Volvo 960 Workshop Manuals and Repair Manuals

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Volvo 960

The Volvo 900 Series is a range of executive cars produced by the Swedish manufacturer Volvo Cars from 1990 to 1998. The 900 series was introduced in 1990 to replace the 700 series from which it derived. Prior to the end of its production, the series was renamed S90 and V90, becoming the last rear-wheel-drive cars from Volvo. Autumn of 1990 marked the launch of the Volvo 960 in time for the 1991 model year. This was the replacement for the 760. The 1991 960 was an evolutionary progression of the 1990 760. he very first Volvo 960 for the US-market rolled off the assembly line on August 12, 1991 as a 1992 model. Production of the 960 and its S90 and V90 derivatives ended on 5 February 1998.

Volvo 960 FAQ's

How do I change the oil in a Volvo 960?

To change the oil in a Volvo 960, first locate the oil drain plug underneath the engine and remove it using a wrench. Allow the old oil to fully drain into a suitable container. Once drained, replace the drain plug and then remove the oil filter using an oil filter wrench. Install a new filter and then pour in the recommended amount of fresh oil, making sure to use the correct viscosity specified in the manual.

How do I check and add transmission fluid in a Volvo 960?

To check and add transmission fluid in a Volvo 960, start the engine and let it warm up to operating temperature. Park the vehicle on a level surface and engage the parking brake. Locate the transmission dipstick, usually labeled with a yellow or red handle, and remove it. Wipe the dipstick clean, reinsert it fully, and then remove it again to check the fluid level. Add the recommended transmission fluid, if necessary, through the dipstick tube using a funnel.

How do I replace a brake pad in a Volvo 960?

To replace a brake pad in a Volvo 960, start by safely lifting and supporting the vehicle. Remove the wheel to access the brake caliper. Unbolt the caliper guide pins and carefully slide the caliper off the rotor. Remove the old brake pads and inspect the caliper and rotor for any signs of damage or excessive wear. Install new brake pads, making sure they are properly aligned, and then reassemble the caliper. Repeat the process for the other side and ensure proper brake bleeding after pad replacement.

How do I replace a fuel filter in a Volvo 960?

Start by relieving the fuel system pressure by disconnecting the fuel pump relay or fuse. Locate the fuel filter, usually along the frame rail or under the vehicle. Use line wrenches to disconnect the fuel lines from the filter, being cautious of any fuel spillage. Remove the mounting bracket or clamp securing the filter and then replace it with a new filter. Reconnect the fuel lines, ensuring they are properly tightened, and then restore the fuel system pressure. It is recommended to check for any fuel leaks after replacement.

How do I replace a headlight bulb in a Volvo 960?

To replace a headlight bulb in a Volvo 960, start by opening the hood and locating the back of the headlight assembly. Disconnect the electrical connector by pressing the release tab and gently pulling it off. Next, twist the bulb socket counterclockwise and carefully remove it from the assembly. Pull out the old bulb and insert a new one, being careful not to touch the glass with bare hands. Finally, reinsert the bulb socket, twist it clockwise to secure it, and reconnect the electrical connector.

How do I replace a serpentine belt in a Volvo 960?

Start by locating the belt routing diagram usually found on the engine compartment. Use this diagram as a reference for routing the new serpentine belt. Locate the belt tensioner pulley, often equipped with a square hole to insert a ratchet or breaker bar. Rotate the tensioner counterclockwise to relieve tension on the belt and remove the old belt. Install the new belt following the diagram and ensure it is properly seated on all pulleys. Finally, release the tensioner to apply tension on the new belt.

How do I replace a spark plug in a Volvo 960?

Start by disconnecting the negative battery cable to ensure safety. Locate the spark plugs, which are usually located on the top of the engine and covered by individual ignition coil packs. Carefully remove the ignition coil pack by unplugging the electrical connector and removing any mounting bolts. Once the coil pack is removed, use a spark plug socket and extension to unscrew the old spark plug. Install a new spark plug, ensuring it is properly gapped, and then reassemble the ignition coil pack.

How do I replace a thermostat in a Volvo 960?

Start by locating the thermostat housing, usually connected to the engine block with bolts or screws. Drain some coolant from the radiator to prevent spillage. Remove the bolts securing the housing and carefully lift it off. Note the orientation of the old thermostat and remove it, ensuring any gasket material is also removed. Install a new thermostat and a new gasket if required, then reattach the housing and tighten the bolts to the specified torque. Refill the coolant and check for any leaks.

How do I replace a wheel bearing in a Volvo 960?

Safely lift and support the vehicle, then remove the wheel and brake caliper to access the wheel bearing. Remove the axle nut and slide the rotor or hub assembly off the axle shaft. Using a suitable tool, press or pull the old wheel bearing out of the hub assembly. Clean the hub and install the new wheel bearing, ensuring it is properly seated. Reassemble the components in the reverse order, torque the axle nut to specifications, and perform a road test to verify proper bearing operation.

How do I replace the air filter in a Volvo 960?

Open the hood and locate the air filter housing, which is usually rectangular and made of plastic. Unfasten the clips or screws securing the housing and remove the cover. Take note of the airflow direction indicated on the old filter. Carefully remove the old filter and clean any debris from the housing. Install a new air filter, making sure it is properly seated and aligned with the airflow direction, and then reattach the housing cover securely.

How do I reset the service light in a Volvo 960?

To reset the service light in a Volvo 960, start by turning the ignition key to the "I" position (do not start the engine). Press and hold the odometer reset button located on the instrument cluster. While holding the button, turn the key to the "II" position and continue holding the button for approximately 10 seconds until the service light starts flashing. Release the button and turn off the ignition. The service light should now be reset.

How do I troubleshoot a non-starting Volvo 960?

First, check the battery connections to ensure they are clean and tight. If the battery is in good condition, turn the ignition key to the "II" position and check if the dashboard lights illuminate. If not, it could indicate a problem with the ignition switch or electrical system. If the lights come on but the engine does not crank, it could be an issue with the starter motor or ignition system. It is recommended to consult the repair manual for further troubleshooting steps.

How often should I replace the timing belt in a Volvo 960?

The timing belt in a Volvo 960 should be replaced every 60,000 miles or every 5 years, whichever comes first. This is crucial, as a worn or broken timing belt can lead to severe engine damage. It is recommended to consult the repair manual for specific instructions and to ensure the replacement is done correctly.

What is the recommended tire pressure for a Volvo 960?

The recommended tire pressure for a Volvo 960 can vary depending on the tire size and load capacity. It is best to consult the tire information label located on the driver's door jamb or the owner's manual for the specific recommended tire pressure. Maintaining the correct tire pressure is important for optimal tire performance, fuel efficiency, and overall safety.

What type of coolant should I use in a Volvo 960?

It is recommended to use a high-quality ethylene glycol-based coolant in a Volvo 960. This coolant should have a 50/50 mix of antifreeze and distilled water. Avoid using tap water or mixing different types of coolant, as this can lead to corrosion and cooling system damage. It is important to regularly check the coolant level and ensure it is at the appropriate level marked on the coolant reservoir.

Volvo 960 Manuals Index

Volvo 960 Workshop Manual

Volvo 960 Owners Manual

Volvo 960 Misc Document

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