Volvo P 120 Service Manual Download Page 30 | Manualshive

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Summary of Contents for P 120

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Page 2: ...nting the fuel tank the upper part of which forms part of the floor in the luggage compartment The scuttle section Fig 2 consists of the bulkhead 7 wheel arches 5 front upper cross member 4 and side plates 3 as well as lower cross members 1 and 2 The bulkhead forms the front transverse wall of the body and is shaped with welded end pieces Two front side members 8 project from the front floor At th...

Page 3: ...he inner door plate with screws The handle transmits the move ment to the toothed roller by means of a link rod The lock insert is fitted in the press button on the door handle The doors can be locked from inside the vehicle by pressing down the locking knobs The window winders are of the cable and chain type The movement of the window winding handle is transmitted to the window itself by a cable ...

Page 4: ...ent 4 Adjustment of seat height 5 Adjustment of seat inclination P 120 is adjusted with a screw 1 Fig 5 and 3 Fig 7 on each side of the backrest The seat cushions are attached to the seat frame by means of press fasteners REAR SEAT The rear seat and backrest are built up in principle in the same way as the front seats although in this case the seat frame consists of a wooden frame DOOR UPHOLSTERY ...

Page 5: ...the same as that on the 2 door and 4 door models The floor section Fig 8 consists of the front 11 intermediate 3 and rear 4 floor plates tunnel inner cantrail 1 side members 6 front 10 intermediate 8 and rear 5 cross mem bers The front and intermediate floor plates are welded together at the rear seat support The tunnel is spot welded to the front floor plate 11 Two rear side members 6 are welded ...

Page 6: ... models The side section Fig 9 consists of the front pillar 10 intermediate pillar 7 rear section interme diate 9 and outer 8 cantrails inner and outer roof formers 1 and windscreen pillar The rear section is composed of the rear wheel arch 6 rear mudguard 4 inner frame 2 for rear side window and upper 3 and lower rear pillar The upper part of the rear mudguard is extended upwards and forms the ou...

Page 7: ...erent opening positions Interior fittings and upholstery FRONT SEATS See the corresponding section for the 4 door model REAR SEAT The rear seat is built up of springs on a frame and has foam plastic padding which is covered with vinyl The seat cushion is provided with two hinges at the lower front edge and can if necessary be tipped up against the front seats It is covered with a mat underneath an...

Page 8: ...he wheel arch plates Bonnet and bonnet lock The bonnet is attached by means of screws in each hinge The bonnet is removed by taking out the screws between the hinges and bonnet The hinges are attached to the body with four screws each All the holes in the hinges are oval in order to permit the bonnet to be adjusted There are two types of bonnet lock The early pro duction lock up to chassis number ...

Page 9: ...door check can also be removed by unscrewing the guide roller and pulling it off In order to get at the guide roller the door upholstery must be removed see under Removing the door handle and upholstery 2 Unscrew the four countersunk screws which hold the door to the upper and lower hinges The door sealing strip must be moved in order to get at the hinge screws This is done by releasing the two pl...

Page 10: ...emove the armrest which is attached with two screws accessible from underneath the armrest see Fig 16 2 Remove the door handle and window winding handle These are removed by prising out the locking washer which holds them with tool SVO 2297 see Fig 1 7 The window winder locking washer and circlip are illustrated in Fig 18 3 Remove the upper trim moulding This is attached to the door edges by four ...

Page 11: ...ich hold the guide rail for the window The screws are accessible from the edge of the door as shown in Fig 21 Lift out the guide rail 2 Unscrew the three screws which hold the inner handle mechanism remote control 3 Lift off the link arm between the lock knob roller mechanism and disconnect the link for the outer handle from the roller mechanism 4 Unscrew the four screws on the edge of the door wh...

Page 12: ...le to obtain the correct measurement for A by turning the lock after it has been tightened up as near to A as possible the remaining adjustment is done by bending the lever 5 Measurement A must be checked within the specified tolerances 3 The remote control 12 with split pin 11 fitted is pushed backwards so that the lever 9 stops against the lock 10 The remote control is screwed on in this positio...

Page 13: ...lit pin 12 4 Fit the lever 17 and connect the link 16 to the lever 1 5 Set the lever 7 in the locked position i e backwards against the lock and lever 14 in the rear catch position Check through the control hole 12 that the lever moves fully to the catch position In this position the lever 14 is locked to the link 16 with screws at the clips 15 Check that the link 16 does not rub against the inner...

Page 14: ...e screw 3 Fig 27 2 Fit the outer handle 1 with link 6 fitted on 3 Connect the link 6 with the lever 8 The l ever in the handle is set in such a position that a pin 4 3 mm 0 12 can be inserted i n the hole in the handle Adjusting is done by screwing the link up or down so that the loop of the link 6 comes in line with the lever 8 on the lock P 120 Inner locking knob With the locking knob in the pre...

Page 15: ...he carrier on the winding cable to the rail under the window and lift it up as shown in Fig 35 On the rear doors there is no carrier and the clip fits directly on the winding chain 2 Release the cable tensioning device by slackening the nut for the catch screw on the lower pulley Lift off the cable and chain 3 If necessary remove the upper pulley lower pulley with tensioning device and winding spr...

Page 16: ...Requirements thick hair brush 5 The metal surfaces to which the rubber strips are to be attached are then coated with Dekalin TH Requirements thick hair brush 6 The treated and non tacky rubber strips are then pressed on to the newly coated adhesive on the metal 7 The rubber strips should be pressed firmly against the metal surfaces so that there is no air trapped in the joints N B Wait for at lea...

Page 17: ...wards as shown in Fig 39 so that it releases from the bracket when the tool is moved back and the torsion rod is relieved of tension The locking device on vehicles with chassis num bers lower then 21000 is attached with two screws and a circlip on the body under the luggage compartment lid The locking device is released by pressing in the lockable press button The lock ing clamp on the lower edge ...

Page 18: ...uts for the hinges and remove the latter FITTING THE UPPER TAILGATE 1 Place the hinges with packings in position Screw on the nuts adjust the position of the tailgate and tighten the nuts 2 Fold the plastic strip for the headlining as shown in Fig 43 and press it up into position with the help of the putty knife Attach the fabric at the corners as shown in Fig 44 3 Adjust the teazel strip against ...

Page 19: ...river and at the same time pull outwards and downwards with the hand so that the rear retaining spring can be hooked off with SVO 2297 see Fig 49 Carefully pull out the moulding backwards FITTING Stick the profile rubber strips at both ends of the window moulding and apply sealing compound along the inner section of the moulding see Fig 46 Place the retaining springs in position and apply sealing ...

Page 20: ...Fig 47 Application of masking tape Fig 48 Removing window moulding Fig 49 Removing spring P 120 Fig 50 Position of springs Fig 51 Fitting window moulding Fig 52 Fitting spring 8 1 9 ...

Page 21: ... for the trim moulding Place one half of the trim moulding in position and hold it there while pulling the leather cord out upwards over the moulding so that it is pressed against the rubber strip as shown in Fig 56 Push on the j oining pieces and repeat the procedure with the other half of the moulding Adjust the position of the joining pieces over the joints Trim mouldings rear window 2 and 4 do...

Page 22: ... with naph tha otherwise replace it FITTING THE WINDSCREEN 1 Place the windscreen on a stand as shown in Fig 59 Moisten the outer edge of the windscreen and fit the rubber strip starting at one of the corners Adjust the strip so that it lies correctly all round Fig 57 Releasing rubber strip Fig 58 Removing rubber strip P 120 VOLVO 1 00 967 VOLVO 100 910 8 2 1 Fig 56 Fitting trim moulding 2 Place t...

Page 23: ... damage to the strip in which case strike the windscreen from inside with the palm of the hand and vice versa if the rubber strip does not creep over the edge of the sheet metal properly 5 Check that the rubber strip seals well all round If necessary adjust the position of the windscreen both vertically and laterally by striking with the palm of the hand 6 Fit the trim mouldings as previously desc...

Page 24: ...t Slacken the adjusting screw and adjust the eyebolt to the desired position 2 The height of the seat is adjusted by attaching the rail in a suitable hole in the bracket 2 3 The lumbar support is adjusted with the screw 3 On a number of earlier vehicles with lum bar support where the adjusting device does not have a countersink the adjusting screw can most easily be found by pressing the up holste...

Page 25: ...ing inner roof headlining STRETCHING THE HEADLINING FOR REMOVING SMALL HOLES AT THE OUTER EDGE In most cases where there are small holes at the outer edge of the headlining it is sufficient just to stretch it 1 Remove the interior light sun visors rear view mirror and upper part of the windscreen trim moulding Remove the side mouldings as shown in Fig 67 2 Release the trim strip Prise out the teaz...

Page 26: ...nner trim mouldings removed Fig 68 Headlining and trim strip released Fig 69 Stretching the headlining Fig 70 Knocking in the teazel strip Fig 71 Fitting sun visor Fig 72 Cutting away the headlining P 120 8 25 ...

Page 27: ...8 Fit the headlining above the rear window as described in point 7 The seam running across at the back should come at an equal distance from both the corners of the rear window see Fig 75 9 Stick the headlining to the body metal at the rear window and to the wheel arch plate 1 0 Fit the sun visors see Fig 71 11 Stretch up the headlining in the teazel strip This is done stretcher by stretcher begin...

Page 28: ... after the front doors have been opened and the inner trim moulding for the windscreen removed as shown in Fig 77 SPECIAL TOOLS FOR CARRYING OUT WORK ON THE BODY SVO 2572 SVO 2297 SVO 2486 SVO 2297 Tool for removing clips on door and window winder handles and for removing and fitting spring clips for window mouldings SVO 2486 Tool for fitting plate nut SVO 2572 Tool for removing and fitting torsio...

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