1988 Volvo 240 Service Manual

The 1988 Volvo 240 is a rear-wheel drive sedan/wagon featuring a 2.3L B230F inline-4 engine, Bosch LH-Jetronic fuel injection, 4-speed manual or automatic transmission, robust chassis design, and renowned safety features. This comprehensive service manual covers maintenance procedures, troubleshooting, specifications, and repair guidelines for the complete vehicle system. Below are key sections for technical data, maintenance schedules, systems overview, and repair procedures.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine System 4. Transmission & Drivetrain 5. Braking System 6. Electrical System 7. Suspension & Steering 8. Fuel System 9. Cooling System 10. Troubleshooting Guide 11. Technical Bulletins

Vehicle Specifications

Complete technical specifications for the 1988 Volvo 240 series including engine, transmission, dimensions, and capacities.

Specification	Description
Engine Type	B230F 2.3L inline-4 cylinder
Displacement	2316 cc
Fuel System	Bosch LH-Jetronic fuel injection
Horsepower	114 hp @ 5400 rpm
Torque	136 lb-ft @ 2700 rpm
Transmission	M46 4-speed manual or AW70 automatic
Fuel Capacity	15.8 gallons
Curb Weight	2880 lbs (sedan)
Wheelbase	104.3 inches
Braking System	Front disc, rear drum with ABS

Maintenance Schedule

Recommended service intervals and procedures for optimal vehicle performance and longevity.

Oil Change: Every 5,000 miles or 6 months - Use 10W-30 motor oil
Spark Plugs: Replace every 30,000 miles - Bosch WR8DS or equivalent
Timing Belt: Replace every 60,000 miles - Critical maintenance item
Air Filter: Replace every 15,000 miles or as needed
Fuel Filter: Replace every 30,000 miles
Brake Fluid: Flush every 2 years or 30,000 miles
Coolant: Replace every 2 years or 30,000 miles

WARNING! Always use genuine Volvo parts or equivalent quality replacements. Follow torque specifications precisely.

Engine System

B230F engine maintenance, repair procedures, and component specifications.

Compression Test: Should read 150-175 psi across all cylinders
Valve Adjustment: Hydraulic lifters - no adjustment required
Ignition System: Bosch EZK ignition with mechanical advance
Oil Pressure: 25-40 psi at idle, 40-60 psi at 2000 rpm
Cooling System: Operating temperature 87-93°C

CAUTION! Engine components operate at high temperatures. Allow engine to cool before servicing.

Transmission & Drivetrain

Manual Transmission: M46 4-speed with overdrive - Fluid: ATF Type F
Automatic Transmission: AW70 4-speed - Fluid: ATF Dexron II
Clutch: Hydraulic system - Fluid: DOT 4 brake fluid
Differential: Dana 30 rear axle - Fluid: 80W-90 gear oil
Drive Shaft: Two-piece with center support bearing
U-Joints: Greaseable - Service every 15,000 miles

Braking System

Service procedures for front disc brakes, rear drum brakes, and ABS components.

Front Brakes: Girling calipers, 10.9" ventilated discs. Rear Brakes: Girling drum brakes, 10" drums. Master Cylinder: Tandem type with brake fluid reservoir.

Brake Pad Replacement: Minimum thickness 3mm. Rotor Specifications: Minimum thickness 20mm. Drum Brakes: Adjust automatically during reverse braking. ABS System: Bosch ABS with wheel speed sensors.

Electrical System

Wiring diagrams, component locations, and electrical troubleshooting procedures.

Battery: 12V 55Ah - Located in engine compartment
Alternator: 65-amp output - Bosch or equivalent
Starter Motor: Bosch reduction gear type
Fuse Panel: Located under dashboard - 25 fuses total
Relays: Main relay, fuel pump relay, fan relays in relay panel

Tip: Always disconnect battery before performing electrical work to prevent short circuits.

Suspension & Steering

MacPherson strut front suspension, multi-link rear suspension, and power steering system.

Front Suspension: MacPherson struts with coil springs and anti-roll bar
Rear Suspension: Multi-link with coil springs and Panhard rod
Steering: Power-assisted rack and pinion - 3.2 turns lock-to-lock
Wheel Alignment: Toe-in 0° ± 0.2°, Camber -0.5° ± 0.5°
Shock Absorbers: Replace in pairs - Boge or Sachs recommended
Ball Joints: Check for play every 15,000 miles
Tie Rod Ends: Inspect for wear during tire rotation

WARNING! Use proper jack stands when working under vehicle. Never rely on jack alone.

Fuel System

Bosch LH-Jetronic fuel injection components, fuel pump, and fuel delivery system.

Cooling System

Radiator, thermostat, water pump, and cooling system maintenance procedures.

Pressurized system with expansion tank. Thermostat opens at 87°C. Radiator cap pressure: 15 psi. Coolant mixture: 50/50 ethylene glycol and distilled water.

CAUTION! Never remove radiator cap when engine is hot. System operates under pressure.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel pressure, ignition	Check fuel pump relay, test fuel pressure (38-44 psi), inspect spark plugs
Overheating	Cooling system	Check thermostat, water pump, radiator cap, coolant level
Poor fuel economy	O2 sensor, filters	Replace O2 sensor, check air filter, inspect fuel injectors
Brake vibration	Rotors, alignment	Resurface or replace rotors, check brake calipers
Electrical issues	Battery, alternator	Test battery voltage (12.6V), alternator output (13.5-14.5V)

Reset: Disconnect battery for 10 minutes to reset ECU if needed.

Service: Contact Volvo dealership or certified Volvo specialist for complex repairs.