General Info OCR

8/2/2019 General Info OCR

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ContentsPage

About this manual 5Introduction to the Volvo 300 Series 5General dimensions, weights and capaci ties 6Jacking and towing 8Buying spare parts and vehicle identifica tion numbers 9General repair procedures 10Too ls and working facilit ies 11Conversion factors 13Safety fir st 14Routine maintenance (also see Chapter 11. page 395) 15Recommended lubr icants and fluids 24Fault diagnosis 25Chapter 1 Engine (a lso see Chapter 11, page 395) 29Chapter 2 Cooling system 94Chapter 3 Fuel and exhaust sys tems (also see Chapter 11, page 395) 107Chapter 4 Ignition system 157Chapter 5 Clutch 174Chapter 6 Transmi ss ion and final drive 187Chapter 7 Braking system 232Chapter 8 Suspension and steering (see also Chapter 11, page 395) 251Chapter 9 Bodywork and fittings (see also Chapter 11, page 395) 272Chapter 10 Electri ca l system (see also Chapter 11, page 395) 305Chapter 11 Supplement: Revisions and information on lat er models , 395Ind ex 404

Spark plCJ2 condition and bodywork repair colour pages between pages 32 and 33. ', - ,


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Volvo 340 Gl Hat chbac k

Vo lvo 360 GLE Sa loo n


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About this manualIts aimThe aim of thi s manual is to help you get the best value from yourvehicle . It ca n do so in several ways. It ca n help you decide what work.must be done (even should you choose to get it done by a garage),provide informat ion on rou tine maintenance and servicing. and g ive alogica l cou rse of action and diagnosis when random faults occur.However, it is hoped that you will use the manual by tackling the workyourself . On simpler jobs it may even be quicker than book ing the ca rinto il garage and going there tw ice, to leave and collect it. Perhapsmost important, a 10 1 of money can be saved by avoiding the cos ts agarage must charge to cover its l abour and overheads.The manual has draWings and descript ions to sho w the function o fthe various co mponenl S so that their layout ca n be understood. Thenthe tasks are descnbed and pho tographed in a step-by -step sequ enceso that even a nov ice can do the work .

Its arrangementThe manual is divided in to ten Chapters, each covering a logicalsub-division of th e vehicle. The Chapters are each divided intoSect ions, numbered with 5ing le -figures, eg 5; and the Sections intoparagraphs (o r sub-sectionsl, with decimal numbers following onfrom th e Sec tion they are in, eg 5.1,5.2 , 5.3 etc.It is freely illustrated, especia lly in those parts where there is adetailed sequence of operat io ns to be carried oul. There are two formsof illustration: figures an d photographs . The f igures are numbered in

sequence w ith decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration II I Chapter 6Photographs carry the same number (either individually or in relatedgroups) as th e Section or sub-section to which they re late.There is an alphabetical index at the back of the manual as well as aco ntents list at the front . Each Chapter is also preceded by its ownindividual co ntents list.References to the ' left' or 'right" of th e vehicle are in the sense of aperson in the dr iver's seat facing forwards .Unless otherwise stated, nu ts and bolts are removed by turningan ti -clockwise. and ti ghtened by turning clockWise.

Vehic le manufacturers co nt inu all y make changes to specificat ionand recommendat ions, and these, when notified. are incorporated intoour manuals at the earliest op portun ity.

We take great pride in the accuracy of information given in thismanual, but vehicle manufacturers make alterations and designchanges during th e production run of a particular vehicle of whichthey do not inform us. No l iability can be accepted by the authorsor publishers for loss, damage or injury caused by any errors in . orom issions from . the information given.Project v ~ h i c l e s

The vehicles used in the preparation of th is manual, and appearingin many of the photographic sequences, were tln ear ly Volvo 343, a360 GLEi , a 360 GLS w ith 8200 eng ine, and a 340 GL with B172engine .

Introduction to the Volvo 300 SeriesThe Volvo 343 three-door Hat chback was introduced in the UK inSeptember 1976, being built wi th traditional Volvo expertise , and

incorpora ting many safety features such as impact bars in the sidedoors. The first models were avai lable only wi th th e double beltcon tinu ous ly variable (CVT) automat ic transmission, wh ich wascarried over from the Volvo 66 model. M anual versions becameavailable in September 1978 and were fitted with a reLI t moun tedmallual gearbox Similar to that fitted to the 240 se ries.The 345 five-door Hatchb ack models Were introduced in January1980.

In 1982 the models were redeSigna ted 340 OL and GL, and at thesame time the 360 Series was in t roduced With a 2 litre engine andtransmission torque tube . The top of the range G E model wasint rod uced in late 1983 and incorporated a boot. It was available w itha carburettor or fue l inject io n engine .In May 1985 the 360 GLS was redesignated the GL and in A ugusof the same year the 1.7 litre 340 GL and GLE were introduce d.80th 340 and 360 models have received periodic updates toincorporate a number of modern motoring developments; maintainingVolvo 's reputation for sa fety and so lid dependability.


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General dimensions, capacities and weightsD imensionsOverall length:Models up to 1981 .. ..... ... .. .. .. ..... .............. ... ... ...... .. ....... .. ......... .. .. .........1982 models ... ......... ............................... .. ....... , . " ..... , ............. .... ......... .Models from 1982 to 1989:

Hatchback , .. ................. ..... ...... .. ........... .. .. .. ..................................... .Saloon ................ .................... ................ ........ ...................................M odels lrom 1989 :Hatchback ..... ...... ...... .... ........................... ..... ...... .. ........... .... ............. .Sa loon .......................... .. .. ........ ....... ........ .. .... .... ...... .. .......... .. ............wIdth ................................................... .... .. .. ........ .... ........................ .he ig ht ( unladen):340 se ries.

Up to 1984 .......................... ........ .. ....... ..... ... ....... .. .. .. ... ....................FrOln 1984 ' . ..................... , . ........... .. ...................... .. ...... .. ...... ........ .360 se ries .Carburettor:

Mode ls to 1982 .............. .. .... .. .. ..... .. .. ................ ... ...... ....... ... .1982 and 1983 models ......................... ........ ....... ...... .. .............Mode ls from 1984 ..... .. ....... .. .. .. ..... .. .. ... .. .. .. ... ...... ...... .. .. ........ .. ..

Fuel injec tion1983 models ... ..... ..... ...... .. .. .......... ... ............. ..... .... ...... ...... .. .... .. .1984 ")ode ls ...... .... .. ...... ... ............. ........ ... ............. ............. .... .. .. .Models from 1985 ......................... .... .. ................... ........... ........ .

elbase:340 series (except 1.7 litre) ...................... ... .. ..... ..................................360 series and 1.7 litre .. .. .. .. .. ... ........................... ...... .. ... .. ..... ............... .ck (front) :340 series .

Models up 10 1980 ..... ....... .. ...... ...... ............ ... .. .... ....... ...... ........ .. .. .Models from 1980 ............ ......... ......... ...... .. .. ............ ... ....... .......... .. .

360 series .... .. ........... _................................................. .................. .. ....... .ack (rear) :340 se ries.

Models up 10 1980 ................. .. .. .. .. . .... ... ..... .... .. .. ... ... .......... ............Models from 1980 .... ..... .. .... .... .. .. .. ...... ...... .. ............ .. ... ... .......... .. .... .

360 series ................................... ....... ...... .... .. ...................... .. ... .............. .g cilcle (belween kerbs):340 se ries (excepi 1.7 IlI re ) .. .................... ...... ......... ....... ...... ...............360 se ries and 1.7 litre ............. .......................................... ............ -..... .

a pacit iesEngine ai' - at oil and filter change:

' 65.4 in (4200 mm)'66 .7 in (42 35 mm )' 69 .3 in (4300 mm )173.8 in (44 '5 mm), 70 .2 in (4380 mm)175.3 in (4450 mm)65.4 in (1660 mm)

56 .7 in ( 1440 mm )56 .3 in ('4 30 mm)

57 .1 rn (1450 mm )56 .7 in (1440mm )56 .3 in (1430 mm)56 .0 in ( 14 23 mm )56.3 in (1430 mm )55 :9 in (1420 mm )94.3 in (2395 mm)94.5 in (2400 mm )

53 .' in (1350 mm)53 .9 in (1370 mm)54.3 in (' 380 mm )

54 .3 in (1380 mm)55 .1 in ( 1400 mm )55 .3 in (1 405 mm)30 .2 It (9 .20 m)30 .7 It (9 .35 m)

1.4 litre models .. .............................. .. ........... ...... ... ....... ................. ..................... 7.0 pints (4.0 litres)1.7 litre m ode ls ........................ ................. ............................. .... ......................... 8.8 pints (5.0 lilres)2.0 litre morle ls .................................... ......... .................................. ........ ............ 7.9 pints (4.5 lit res)Amount required to ra ise oil level from dipstick MIN to MAX marks:

1.4 and 2.0 litre models ....................... .. ........ .... ..... ................ ........... ............. 1.8 pints (1.0 litres)1.7 litre models .............. .. .............................. ..................... ... .. ...... .. ......... .. ........ 2.6 pints (1.5 lilres)

Coo li ng sys tem ( including ex pansion tank) :B14 (upto 1989) ............ ...... ................ ................................................814 (1989 0n) ............................ ................... .. .... ........... ......... .... ......... .B172 .......................................................................................................B' 9 :M odels up to 1982 .............. .. .. ..................... ..... .. ................. ........ .. .

Models from 1982 .............. .. .. ..... ... .... .... .... .... .... ....... .. .....................B200 .. ........ .... .. ......... .. ' ........ ........... .. ...... .. .. .. .. ..... .... ... ....... ...... ....... ........ .Automatic transmission.Pri mary gear case ............................................ ..... ................................. .Secondary gear case ....................... ........... ............... ........... ..... ....... ......

9.2 pints (5.2 ' ttres)11 .5 pints (6 .5 litres)14.1 pints (8 .0 Irtres)14.1 pints (8.0 I;tres)12.3 pints (7.0 HIres)12.3 pints ( 7.0 'il res)1 .0 pints (0 .55 litre)1 .8 pints (1 .0 litre)


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General dimensions, capacities and weightsManual gearbox (total ):Four-speed:

Models up to 1984 .... .. ............... ...... .. ...................................................Models from 1984 ..... ........ ...... ................ .... .. ..... ............ .... .. .. .. .... ... .Five-speed:Plug at rear .... .. ........ ... .. .. .. ... .. ... ..... .. .. .. ........ ... .. .. .. .. .... .. .. .. .. .. ... ... .. .. .. .Plug at front:Models up to 1985 ...... .................. .. ..........................................Models from 1985 to 1989 ... ..... .. .. .. .. ............. .. .. ..... ............... .

Models from 1989 ..................................................... ................ .Final drive unit:814 ,Models up to 1982 ... .... .... ... .. ... .... .. ... ......... .. .. .. .. .. .... ............... ... ... .Models from 1982 ................................... ... .. .. ............. ....... ........ ..... .B 17 2 ..... ......................... ............. .... .... ....... ......... ... .... .... ..... .................... .819 and 8200,Four-speed ... ...................................... ..... .................................... .. .. .Five-speed ... ......... ........ .. .. .. .. .. .. .. .. .. ...... ... .. ........... .. ... ... .. ... .............. .

Fuel tank:340 Series ..... .. ... ... ... .................. ............ ......... ... .... .... ... ... .. .. .. .. .. .. .......... .360 Series ............... ........ ... .. ..... ....... .. .. ........ .... .. .... ....... ............. .. .......... .

WeightsKerb weight:

81 4 automatic:Models up to 1984 ......... .... .... ......... ... ............................................Models from 1984 to 1986 ....................... ................... ...... .. .. .. ...... .Models from 1986 ........................................................................... .

81 4 manual:Models up to 1984 .. .. .. .... .... .. ... .... ... .. .. .... .. ..... .... .................. ....... .Models from 1984 to 1986 ..................................... .. .. .. .. ..... ..... ..... .Models from 1986 .... .... .. .. .... .. ... .. .. .. .. ....... .. ..... .. ... .. .... ..................... .

8172 ........................................... .......... ... ..... ......... .. .. ... .............. ............ .819 and B200 (carburettor ) .. .. ... .... ...... ..... ... ... ..... ... ............................819 and B200 (fuel injection ) .. .. ... .. ... ... ... ... ... .. .. .. .. ...... .. ... ... ............. .

Maximum permissible weight:814 automatic ......... ....... .... .. .... .... .. .. .. ... ... ... .. ....... .... .... ........ .. .. .. ....... ... .B14 manual .... ..................... .. .. .... ..... .. .. .. .. ....... ..... .................................. .8172 .. .. .. .. .. ... .. .... ...... ....... .. .. ........... .. ... ....... ..... ....... ... .. ....... .. ........... ... .... .81 9 and B200 ...................................................................................... .

. Trailer weight (maximum ):81 4 automatic ................................................................................... .... .B14 manual .... .. ........ .... .. ... ... .. .... ..... ... ........... .. ... .... .... .. ........... .... ... .. ... ... .8172 ........................ ................ ..... ..... .. .. ... .. .......... .. ...... .. .. .. .. ... ....... ...... .. .819 and 8200 ...... ..... ... .... ... .. .. ... .. ... ... ... .......... .. .. ........... .. ................ ..... .

Roof rack load (maximum):81 4 automatic ......................... .. ..... ..... .... .. .. ......... .. ......... ... .. ... ... .. ... ... .. .81 4 manual ... ....... ..... ............................................................................. .B172 .. ... ...... .. ............. .... ............ ..... .. .... ......... ..... .................................... .B19and 8200 ................................................................... .. ... ... .. ... ... ... .

3.7 pints (2 .10 litres)4.1 pints (2.35Iitres)4.8 pints (2 .70 Htres)6.2 pints (3 .50 Htres)5.3 pints (3.0 litres)4.9 pints (2 .8 litres)2.6 pints (1 .45 litres)2.4 pints (1.35 litres)2.4 pints (1 .35 litres)2.6 pints (1 .50 litres)2.4 pints (1 .35 litres)9.9 gal (45 litres)12 .5 gal (57 litres)l -door

2160 Ib (980 kg)2152 Ib (976 kg)2176 Ib (987 kg)2105 Ib (955 kg)2099 Ib (952 kg)2116 Ib (960 kg)2167 Ib (983 kg)2372 Ib (1076 kg)2425 Ib (1100 kg)3197 Ib (1450 kg)3131 Ib (1420 kg)3263 Ib (1480 kg)3395 Ib (1540 kg)1984 Ib (900 kg)2205 Ib (1000 kg)2205 Ib (1000 kg)2646 Ib (1200 kg)

99 Ib (45 kg)110 Ib (50 kg)110 Ib (50 kg)132 Ib (60 kg)

4-door

2072 Ib (940 kg )

2110 Ib (957 kg)

2370 Ib (1075 kg)2410 Ib (1093 kg)

5-door

2216 Ib (1005 kg)2196 Ib (996 kg)2229 Ib (1011 kg)2160 Ib (980 kg)2143 Ib (972 kg)2172 Ib (985 kg)2209 Ib (1002 kg)2414 Ib (1095 kg)2467 Ib (1119 kg)


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Jacking and towingTo change a roadwheel. remove the spare wheel and tool kit fromthe engine compartment or bool. Check that the hand brake is fu ll y

applied, then engage P (automatic transmission) or 1st (manualtransmission) . Two jacking points are provided on each side of the car.With the car on level ground. open up the jack and sl ide the lift ing padint o the jacking po int. Con tinue to open th e jack un t il it is in con tactwith the ground. On early models, remove the hub cap or w hee l nutcaps . Using the brace, unscrew the wheel nuts half a turn . Raise theack until the wheel is off the ground, then remove the wheel nuts andwithdraw the wheel . On late models remove the hub cover.

Fi t the spare wheel using a reversal of the removill procedure, buton late mode ls remember to f it the hub cover before fllt ing the nuts.

W hen us ing a trolley lack, pos it ion the jack under the four jackingpoints, the rear engine bearer, or midway along the De Dian rear axle.Tow ing eyes are provided below the front and rear bumpers on therigh i -hand side; do not use these eyes for lifting the ca r. If being towed ,se lect N (automat ic transmiSSion) or neutral (manua l transmission )and remember thal with the engine stopped, more effort witt berequired when depressing the foot brake pedal since the servo will beinoperat ive .

Sp a re wh ee l loca ti on (340 mode ls ) Spare wheel location (360 models ) Too l k it w it h sp a re whee l re m o ved(3 40 mode ls)

Jac king up th e ca r (n o t e th e ea rl ysc isso r ty pe j ac k )

-Front towing ey e Rea r t ow ing ey e


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Buying spare parts andvehicle identification numbersBuying spare partsSpare parts are available from many sources, for example: Vo lvogarages, other garages and accessory shops, and motor factors. Ouradvice regarding spare part sources is as follows.Officially appo inted Volvo garages - This is the best source of partswhich are peculiar to your car and otherwise no t generally avai lab le(e9 complete cylinder heads, transmission components, badges,interior trim etc} . It is also the only place at which you shou ld buy partsif your vehicle is still under warranty - use of non-Volvo compo nentsmay invalidate the warranty. To be sure of obtaining the correct parts itwill plways be necessary to give the storeman your car's vehicleidentification number, and if possible. to take the 'old' part along forpositive identification . Remember that many parts are available on afactory exchange scheme - any parts returned should always be clean!It obviously makes good sense to go straight to the specialists on yourcar for this type of part for they are best equipped to supply you.Other garages and accessory shops - These are often very goodplaces to buy materials and components needed for the maintenanceof your car (eg oil filters, spark plugs, bulbs, drivebelts, oils andgreases, touch -Up paint, filler paste etc). They also se ll generalaccessories, usually have conven ient opening hours. charge lowerprices and can often be found no t far from home.Motor factors - Good factors will stock all of the more important

Engine number lo ca t io n

components which wear out relatively quickly (eg clutch componen ts,pistons, valves, exhaust systems, brake cylinders/pipes/hoses/sea ls/shoes and pads etc) . Motor factors will often provide new orreconditioned components on a part exchange basis - this can save aconsiderable amount of money.

Vehicle identification numbersAlthough many individual parts, and in some cases sub -assemblies,f it a number of different models it is dangerous to assume that justbecause they look the same, they are the same. Differences are not

always easy to detect except by se rial numbers. Make sure, therefore.that the appropriate identity number for the model or sub -assembly isknown and quoted when a spare part is ordered.The engine number on B14 models is located on a metal plate fjxedto the left-hand side of the cylinder block above the oil filter. On B19and B200 models it is punched in the cylinder block above thedistributor and on 6172 models, next to the oil dipstick.

The chassis number is stamped on the right -hand side of thebulkhead, behind the fusebox in the engine compartment.The vehicle identification plate is located within the engine

compartment on the front crossmember.The servicing data plate is located under the driver's side door lock.

Vehicle identif ication plate location


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General repair proceduresWhenever servicing, repair or overhaul work is c arried out on thecar or its components. it is necessary to observe the followingprocedures and instructions. This will assist in ca rrying out theoperation eff icientl y and to a professional standard of workmanship.

Joint mating faces and gasketsWhere a gasket is used between the mating faces of twocomponents, ensure that it is renewed on reassembly, and fi t it dryunless otherwise stated in the repair procedure. Make sure that thema t ing faces are clean and dry with all traces of old gasket removed.When cleaning a jo int face, use a tool which is not likely to score ordamage the face, and remove any burrs or nicks with an oilstone or finefile.Make sure that tapped holes are cleaned with a pipe cleaner, andkeep them free of jointing compound if thi s is being used un lessspecifically instructed otherwise .Ensure that all orifices, channels or pipes are clear and blowthroug h them. preferably using compressed air.Oil sea lsWhenever an oi l seal is removed from its working location. eitherindividually or as part of an assembly, it shou ld be renewed.The very fine sea ling li p of the sea l is easily damaged and will notseal if the surface it contacts is not comp letely clean and free fromscratches, nicks or grooves. If the original sealing surface of thecomponen t cannot be restored, the component should be renewed .Protect the lips of the sea l from any su rface which may damagethem in the course of fitt ing. Use tape or a conical sleeve wherepossible. Lubricate the seal lips with oil before fitting and, on duallipped seals, fill the space between the lips with grease.Un less otherw ise stated . oil sea ls must be fitted with their sea linglips toward the lubricant to be sea led .Use a tubular dr ift or block of wood of the appropriate size to installthe seal and, if the seal housing is shouldered. dr ive the sea l down tothe shoulder. If the seal housing is unshoutdered. th e seal should befitted with its face flush with the housing top face.Screw threads and fasteningsAlways ensure that a b lind tapped hole is completely free from oil.

grease. water or other ftuid before installing the bolt or stud . Fai lure todo this could ca use the hou sing to crack due to the hydraulic action ofthe bo lt or stud as it is screwed in.When tigh tening a castellated nut to accept a split pin, tighten thenut to the specified torque. where applicable. and then tighten furtherto the next spli t pin hole. Never slacken the nut to align a split pin holeunless stated in the repair procedure.When checking or retightening a nut or bolt to a specified torquesett ing, slacken the nut Or bolt by a quarter of a turn, and then retightento the specified se tting .Locknuts. locktabs and washersAny fastening wh ich will rotate against a component or housing inthe course of tighten ing should always ha ve a washer between it andthe relevant component or housing.Spring or split washers should always be renewed when they areused to lock a crit ical component such as a big -end bearing retainingnut or bolt.Locktabs which are folded over to retain a nut or bah should alwaysbe renewed.

Self-locking nuts can be reused in non -cri tical area s, provi dingres is tance can be felt when th e locking port ion passes over the bolt orstud thread.Split pin s must alwa ys be replaced wi th new ones of the correctsize for the hole.Special toolsSome repair procedures in this manual entail the use of special too lssuch as a press , tw o or three-legged pullers, spring compressors etc.Wherever possi ble, sui table readily available alternat ives to themanufacturer's special too ls are described, and are shown in use. Insome instances. where no alternat ive is possible. i t has been necessaryto resort to the use of a manufacturer's too l and th is has been done forreasons of safety as well as the efficient completion of the repa iroperation . Unless you are highly skilled and ha ve a thoroughunderstanding of the procedure described, never attempt to bypass theuse of any special too l w hen the procedure described specif ies its use .Not only is there a very great risk of personal injury, but expensivedamage cou ld be caused to the components involved.


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and working facilitiesA selection of good tools is a fundamental requirement to r anyone

the maintenemce and repair of a motor vehicle. For thewho does no t possess any, their purchase will prove ansiderable expense, offsett ing some of the savings made byHowever. provided that the tools purchased meet

sa fety standards and are of good quality. they willfor many yems and prove an extremely worthwhile investment.

To help the average owner to decide which tools are needed to carryt the various tusks detuiled in this manual. we have compiled threets of tools under the following headings: Maintenance and minorRepair an d overhaul and Special The newcomer to practical

should stmt of f with the Maintenance an d minur repair toolt and confine himself to the simpler Jobs around the vehic le. Then , asis confidence and experience grow, he can undertake more difficult

buying extra tools as , and when , they are needed . In this way, aand minor repair tool kit can be built-up into a Repair an d

tool kit over rI considerrlble period of t ime w ithout any majorThe experienced do - it -yourselfe r will have a tool ki t goodmost repair and overhaul procedures and will add tools

the Special category when he feels the expense is justified by theof use to which these tools will be put .

and minor repair tool kitThe tools g iven in this list should be considered as a minimumif routine mainteneJnce, servicing and minor repair

are to be undertaken. We recommend the purchase ofspanners (ring one end, open-ended the other) ; althoughexpensive than open -ended ones, they do give the advantages oftypes of spanner.Combination spanners - la , II , 12, 13, 14 & 17 mmAdjustable spanner - 9 inchEngine sump /gearbox drain plug keySpark plug spanner (with rubber insert)Spark plug gap adjustment tool

Se t of feeler gaugesBrake adjuster spannerBrake bleed nipple spannerScrewdriver - 4 in long x ' /4 in dia (flat blade)Screwdriver - 4 in long x '/4 in dia (cross blade)Combination pliers - 6 inchHacksaw (junior)Tyre pumpTyre pressure gaugeGrease gunOil canFine emery cloth (1 sheet)Wire brush (small)Funnel (medium size)

Repair and overhaul tool kitThese tools are virtuilily essentiill for ilnyone undertilkinf:! any majorrepairs to a motor vehicle, and are addit ional to those given in theMaintenance an d minor repair list. Incl uded In thiS list is acomprehensive set of sockets . Alth ough these are expensive they willhe found invaluable as they are so versatile - pilrtlclJlrlrly if variousdrives are included in the set. We recommend the )6 in square-drivetype , as this can be used with most proprietary torque wrenches. If youcannot afford a socket se t, even bought piecemeal , then inexpensivetubular box spanners are a useful alternative_The tools in this list w ill occasionally need to be supplemented bytools from the Special list.

Suckets (or box spanners) to cover range in previous listReversible ratchet drive (for use with sockets)Extension piece, 10 inch (for use with sockets)Universal joint (for use with sockets)Torque wrench (for use with sockets)'Mole' wrench - 8 inchBall pein hammerSoft-faced hammer, plastic or rubberScrewdriv(J{ 6 in long x 5116 in dia (flat blade)Screwdriver - 2 in long x 5 /16 in square (ffat blade)Screwdriver - 11/2 in long x 1/ 4 ill diu (cruss blade)Screwdriver - 3 in long x ,/& in dia (electricians)Pliers - electricians side cutlersPliers - needle nusedPliers - circlip (internal an d external)Cold chisel - 1/2 illchScriberScraperCentre punchPin punchHacksawValve grinding toolSteel rule/straight -edgeAllen keysSplined (12 -point) keysSelectioll of filesWire brush (large)Axle -standsJack (strong trolley or hydraulic type)

Special toolsThe tools in this l ist are those which are not used regularly, areexpensive to buy, or which need to be used in accordance with their

ma n ufacturers' instructions . Unless relatively d fficu t mechan ca I -jobsare undertaken frequently, it will not be economic to buy many of thesetools. Where this is the case, you could consider clubbing togetherwith friends (or joining a motorists' cl ub) to make a joint purchase, orborrowing the tools against a deposit from a local garage or 1001 hirespecialist.The follow ing l is t conta ins only those tools and instruments freelyavaililb le to the public, rind not those special tools produced by the


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12 Too ls and working facil i t iesvehicle manufaclUrer specifica lly fo r its dealer network. You will findoccasional references to these manufacturers' special tools In the textof th is manual. Generally. an alternative method of domg the Jobwithout the vehicle manufacturers' special 1001 IS given . However,sometimes, there IS no alternative to using them. Where th is is the caseand the relevant tool canno t be bought Or borrowed, you will have toentrust the w ork to a franchised garage.

Valve spring compressor (where applicable)Piston ring compressOrSal/join t separatorUniversal hub/ bearing pullerImpact screwdriverMicrometer and/or vernier gaugeDial gaugeStroboscopic liming lightDwell anyle meter/tachometerUniversal electrical mufti -meterCylinder compression gaugeLifting tackleTrolley jackLight with extension lead

Buying toolsFor pract ically all loo ls. a tool factor IS the best source since he Willhave a very comprehensive range com pared with the average garage oraccessory shop. HaVing said that accessory shops often offer excellent

Quality t o o l at discount prices. so it pays to shop aroundThere are plenty of good tools around at reasonable prices, butalwavs aim to purchase items which meet the relevant "atlonill safetystandards. If in doubt, ask the proprietor or manager of Ihe shop foradvice before making a purchase.Care and maintenance of toolsHaving purchased a reasonab le tool kit. it is necessary to keep thetools in a c lean serviceable condition. After use, always wipe of f anydirt . grease and metal partic les using a clean, dry clOth, before puttingthe too ls away. Never leave them lying around after they have beenused. A simple too l rack on the garage or workshop wall, for items suchas sc rewd rivers and pliers is a good idea . Store all normal wrenchesand sockets in a metal box . Any measuring instruments, gauges.meters, etc. must be carefully stored where they cannot be damaged orbecome rusty.

Take a little care when tools are used. Hammer heads inevitablybecome marked and screwdrivers lose the keen edge on the ir bladesfrom t ime to time . A l ittle timely attention wi th emery c lolh or a file willsoon restore items like th is to a good serviceable finish .Working facilities

Not to be forgotten when discussing tools. is the workshop itself . Ifanything more than routine maintenance is to be carned out, someform of suitable work ing area becomes essential .It is appreciated that many an owner mechanic is forced bycircumstances to remove an engine or simi lar item, wi thout the benef itof a garage or workshop . Having done th is, any repaIrs should alwaysbe done under the cover of a roof.Wherever possible. any dismantling should be done on a clean. flatwo rkbench or table at a sui table work ing height.Any workbench needs a vice: one w ith a jaw opening of 4 in (100mm) is sui table for most Jobs. As mentioned previously, some clean drystorage space is also required for tools, as well as for lubrican ts ,cleaning fluids. touch -up paints nnd so on, which become necessary.Another item which may be reqUired. and which has a much moregeneral usage, is an electric drill with a chuck capacity of al least 5/16in (8 mm) . ThiS. tog ethe r with a good range of twist drillS, is Virtuallyessential for fitting accessories such as mirrors and reversing ligh ts.LdS I, but not least, always keep a supply of old newspapers andclean, lint -free rags available, and try to keep any working area as cleanas possible.

Spanner iaw gap comparison tableJaw ga p ( in)0 .2500.2760.3130.3150.3440.354037503940.4330.4380.4450.4720.5000.5120.5250.5510.5630.5910.6000.6250.6300.6690.6860.7090.7100.7480.7500.8130.8200.8660.8750.9200.9380.9451.0001.0101.0241.0631.1001.1251.1811.2001.2501.2601.3001.3131.3901.4171.4381.4801.5001.5751.6141.6251.6701.6881.81 11.8131.8601.8751.9692.0002.0502.1652.362

Spanner size1 4 11lAF7 mm5 ' GIn AF80110, " 32 in AF , '8 In Whitworth9 mm38 In AF10 nun11 10m7/ 11i in AF3/ 16 In Wh itworth; 1/ 4 In BSF12 mOl1(2 In AF130110' /4 In Whitworth , 5/ 16 In BSF14 mm9/16 In AF15 mm!;o11 6 In Whitworth; 3/8 In BSF5/8 111 AF16 mm17 10m11 / 16 III AF18mm3/8 III WhilWOrlh, 7/16 in BSF19 mOl3 /4 In AF13/H in AF7/16 in Wh itworth , ' / 2 in BSF22 mm7f t!, in AF' /2 in Whitworth. 9/16 In BSF15/ 16 in AF24 10m1 in AF91 6 in Whitworth, 51a in BSF26 mOl1' / 16 in AF. 27 millb/s 10 Whitworth; I ' n6 In BSFl' /ainAF30 mOl11 /16 In Whitworth . "J /4 in BSF1' /4 II I AF32 mm314 in Whitworth; 7/S In BSF15/161nAF13/ 16 In Wh itworth ; '5/Hi in BSF36 mill1 ' /16 In AF7/8 in Whitworth; 1 in BSF11/21n AF40 mm ; IS/ If; in Whi twor lh41 mm15/8 in AF1 in Whi IWOrl h, 1 /a in BSF11' / '6 inAF46 mm1 1:1116 In AFl' l a in Whllworth, 1' /4 in BSF17;slnAF50mm2 In AF1' /4 in Whilworlh ; 13/s in BSF55 mm60 mm


12/13

onversion factors(distance)nches ( in)

(t t )

(capacity)inches (cu in; inl )ial pints ( Imp pt )ial quarts ( Imp qt )

quarts ( Imp qt )(US ql )

gallons (Imp gal)al gallons ( Imp gal)gallons (US gal)

(weigh t)(oz)s ( Ib )ce (ozf; oz)s-force (Ibf; Ib)(N )

ounds-force per square inchpSI ; i n ~ ; Ib/ inl)- force per square inchIbf / in 2: Ib/ in2)- force per square inchps i: Ibf / in2; Ib / in2)- force per squ are inchIbf /i n2; Ib / in 2 )i lopascals (kPa)(mbar)(mbar)

ibar (mbar)(mbar)of mercury (mmHg)nches of water (i nHzO)

(moment of force)-force inchesIb l in; Ib in ) inchesin; Ib in) inchesbl in; Ib in)ounds-fo rce feet (Ibf ft : Ib ft l

s-force feet (Ibf ft ; Ib tt )ewton me tres (Nm )

(hp)ty (speed)les / hr; mph )

consumption', Imperial (mpg)per gallon, US (mpg)

X 25 .4X 0.305X 1.609

X 16 .387X 0.568X 1.137X 1.201X 0.946X 4.546X 1.201X 3.785

X 28.35X 0.454

X 0.278X 4.448X 0.1

X 0.070X 0.068X 0.069X 6.895X 0 .01x 100X 0.0145X 0.75X 0.40 1X 0.535X 0.036

X 1.15 2X 0.113X 0.083X 0.13 8X 1.356X 0.102

X 745.7

X 1.609

X 0.354X 0.425

- Mill imetres (mm)- Metres (m )Kilometres (km)- Cubic centimetres (ee; c m ~ ) Litres ( I)Litres (I)US quarts (US qt )- Litres ( I)Litres ( I)US gallons (US gal)Litre s ( I)

Grams (g )- Kilograms (kg)

- New tons (N)= New tons (N)- Kilograms -force (kgf; kg)

Kilograms -for ce per squarecentimetre (kgf /c m2 ; kg /c m2 )Atmospheres (atm)BarsKilopasca ls (kPa)

- Kilograms- force pe r sq uarecentimetre (kgf/ cm2 ; kg /cm2)- Pascals ( PalPounds -force per sq uare inch(psi; Ibf / in 2 ; Ib / in2)Millimetres of mercury (mm Hg)- Inches of water (inH 20)- Inches of wa ter ( inH 20 )- Pound s- force per square inch(psi; Ibf/ inl ; Ib/ in l)

Kilograms-force cent imetre(kgf cm; kg cm)New ton metres (Nm)Pounds - force feet ( Ibf It ; Ib It )Kilogram s- force metres(kgl m; kg m)New ton metres ( Nm)

= Kilograms-force metres(kgl m; kg m)

Watts (W)

X 0.0394X 3.281X 0.621

X 0.061X 1.76X 0.88X 0.833X 1.057X 0.22X 0 .833X 0.264

X 0.035X 2.205

X 3.6X 0.225X 9.81X 14 .223X 14 .696X 14 .5X 0.145X 98 .1X 0.01X 68 .947X 1.333X 2.491X 1.868X 27.68

X 0.868X 8.85X 12X 7.233X 0.738X 9.804

X 0.0013

Kilometres per hour (km/ hr; kph ) X 0.621

- Kilometres per litre (km/ I)Kilometres per litre (km/ I) X 2.825X 2.352

-

--

-

Inches (in)Fee l (It )Mi les

Cubic inches (cu in; inl)Imperial pints (Imp pt)Imperial quarts (Imp qt)Imperial quarts ( Imp qt )US quar ts (US qt)Imperial gallons ( Imp ga l)Imperia l gallons ( Imp gal)US gallons (US gal)

Ounces (oz)Pounds (Ib)

- Ounces- force (ozf; oz)- Pounds- force (Ibf; Ib)= Newtons (N )

- Pounds-force per square inch(psi; Ibf/ i n2; tb/i n2)- Pounds-fo rce per square inch(psi ; Ibf / in2 ; Ib/ in2 )- Pound s-force per square inch(psi; ~ ; Pounds-force pe r sq uare inch(psi; Ibf /i n2; Ib/ in2 )Kilopascals (k Pa)Millibar (mbar )Millibar (m bar)

= Millibar (mbar)Millibar (mbar)Millimetres of mercury (mmHg)Inches of water (inHzO)

= Pounds-force inc hes(Ibf in; Ib in)= Pounds- force inches(Ib l in ; Ib in)- Pounds-force inches(Ibf in; Ib in)= Pounds-force fee t (Ibf It ; Ib It)= Pounds-for ce feet (Ibf ft; Ib ft l

Newton metres (Nm)

Horsepower (hp)

Mi les per hour (mi les / hr; mph)

Miles per gallon, Imper ia l (mpg)- Miles per galion, US (mpg )

s Fahrenheit - ("C x 1.8) I 32 Deg rees Celsius ( Degrees Centigrade; ' C) = (OF - 32) x 0.56t is common practice to con vert from miles per gallon (mpg) to fitres/l00 kilometres (l/ l00km),

mpg (Imperial) x 1/ 100 km = 282 and mpg (US) x 1/ 100 km = 235

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14Safety f irst!

Professional motOr mechanics arc tramed in safe workIng prourage a sa fety -conscious approach to all work you carry out onyow vch ic:\e .

Essen tia l DOs and DON'TsDON 'T rely on a single lack when working undernCJ lh Ihe vehicle.AlwClYs use ,cllable additlon .1means of SUfJPorl , such ilS uxle stands,securely plilced under a part 01 the vehicle that you know will not g iveway.DON 'T attempt to loosen or t igh ten high -torque nuts (e .g . wheel hubnuts) w hile Ihe ve hicle .s on a lack, it may be pulled off .DON 'T sta rt the cngine wi thout first ascertaining that the transmiSS ionIS in neutral (or 'Park ' w here applicilble) and the parking brake ;)pplied.DON 'T suddenly remove the filler cap from a hot cooling systemcover il w ith a cloth and release the pressure gradually f irst, or you mayget sc;)lded by escaping coolant.DON 'T attempt to drain oil un til you arc sure it has coo led sufficientl yto avoid scald ing you.DON 'T grasp any part of the engine, exhaust Or ca talyllc converte rw ith out first uscertainmg that it is sufficiently cool to avoid bu rningyou.DON 'T allow brake flUid or ant ifreeze to co ntact vehicle pain two rk.DON 'T syphon 10XIC liquids such as fuel. brakc fluid or ant ifreeze bymouth, or allow them to rema in on you r skin.DON 'T Inhille dust - it may be injuriotJs 10 health (sec Asbestosbelow ).DON 'T allow any spi l t oil or grease to re mil in on Ihe floor w ipe it upStra ight away, before someone sl ips on it .DON 'T usc III -fitting spilnners or o ther too ls which may slip and ca useInjury.DON 'T all emp l to lift iI heavy component wh ich may be beyond yourcapabili ty - get assistance.DON 'T rush to finish a job, or take unverified shari cuts.DON 'T allow children or animals In or around an unattended vehicle.DO wear eye protec t ion when uSlllg power tools such as dr ill , Silnder,bench g.inder e:c, and when WOtklOg under the vehicle.00 use a bamer creum on your hands prior to undertaking dirt y Jobs it will plOtecl your skin from infection as well as making the dirt easielto remove afterwards; but make slife your hands aren 't leh slippery.Notc that long -term con taCt with used engine oil ca n be a healthhazard .00 keep loose cloth ing (c uf fs, tie ete) and long hair well out of Iheway of moving mechanical parts.00 remove lings. wristwatch etc, before wo rking on the vehiclecspccially the electrical system.00 ensure tha i any lilting tackle used has a sa le worktng load ratingadequate for the job.00 keep your work area tidy - it is only 100 easy to fall over ar ticles leftly ing around.DO get someone to check periodically that iJ lI is we ll , when workingalone on the vehicle.00 ca rry Out work in a 10glCD I sequence and check thai evel"y th ing iscorrectly assembled and tightened afterwards.00 remember that your vehlcle's sDfety affects that of yourself andothers. If In doubt on Dny pOlllt, get specialist advice.IF, in spi te of follow ing these precautions, you are unfortunate enoughto injure yourself, see k medical attention as soon as possible.

AsbestosCenilin f(l(.: tion. insula ting . sealmg, and other produc ts such as

brake linings, brake bands. clutch lin ings, torque conveners. gaskets,etc - cOOla in asbestos. Ex treme care must be taken 10 aVQf(1 in hallt(iofJof dust/rom slIt;h p roducts since il is hazardous to health. If In l.loub t.

FireRemember all times that petrol (gasoline) is highly flammable .Never smoke, or have any kind of nakel.l fla me around. when workingon the vehicle. But the risk do es no t end the re - a spark caused by anelectrical Sho rt -ci rcuit , by twO mewl su rfaces con tact ing each ot her. bycareless usc of tools, or even by s{;Jtic el ectricity bUIlt up In your bodyunder certain cond itions, can ign i te petrol vaIJOW , which In a confinedspace is high ly eXlJlosive.AlwuYs disconnect the buttery carth (ground) termina l befOreworking on any p;)rt of the fuel or electrical sys tem, and never riskspilting fllel on 10 ;) hot eng ine 01 exhaust.

It is recommended that a fire extingUisher of a type SUitable for fuelund elet:trical fifes is kept ha ndy in the 9

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