Frontwheel

•
6
Groups
60, 61

suspension Front wheel

suspension

240, 260
240,260
 1

Contents
Page Step
Specifications . . .. . . .... . . 1
Special tool5 . . . .. .. . ...... . 2
Illustrations . ....... . . ... . 4

Group 60: General

Wheel alignment ............. ... .... . .......... ••. .

Group 61: Front wheel suspension

6 Al - A2l

•
•
Replacing steering swivel ball joints:
- early prod. ..... . . ... . ...... .. . ... .. .... . ... . 11 a' - 833
- late prod. . . ..... ............... . ...... .. . .. . .. . 19 Cl-C12
Replacing strut upper journal . .. .. . ....... . •. ........ 23 01-020
Replacing contral arms and / or bushings
Vehicle on rail lift . . .. . .. . ....... .. . ... . . . 28 E l--E20
Replacing front contrel arm rear bushing:
- vehicle on rail lift ... .. .. ...... . ......... ...... • . . 33 Fl - FlO
- vehicle on l loor . . .. . .. , . ... "" .. 36 Gl-G15
Replacing front shack absorber ........ • . .. . ........ ... ..... 40 Hl -H25
Replacing front coil spring . ....... . ... .. .... ....... . ....... 46 11- 125

•
TP 30000 / 1
4500.3.79

Printed in USA
•

j
 Specifications

Specifications

Wheel alignment (unloaded carl

Caster: (An cars up 10 and including 1978 year modeis) +:ZG to +;30
1979 year models with manual steering .. . ... .... , +2° to +3°
1979 year models with power steering " .. "... +3° to +4°
Camber set as near (jJ as Possible O to + lO
King pin inclination at rP camber 12"
Turning angles: At 20.00 turning of outer wheel, inner wheel should
be turned 20.ao

Angle (2 a) A-a (mm) B-b (mm) C-c (mm)

Manual steering 24'±S' 4.5±1.5 3.5±1 2.5±1

Power sleering 1S' ±8' 3.0± 1.5 2,O±1 1.5± l

All measurements are made with the ear unloaded. The measurements
are taken at hub height, as the angle measurement a, or the difference
in mm between the front and rear edge of the wheels at points A, 8
or C {the tire's wear thread inside shoulder or rim corner~
,,' ...

Ball joints
Max. axial play with normally loaded front end:
1/ 8" (3 mml

.'*

Tightening torques Nm Ft. Ibs.

Nut for controi arm rear bushing 55±5 40±4
Bracke! for controi arm rear bushing 40±10 29±7
Front bolt for controi arm bushing 75±20 54±14
Ball joint. to controi arm ..... , ... 115±15 83± l l
Ball joint to attachment or strut 60±10 43±7
Ball joint attachment to strut 23±5 17±4
Steerin g rad to steering arm .......... . ............ , . 60±10 43±7
Nuts for upper journalling , , , .. , . • . . . ....... . 20±5 14±4
Steering wheel nut ........... . 60±15 43±11
Wheel nuts ., ................• ", .. " .. , .. . . " .. " .. 120±20 B7±9

Group 60
General 1
Special (ools

Special tools

1801 Standard handle 5045 Retainirog hook

2263 PuUer for controi arm when replaclng shock absorber
remol/mg steenng whool 5081 Adapter
5036 Socket preSSIng In controi arm rear bustllng
shock absorbef shaft nut 5082 Adapter
5037 Socket preSSIng out / in controi arm rear bushlng
to retain shock absorber shaft when rerTlOving and 5083 Adapter
tightening nut preSSIng In controi arm rear busl"lIng
5038 Adjustment tool 5084 Adapter
front end alignment preSSIng In controi arm front bushlng
5039 Spanner 5085 Adapter
shock absorber nut on Strut preSSIng out / in controi arm front bushing

•
(hydraulic shock absorberf 5091 Adapter
5040 Coil spring hook-up tool pressing out controi arm front bushing
removing and installing coil spring 5173 Wrench
shock absorber nut on strut
5041 CoU spring compressor Igas-pressure shock absorberf
replacing coil spnng

•
5043 Pullar
removlng tiB rod end

,,,,.. 5036 •
•
2263 5037

5038

'/lnn\\.. ,

5038 5039

Group 60
2
j
General
 Special tOOl5

..,.~ 5041

.
,,. '
5040 5141 5043

1601~-
01

,lO,."
5045 1801
50S1
5082
5083

~
•
5064
5065 ~ 5173
Q
~ -I
"
L---
® ®
..- 5084
'.- 5173
"".,
5085
5091

Group 60
General 3
Illustration

front axle

controi arm

shock
absorber

spring

strut

stabilizer bar

steering gear

Group 60
4 General
 Illustration

------- ------ ------1-;;,

upp."
attachment
strut

----- ----- e
""
Ö O late
earlv

-.
front
axle

,,
L_---i .-- ---
1
J

Group 60
General 5
Wheel alignment

Group 60
General

Cheeking front end for wear. Cheeking and adjusting eamber,

easter and toe-in
Special cools: 2263, 5038

Al

Raise the front end.

Support under the controi arms as near as possible to
the ball studs.

A2

Check steering rod ends, ball joints and steering

linkage.

A3

Check wheel bearings. shock absorber bushing

and upper attachment or upper journalling for
play and wear.

A4

Check other side in the same way according to

A2-A3.

Group 60
6 General
 Wheel alignment

AS

Check steering swivel ball joints for play.

Check ball ,oints for play with, for example, a l ire lever.
Do not damage the rubber dust cover.
Maximum permissible play is 3 mm.

A6

Place wheel alignment turntables under front

wheels.

A7

Lower front end and remove turntable catches.

AB

Check, and if necessary, adjust tire pressure,

Group 60
Genera! 7
Wheel alignment

A9

Bounce the front end up and down several times.

This must be done, otherwise the eamber will be exeessive
since the controi arms do not return to normal position
when front end goes down. If the turntables cannot stand
side forees, roll the ear back a few feet, then forward
again.

Ala

Install projectors.
Follow the instructions for equipment used. If compen-
sation for rim warp is made with front wheels raised,
front end must be bounced several times to return to
eorrect poSition .

.~

A77

Check eamber on both front wheels.

Correct camber: max. + 1°, not to exeeed 1/ 2° difference
between sides. Camber should be as near CP as possible
in order to avoid shoulder wear on the tires.

,""
A12

\ '

Check easter on both front wheels.

Correct easter: +2° to +3°.
Effective with 1979 modeis. easter on cars with power
steering is +3° to +4°.
Caster cannot be adjusted. If easter angle is incorrect,
front end components must be checked.

,.-
Group 60
8 General
 Wheel alignment

Toe-in A73
The toe -in should be set as follows:
Angle 2 Q: A~ B-b C<
manual 45±15 mn 35±1 mm 2.5± mm
Sleefflg 24'±8' J'S"
IQ.1S±O.06") IO.1 4±O.Q4· IO_lO±O,Q4")

2<0 powe' J.O±1 .5 mn 2.0±! mm 1.5::1:1 mm

260 stee"ng 16'±8' l / S"
senes IO.12±O.06·· l Q,08±O.Q4'") IQ.06±O.04")

Vehicle sheukf not be Ioaded. Measurements must be made at

center hu bl height,Q as in an angla, read on cenain instruments.
A. B and C refer to tire GUter diameter, tire inner shoulder and
""" rim, respect ively.
, Al4

To adjust . proceed as follows:

Rema ve nuts on strut upper attachment.

A75

Adjust ca mber :
Use to 01 5038.
Correc t camber: max. + 1°. Max. 0.5 0 difference between
right and left wheels. Camber should be as near (fJ as
possible to avold shoulder wear on tires.

Al6

Instal I and t ighten nuts for upper attachments.

Torque 20 ± 5 Nm = 14±4 ft.lbs.

Group 60
General 9
Wheel alignment

AI7

Recheck easter on both front wheels.

+2° to +3°
Effective with 1979 modeis, easter on cars with power
steering is +3° to +4° .

...
•
AI8

Adjusting toe-in:

.
Loosen lock nuts and adjust tae-in with steering rods .
Correct toe-in: see A 13.
Steering rads must not differ more than 2 mm in length.
Measure between wrench grip and lock nut.
AI9

Tighten nuts and spray threads with rustproofing

oil.

A20
2263
Check, and if necessary, adjust steering wheel
position.
Carefully pry impact pad loose with screwdriver. Remove
steering wheel with puller 2263.
No puller is needed to remove steering wheel on 1979
year modeis. However. a special socket (Volvo P I N
1158146) is required to remove steering wheel nut. Pry
cover washer in center of steering whee! with screwdriver.

u,,.,,

A21

Instal1 steering wheel.

Torque: 60±15 Nm = 43±11 ft.lbs.
Coat insulation pins with vaseline and press impact pad
securely inta position.
Effective with 1979 modeis, a thin wall socket, 27 mm,
is required to tighten the sleering wheel.

" , ....J

Group 60
10 General
 Steering swivef
ball joints

Group 61
Front wheel suspension

Replacing early prod. steering swivel ball joints

$pedal tooIs.. 5036,5037,5039,5040,5043,5045,5173

BI

Support front end on stands.

Place stands under front Jack attachments.
Mark front wheels to avoid rebalancing.
Remove front wheels.

B2

Loosen shock absorber retaining nut a couple of

turns.
Use tool 5039 for standard (hydraulicJ shock absorber
and 5173 for gas-pressure shock absorber.

B3

Place jack under control arm, disconnect steering

rod from steering arm.
Remove nut and detach rad with 5043.

Group 67
Front wheel 11
suspension
Steering swivel
ball joints

B4

Disconnect stabilizer bar from stabilizer link

upper attachment.

85

Remove brake pipe braeket bolt .

86
1111111.

Remove protective cover over shock absorber

nut.
Pry loose with screwdriver.

87

loosen center nut.

Loosen nut several turns with 5036. Hold shock absorber
plunger rcd with 5037.

Group 61
12 Front wheel
suspension
 Steering swivel
ball joints

BB

line-mark upper journal position and remove nuts.

Line-mark over nut plate and wheel housing plate as il-
lustrated.

B9

lower jack and guide out spring assembly.

Hook spring assembly to shock absorber with retaining
hook 5045.

BIO

Use tool 5040 to compress spring.

Place the two hook-up tools opposite each other and
with three spring coils free between the claws. Compress
alternately.

Bil

Remove center nut, lift off upper journal.

Use tool 5036 to remove nut. Hold shock absorber with
5037.

Group 61
Front wheel 13
suspension
Steering swivel
ball joincs

812

Remove shock absorber retaining nut.

Use tool 5039 for standard {hydraulic) shack absorber
and 5173 for gas-pressure shock absorber.

813

Pull up shock absorber.

814

{'
Loosen ball joint retaining nut.
l Loosen a few turns until ball joint bracket comes loose.
Use 19 mm socket.
Use pipe wrench to hold on the weld.

" " .
815

Loosen balljoint conical part from strut assembly.

Use long brass drift and hammer.

,.....
Group 61
14 Front wheel
suspension
 Sreering swivel
ball joints

B76

Remove nut.
eoat inside of socket wi th vaseline or similar lubricant
so nut may be lifted when loose from thread.

B77

Hang up strut assembly.

Use steel wire to hang strut assembly to upper attach-
ment. Remove hook. Disconnect ball joint from strut as-
sembly.
Do not stretch or damage brake heses.

B78

Disconnect ball joint from controi arm.

B79

Attach new ball joint to controi arm.

Torque: 115 ± 15 Nm = 83±1 1 fUbs.
Clear grease from' ball joinl. If this is neglected. stud can
be tightened too far inta cone so that rubber bellow sticks
to strut.

Group 61
Front wheel 15
suspension
Steering swivel
balljoints

820

Lift strut assembly onto ball joint.

Remove wire and hook up retaining hook 5045.

821

Install ball joint nut.

Torque: 60±10 Nm = 43±7 ft.lbs.
Hold with pipe pliers around the weld.

822

Install shock absorber and retaining nut.

Tighten nut as much as possible without tuming strut.
Use tool 5039 for standard \hydraulic) shock absorber
and 1001 5173 for gas-pressure shock absorber.

823

Position spring, rubber bumper and shock

absorber protection.
Tum spring so that spring compressor claws face up.

Group 61
16 Front wheel
suspension
 Steering swivel
ball jolms

824

Install spring seat, upper journal. washer and nut.

Tighten nut with 5036 and hold with 5037.

825

Remove spring compressor.

Loosen spring compressor bolts alternately. Make sure
spring ends seat correctly in upper and lower seats.

826

Guide strut assembly into upper attachment in

wheel housing.
Remove retaining hook and raise jack.. Make sure stabilizer
link is guided into position.

827

Turn journal to correct position and tighten nuts.

Position journal according to line-up marks.
Torque: 20 ± 5 Nm = 14±4 ft.lbs.

Group 61
Front wheeJ 17
suspension
Steering swivel
ball joints

828
11111

Tighten shock absorber retaining nut.

Tighten nut with 5036 and hold w ith 5037.
Press protective cover into position.

829

Tighten brake pipa bracket bolt.

830

Tighten stabilizer link to stabilizer bar.

831

Tighten steering rod to steering arm.

• Torque: 60±10 Nm = 43±7 tUbs.

.
" "

Group 61
18 Front wheel
suspension
 Steering swivel
ball joints

832

Tighten shock absorber nut in strut assembly.

Use tool 5039 for standard IhydrauhcJ shock absorber
and tool 5173 for gas·pressure shock absorber.

833

Install front wheel.

Use the marks made previously.
Torque: 120±20 Nm = 87±9 ft.lbs.

Replacing late prod. steering swivel ball joint

Special tooIs: 5039. 5173

el

Support front end on stands.

Place stands under front jack attachments.

Group 61
Front wheel 19
suspension
Steering swivel
ball joints

C2

Remove front wheels.

Mark location to avoid re-balancing.

C3

Loosen shock absorber retaining nut a couple of

tums.
Use tool 5039 for standard IhydraulicJ shock absorber
and 5173 for gas-pressure shock absorber.
On vehicles from 1978 models it is not necessary tO loos-
en the shock absorber retaining nut. The shock absorber
does not rest against ball joint attachment.

C4

Remove four retaining balts for ball joint

attachment.
If bolts are secured with lock washers, first pry these
loose with a screwdriver.

CS

Disconnect ball joint from controi arm.

Group 61
20 Front wheel
suspension
 Steering swivel
ball joints

C6

Remove ball joint retaining nut.

C7

Press ball joint out of anachment.

'"
ca

Anach the new ball joint.

Torque: 60 ± 10 Nm = 43±7 ft.lbs.
Remove grease from ball joint stud. Otherwise it can be
tightened too far inta cone so Ihat rubber bellow sticks
10 attachment.

Effective from 1979 models with power steering, ball

joints are different for left ·and right sides. Compared to
previous years, ball joint is 10 mm forward in controi
rod attachmenl. It is therefore most important that Ihese
ball joims are installed on correct side.
"" ..
C9

Anach ball joint to spring assembly.

Use new lock bolts. On vehicles equipped wilh lock wash-
ers (see step C4), new lock washers must be used.
P/ N 1229417.
Torque: 23±5 Nm = 17±4 ft.1bs.

\ \

-.
Group 61
Front whee! 21
suspension
Steering swivel
ball joints

CIO

Tighten ball joint to controi arm.

T()(que: l 15 ± 15 Nm = 83±1 1 ft.lbs.

" ....
CII

Tighten shock absorber retaining nut if previausly

loosened.
See Step e3.

CI2

Install front wheels.

Use marks previously made.
Torque: 120±15 Nm = 87±9 fl.lbs.
Remove stands.

Group 61
22 Front wheel suspension
 Strut upper journal

Replacing strut upper journal

Special tools: 5036, 5037, 5040, 5043, 5045

DI

Support front end on stands.

Place stands under front jack attachments.
Mark front wheels to avoid rebalancing.
Remove front wheels.

02

Place jack under controI arm, disconnect steering

rad from steering arm.
Remove nut and detach rad with 5043.

03

Disconnect st abilizer bar from stabilizer link

upper attachment.

Group 61
Front wheel 23
suspension
Strut upper journal

D4

Remove brake pipe bracket balt.

05

Remove protective cover over shock absorber

nut.
Pry loose with screwdriver.

06

Loosen center nut.

Loosen nu! several tums with 5036. Hold shock absorber
plunger rcd with 5037.

07

Line-mark upper journal position and remove

nuts.
Line-mark over nut plate and wheel housing plate as il -
lustrated.

Group 67
24 Front wheel
suspension
 Strut upper journal

08

Lower jack and guide out spring assembly.

Haok spring assembly to shock absorber with retaining
haok 5045.

09

Use tool 5040 to compress spring.

Place the two haok-up lools opposite each other and
with three spring eoils f ree between the daws. Compress
alternately.

0 10

Remove center nut, lift off upper journal.

Use tool 5036 to remove nllt. Hold shock absorber with
5037.

011

Replace journal assembly.

For vehicles with reinforcing rad {GT etc~ one bolt is langer
than the others.

...
Group 61
Front wheel 25
suspension
Strut upper journal

012

Install upper journal. washer and nut.

Use tool 5036 to tighten nut. Hold with 5037.

013

Remove spring hook-up tool.

loosen alternately. Make sure spring ends seat correctly
in upper and lower seats.

014

Guide spring assembly into wheel housing.

Remove retaining hook and raise jack. Guide stabilizer
link inta position.

015

Turn journal to correct position and tighten nuts.

Position journal according to linemark made previously.
Torque: 20±5 Nm = 14±4 fUbs.

Group 61
26 Front wheel
suspension
 Strul upper journal

016

Tighten center nut and press protective cover

into position.
Use 1001 5036 to tighten and 5037 to hold.

017

Tighten brake pipe braeket nut.

018

Tighten stabilizer link to stabilizer bar.

019

I
Tighten steering rad to steering arm.
I Torque: 60±10 Nm = 43±7 ft.lbs.

Group 61
Front wheel 27
suspension
Contral arms

020

Install front wheels.

Use marks previouslV made.
Torque: 120±15 Nm = 87±9 ft.lbs.
Remove stands.

Replacing controi arms and / or bushings

Vehicle on rail lift

Special toois: 1801,5081,5082,5083,5084,5085,5091

El

Lift front end.

Lift under jack attachments until wheels almost lift from
raiL

E2

Disconnect stabilizer link from controi arm.

Group 61
28 Front wheel
suspension
 ControI arms

E3

Disconnect ball joint from controi arm.

E4

Disconnect rear bushing bracket from side

member.

E5

Remove controi arm front retaining bolt.

E6

Remove controi arm. Remove braeket.

Group 61
Front wheel 29
suspension
Contral arms

E7

Press out controi arm bushing.

Using vice, place tool 5085 over collar side of bushing.
Use tool' 5091 to press out bushing.

E8

Press in controi arm bushing.

Place tool 5084 against bushing collar side. Press with
tool 5085 on reverse side.

E9

Press out controi arm braeket bushing.

Place tool 5082 under braeket. Press out bushing with
tool 5083 and handle 1801.

ElD

Install new bushing in bracket.

On earlier vehicles, bushings were different for right side
(soft) and left side (hard) to make the ear less sensitive
to imbalance.
This could in certain cases result in steering wheel vi-
brations during braking. Hard bushings are now used on
both sides.
1205826-9 1221982 -0
w" hard '..... P/N 1205826-9 Soft bushing
PI N 1221982-0 Hard bushing

Group 67
30 Front wheel
suspension
 Contral arms

El1

Press in controi arm bracket bushing.

Place tool S081 agamst bushing collar side. Press on
bracket with tool S082 and handle laOl.

,.~

E12

Attach bracket to controi arm.

lostan bracket, washer and nut. Do not tighten nut harder
{han w asher can be turned by finger force.

E13

Attach contral arm.

Install front retaining balt without tightening nut.

E14

Guide stabilizer link inta position. Tighten ball

joint to controi arm.
Torque: 1,S±1S Nm = 83±11 ft.lbs.

Group 61
Front whee! 31
suspension
Contro! arms

E15

Attach bushing rear braeket to side member.

Torque: 40 ± 10 Nm = 29±7 fUbs.

E16

Tighten stabilizer link to controi arm.

E17

Lower front end.

Roll ear back and forth while bouncing it up and down
several times to let con troi arms take up normal position.

E18

Tighten bushing rear nut.

Torque: 55 ± 5 Nm = 40 ± 4 ft.lbs.

E19
Nate:
Replaeing right side bushings on vehicles with 621 engine:
To tighten nut, disconneet exhaust pipe from flange and
attachment. Install new gasket w hen reeonneeting e)(~
haust pipe.

Group 61
32 Front wheel
suspension
 Control arms

E20

Tighten front bushing balt.

Torque: 75±20 Nm = 54±1S fUbs.

..
,,, '

Replacing front controi arm rear bushing

Vehicle on rail lift

Special tooIs: 1801, 5081, 5082, 5083

Fl

Disconnect rear bushing bracket from side

member.

F2

Remave bracket fram contral arm.

Remove nut and bracket from controi arm.

Group 61
Front wheel 33
suspension
Control arms

F3

Press out controi arm bracket bushing.

Place tool 5082 under bracket. Press out bushing with
tool 5083 and handle 1801.

F4

Inst all new bushing in bracket.

On earlier vehicles, bushings were different for right side
(soft) and left side (hard) to make the ear less sensitive
to imbalance.
This could in certain cases result in steering wheel vi-
brations during braking. Hard bushings are now used on
both sides.
1205826-9 1221982-0 P IN 1205826-9 Soft bushing
wf, hard "• .,.
PI N 1221982-0 Ha rd bushfng

F5

Press in controi arm bracket bushing.

Place tool 5081 against bushing collar side. Press on
braeket with tool 5082 and handle 1801 .

F6

Attach bracket to controi arm.

Install bracket. washer and nut. Do not tighten nut harder
than washer can be turned by finger force.

Group 61
34 Fron t wheel
suspension
 Contral arms

Fl

Attach bushing rear bracket to side member.

Torque: 40 ± 10 Nm = 29±7 tt.lbs.

F8
)

Bounce front end.

Bounce front end up and down severaltimes to let contral
arms take up normal position.

m ....

F9

Tighten bushing rear nut.

Torque: 55 ± 5 Nm = 40±4 ft.lbs.

FlO

Note:
Replacing right side bushings on vehicles with 82 1 engine:
To tighten nut, disconnect exhaust pipe from flange and
auachmen!. Install new gasket when recannecting ex-
haust pipe.

Group 61
Front wheel 35
suspension
ControI arms

Replacing controi arm rear bushing

Vehicle on floor

SpecialtooIs: 1801, 5081, 5082, 5083

Gl

Measure distance between fender edge and hub

center.
Before lihing ear from floar. Measure on both sides if
both bushings are to be replaced.

G2

Place front end on stands.

Place stands under front jack attachments.

G3

Disconnect stabilizer links from controi arms.

Disconnecl on both sides even il only one bushing is re-
placed. The reason is to let the contrei arms lake up correct
position when tighlening.

Group 61
36 Front wheel
suspension
 ControI arms

G4

Note:
When replacing right side bushings on vehicles with B21
engines, disconnect exhaust pipe from flange and front
attachment.

G5

Disconnect bracket from side mambar and con-

trol arm.

G6

Press out contral arm brackat bushing.

Place tool 5082 under braeket. Press out bushing with
tool 5083 and handle 1801.

t G7

Install new bushing in brackat.

On earlier vehicles, bushings were different for right side
(soft) and left side {hard} lo make the ear less sensitive
to imbalance.
This could in certain cases result in steering wheel vi-
brations during braking. Hard bushings are now used on
both sides.
1205826-9 1221982 -0
hard p I N 1205826-9 Soft bushing
"'" '.~ p I N 1221982--0 Hard bushing

Group 61
Front wheel 37
suspension
ControI arms

G8

Press in controi a rm bracket bus hing.

Place tool 5081 againsl bushing coilar side. Press on
bracket with too 5082 and handle 1801 .

'.~

G9

Attach bracke t to controi a rm.

Install bracket, washer and nu!. Do not tighten nul harder
than washer can be turned by finger force.

GlO

Tighten bracket to side member.

Torque: 40 ± 10 Nm = 29±7 tUbs.

GlI

Load front s prings to let controi arms take up

normal pos ition.
Remove Slands from jack attachmenls. Place jack as far
out as possible under controi arm with new bushing. l ow-
er car so that il rests on stand and wheel on other side.

Group 61
38 Front wheel
suspension
 Control arms

G12

Measure distance between fender edge and hub

center.
Bounee ear several times and measure distanee, II should
be same as in Step G 1.
NQTE:
One side on wheel, one side on stand will not introduce
Inaccuracy and is necessary to be able to reaeh the nut
In next step.

G13

Tighten rear bushing.

Torque: 55±5 Nm = 40±4 fl.lbs.
Raise ear again and put il on two stands.

G14

NOTE:
When replaeing right side bushings on vehicles with 821
engine, install new flange gasket. Attaeh exhaust pipe to
flange and front attachment.

G15

Tighten stabilizer links on both sides.

Group 61
Front wheel 39
suspension
Front shock absorber

Replacing front shock absorber

Spedaltools .. 5036. 5037. 5039. 5040. 5043. 5045. 5773

H7

Raise front end.

Jack. up front end. Place stands under front jack attach-
ments.
Mark wheel location to avoid rebalancing. Remove
wheels.

H2

Loosen shock absorber retaining nut on strut

assembly.
Loosen nut a couple of tums. Use tool 5039 for standard
Ihydraulic) shock absorbers and 5173 for gas-pressure
shock absorbers.

H3

Disconnect stearing rod from steering arm.

Place jack under controi arm. Aemove nut. Use tool 5043
to disconnect steering rad.

Group 61
40 Front wheel
suspension
 Front shock absorber

H4

Disconnect stabilizer from upper link attachment.

• H5

Remove bolt for braka pipe bracket.

H6

Remove protective CQver over center nut.

Pry loose with screwdriver.

H7

loosen shock absorber retaining nut.

loosen nu! several tums. Use tool 5036 and hold shock
absorber plunger rod with 5037.

Group 61
Front wheel 41
suspension
Front shock absorber

H8

Upper journal.
line-mark over nut plate and wheel housing plate. Ae-
move nuts.

H9

Strut.
Lower jack and guide out strul assembly. Hook it into
stabilizer with retaining tool 5045.

H/O

Spring.
Attach spring hook-up lools opposite eaeh other. Three
spring eoils free between claws. Compress alternately.

HII

Upper journal.
Use tool 5036 to remove center nut. Hold shock absorber
with 5037. Remove upper journal, spring seat and rubber
bumper.

Group 61
42 Front wheel
suspension
 Front shack absorber

H12

Remove shock absorber retaining nut.

Use tool 5039 for standard (hydraulicl shock absorber
and 5173 for gas-pressure shock absorber.

H13

• Pull up shock absorber.

H14

Insert new shock absorber.

Tighten nut as much as possible without turning strut.
Use tool 5039 for standard (hydraulicl shock absorber
and 5173 for gas-pressure shock absarber.

H15

Install spring, rubber damper and shock absorber

proteetion.
Turn spring so that spring haak-up tool claws face up.

Group 61
Front wheel 43
suspension
Front shock absorber

HI6

Install spring seat, upper journal, washer and nut.

Use tool 5036 to tighten and 5037 to hold.

HI7

Remove spring hook·up tool.

Loosen tool alternately. Make sure spring ends position
correctly in upper and lower seats.

HI8

Guide strut assembly inta wheel housing.

Remove retaining hook. Raise jack. Make sure stabilizer
link guides inta position.

Install journal.
Position Journal according to line-marks. Tighten nuts.
Torque: 20±5 Nm = 14±4 ft.lbs.

Group 61
44 Front wheef
suspension
 Front shack absorber

H20

Tighten center nut.

Use tool 5036 to tighten and 5037 to hold. Press pro-
tective cover Into position.

•
H21

Tighten brake pipe bracket.

H22

Tighten stabilizer link to bar.

H23

Tighten steering rad to steering arm.

Torque: 60±lQ Nm = 43±7 fUbs.

..
" "

Group 61
Front whee! 45
suspension
Front coH spring

H24

Tighten shock absorber nut on strut assembly.

Use tool 5039 for standard (hydraulic) shock absorber
and 5173 for gas-pressure $hack absorber.

H25

Install front wheel.

Usa markings, previausly made.
Torque: 120± 20 Nm = 87 ± 9 ftlbs.

Replacing front coil spring

Special toois . 503 6, 5037, 5040, 5041, 5043, 5045

11

Raise front end.

Jack up, place stands under front jack attachments.
Mark lacation of front wheels to avoid re-balancing. Re-
move wheels.

Group 61
46 Front wheef
suspension
 Front coH spring
1
12

Place jack under contral arm as support.

13

• Disconnect steering rad from steering arm.

Use tool 5043.

14

Disconnect stabilizer from link.

15

Remove bolt for braka pipe bracket.

Group 61
Front wheel 47
suspension
Fron t eoil spring

/6

Remove protective cover over center nut.

Pry loose with screwdriver.

/ 7

loosen center nut.

loosen several turns. Use tool 5036 and hold shock
absorber plunger wi th 5037.

/8

Upper journa l.
line-mark across nut plate and wheel housing plate.
Aemove nuts.

/ 9

Disconnect strut.
lower jack and guide out strut assembly. Hook strut
assembly to stabilizer with retaining hook 5045.

Group 61
48 Front wheef
suspension
 Front COI~ spring

I ID

Spring:
Attach spring hook-up tools opposite each other. Three
spring eDils free between claws. Compress alternately.

• Upper Journal:
111

Use tool 5036 tO remove center nut. Hold $hock absorber

with 5037. Remove upper journal, spring seat and rubber
bumper.

I 12

Compress spring.
Use spring compressor 5041 and impact gun.

113

Free spring.
First remove spring haok-up tool 5040, then spring com-
pressar 6041 .

..
" "

Group 61
Front wheel 49
suspension
Front CD/J spring

1 14

Compress new spring.

Use spring compressor 5041 and impact gun .

...
1 15

1nstall spring hook-up tool.

Place spring hook-up tools 5040 opposite each other.
Three tree spring coils between claws. Compress alter-
nately. Aemove spring compressor 5041 .

1 16

Inst all spring.

Turn spring so compressor claws face up. Install rubber
bumper and dust cover.

1 17

Inst all journal.

Install spring seat. upper journal, washer and nut. Use
too 5036 to tighten and 5037 to hold.

Group 6 1
50 Front wheef
suspension

"
 Front col1 spring

/18

Remove spring hook -up tool.

Loosen 1001 alternately. Make sure spring ends position
correctly in upper and lower seats.

• 1 19

• Guide strut assembly into wheel housing.

AemovB retaining hook. Raise jack. Make sure that stab-
ilizer link guides inte position.

120

Install journal.
Position journal according to line-marks. Tighten nuts.
Torque: 20 ± 5 Nm = 14±4 fUbs.

121

Tighten center nut.

Use tool 5036 to tighten and 5037 to hold. Press pro-
tective cover inte position.

Group 61
Front wheel 51
suspension
Front coil spnng

/ 22

Tighten' brake pipa bracket.

/23

Tighten stabilizer link to bar.

/ 24

Tighten steering rad to steering arm.

Torque: 60 ± 10 Nm = 43±7 fUbs.

/ 25

Install front wheel.

Use markings, previously made.
Torque: 120±20 Nm = 87±9 ft.lbs.

Group 61
52 Front wheel
suspension

.
•
•
VOLVO SUPPORTS VOlUNTARY
MECHANIC CERTlFICATlON
BY THE N.I.A.S.E .