Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. (w/ AIR SUSPENSION) MOVE HEIGHT CONTROL ON/OFF SWITCH IN LUGGAGE COMPARTMENT TO “OFF” 2. JACK UP VEHICLE, REMOVE FRONT WHEEL 3. REMOVE FRONT BRAKE CYLINDER AND DISC ROTOR (a) Remove the two bolts and remove the brake cylinder from the steering knuckle. (b) Hang up the brake cylinder using wire, etc. (c) Place matchmarks on the disc rotor and axle hub. (d) Remove the two screws and remove the disc rotor. 4. REMOVE SPEED SENSOR FROM STEERING KNUCKLE 5. CHECK BACKLASH IN BEARING SHAFT DIRECTION Place the dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If greater than the specified maximum, replace the bearing. 6. CHECK AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If greater than the specified maximum, replace the axle hub.

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2. Jack-up vehicle, support it with safety stands, and remove front wheels. 3. Unlock axle nut. See Fig. 9 . CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 4. Remove axle nut while depressing brake pedal to prevent front drive shaft from turning. 5. Remove stabilizer link. See Fig. 10 . 6. Remove disc brake caliper from housing, and suspend it from strut using a wire. 7. Remove disc rotor from hub. See Fig. 11 . If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor. 8. Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm. See Fig. 12 . 9. Using a puller, remove tie-rod ball joint from knuckle arm. See Fig. 13 . 10. Remove ABS sensor assembly and harness. See Fig. 14 . 11. Remove bolt which secures sensor harness to strut. See Fig. 15 . 12. Remove transverse link ball joint from housing. See Fig. 16 . CAUTION: DO NOT pull inner joint when removing axle shaft. 13. Remove inner joint from transmission spindle. 14. Remove front axle shaft assembly from hub. See Fig. 17 . 15. After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut. See Fig. 18 .

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1989-90 BRAKES Volvo – Disc 240 Series, 740 Series, 760 Series DESCRIPTION All models use front and rear disc brakes. Three makes of calipers are used: ATE, Bendix (DBA) and Girling. Service brakes are hydraulically-operated by a tandem master cylinder and vacuum power brake unit. Each rear brake line has a pressure valve to prevent rear wheel lock-up. Parking brake is mechanically operated, using rear wheel disc rotor internally-mounted brake shoes. For information on Volvo anti-lock brake system, see appropriate article for 740 and 760 series: ANTI-LOCK BRAKE SYSTEM – 1989 ANTI-LOCK BRAKE SYSTEM – 1990 BRAKE BLEEDING For vehicles with ABS, see appropriate article for 740 and 760 series: ANTI-LOCK BRAKE SYSTEM – 1989 ANTI-LOCK BRAKE SYSTEM – 1990

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2. Jack-up vehicle, support it with safety stands, and remove front wheels. 3. Unlock axle nut. See Fig. 9 . CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 4. Remove axle nut while depressing brake pedal to prevent front drive shaft from turning. 5. Remove stabilizer link. See Fig. 10 . 6. Remove disc brake caliper from housing, and suspend it from strut using a wire. 7. Remove disc rotor from hub. See Fig. 11 . If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor. 8. Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm. See Fig. 12 . 9. Using a puller, remove tie-rod ball joint from knuckle arm. See Fig. 13 .
10. Remove ABS sensor assembly and harness. See Fig. 14 . 11. Remove bolt which secures sensor harness to strut. See Fig. 15 .
12. Remove transverse link ball joint from housing. See Fig. 16 .

Cause of Rear Brake Problems 1 Combining a drum handbrake and a disc rotor and caliper within the confines of a 16-inch wheel necessitates a small brake caliper and small pad radial section, resulting in an undersized pad area. The standard design has a thin disc and a handbrake of
small diameter and swept area relative to the weight of the vehicle. 2 The backing plate and handbrake arrangement allow mud and slurry to enter but not exit, causing abrasives to accumulate and rapidly destroy the handbrake, including its function as an emergency brake. 3 The small disc pad contact area is at odds with the affects of loading under abrasive conditions where rates of wear are parabolic for wear rate versus load. 4 The handbrake design is fiddly and complicated with many small parts that prove to be difficult to assemble correctly

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