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1991 Volvo 240 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Volvo 240 car and truck
repair procedures including Volvo engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Volvo 240 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
Import Compressor Service -> York & Tecumseh Compressors -> CYLINDER HEAD & VALVES, REPLACE -> YORK CF206, SC206 & TECUMSEH COMPRESSORS
Vehicle: 1991 Volvo 240 2.3 L4 GAS
YORK CF206, SC206 & TECUMSEH COMPRESSORS
- Open service valves and ensure that compressor is free of pressure.
- Remove bolts retaining service valves on model CF206, noting position of valves, then remove remaining head bolts. On model SC206, simply remove head bolts.
- Remove valve plate and head from cylinder by prying or tapping under tabs that extend from valve plate. If head and valve plate stick, hold head and tap valve plate tabs away from head with suitable hammer.
- Remove gasket, being careful not to damage sealing surface. ...
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BRAKE SERVICE PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
VOLVO, HYDRAULIC BRAKE SYSTEMS -> DESCRIPTION
Vehicle: 1991 Volvo 240 2.3 L4 GAS
The function of hydraulic brake system is to transmit pressure from the master cylinder to caliper pistons. The system will operate properly if fluid is tight and brake fluid cannot be compressed. Normally, brake fluid cannot be compressed. If however the fluid overheats sufficiently it can partially change to a vapor form. Vapor can be compressed and since the master cylinder has a specific volume with which to build up pressure, the compression of vapor can result in excess brake pedal travel before the system has time to develop adequate braking pressure.
Brake fluid is h...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
Volvo -> Fuel Filter Scheduled Maintenance -> 1986-95 -> Normal Service -> Severe Service
Vehicle: 1991 Volvo 240 2.3 L4 GAS
Normal Service
Replace every 60,000 m...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
DRIVESHAFT U-JOINT, Replace
Vehicle: 1991 Volvo 240 2.3 L4 GAS
- Raise and support vehicle.
- Remove u-joint bolts.
- Pry shaft backwards slightly and tilt it down forward...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
Alternator, Replace -> With A/C -> Without A/C
Vehicle: 1991 Volvo 240 SE 2.3 L4 GAS
With A/C
- Disconnect battery ground cable at battery.
- Detach pipe from control module box.
- Remove auxiliaries belt.
- Remove power steering pump and place it on top of engine.
- Remove upper bolt.
- Remove bolts common to alternator and compressor; lower bolts on alternator and upper bolts on compressor.
- Raise and support vehicle.
- Loosen lower bolts for compressor (so that there is some clearance).
- Remove air baffle.
- Lower vehicle.
- Disconnect warning lamp positive lead and connector from alternator.
- Pull alternator upwards/away.
- Remove alternator from vehicle.
- Reverse proc...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
Volvo -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 1991 Volvo 240 2.3 L4 GAS
The warning lamp is used to warn of an system fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diagnostic sy...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Volvo 240 AUTOMOBILES
Radiator, Replace
Vehicle: 1991 Volvo 240 2.3 L4 GAS
- Drain coolant into a suitable container.
- Reposition upper hose clamp at radiator and remove hose.
- Reposition lower hose clamp at radiator and remove hose.
- Remove fasteners ...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Volvo 240 AUTOMOBILES
Component location diagrams for most 1991 Volvo 240 cars and light trucks sold in the U.S. from 1990+.
 High/Low Beam System Components Diagram for 1991 Volvo 240 SE 2.3 L4 GASComponents on diagram: |
 Parking Shift Lock Components Diagram for 1991 Volvo 240 2.3 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Volvo 240 AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Volvo 240 cars and light trucks sold in the U.S.
 1991 Volvo 240 2.3 L4 GAS Wiring DiagramComponents on diagram: |
 1991 Volvo 240 2.3 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Volvo 240 AUTOMOBILES
OEM TSB listings for most 1991 Volvo 240 cars and light trucks sold in the U.S. from 1985+.
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Document: STUCK CDS IN AUDIO UNIT Vehicle: 1991 Volvo 240 2.3 L4 GAS Auto Systems: |
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Document: ROAD SIDE ASSISTANCE ON CALL - REVISED Vehicle: 1991 Volvo 240 2.3 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Volvo 240 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Volvo 240 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Volvo 240 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Volvo 240 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Volvo 240 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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