियम और टिल्बर, नीदरलैंड्स (यूरोपीय बाजार के लिए) और गैलिम्पे, स्वीडन (कुछ शुरुआती उत्पादन के लिए)।

🏆 Awards & Recognition

Car And Driver 10Best:

The 850 Turbo (T5) was named to Car and Driver's 10Best list for 1993 and 1994.

Safety Awards:

Consistently recognized for its high safety ratings and innovative safety features.