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Volvo P 120 Service Manual

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  • Page 2 Body frame of the bulkhead (7), wheel arches (5), front upper The Volvo P 120 has an integral body so that there cross-member (4) and side plates (3), as well as i s no chassis frame. The body is composed of a l ower cross-members (1 and 2).
  • Page 3 P 120 The front end is bolted to the upper side mem- bers, front cross-member and front pillar. The front mudguards are pressed in one piece and bolted to the wheel arch plate. The front section forms the front part of the front end as well as the air duct to the radiator.

  • Page 4: Rear Seat

    P 120 i s adjusted with a screw (1, Fig. 5 and 3, Fig. 7) l uggage compartment lid is counter-balanced with on each side of the backrest. The seat cushions are torsion rods and can be set in any position when opening.
  • Page 5 Concerning other fittings and the bumpers, see the Body frame 4-door model. The body frame is largely similar to that of the P 120 STATION WAGON 4-door model. However, the side part is altered so that there is no longer an intermediate pillar Body frame and the rear mudguard (3, Fig.
  • Page 6 P 120 Fig. 9. Side section, Station Wagon Roof former Rear wheel arch I nner frame for side Front intermediate window pillar Upper rear pillar Outer cantrail Fig. 7. Front seat (2-door) Rear mudguard I ntermediate cantrail Rear intermediate Front pillar...

  • Page 7: Front Seats

    P 120 Fig. 10. Roof section, Station Wagon Fig. 11. Catch device for rear seat, Station Wagon The roof section (Fig. 10) consists of the roof plate, windscreen member, two roof arches and 3. Catch sleeve 1. Eccentric 4. Handle rear member.

  • Page 8: Repair Instructions

    P 120 REPAIR INSTRUCTIONS FRONT END Front mudguards The front mudguard is removed by taking out the following screws: the screw between the mudguard and stay at the lower side member, the screw bet- ween the mudguard and body side behind the above-mentioned stay, the screws in the front side section and the screws in the upper side member.

  • Page 9: Removing Front Door

    P 120 Fig. 14. Door check When the bonnet is closed, the U-shaped catch should meet the safety catch as close to the top as possible, but not so high as to cause the hook VOLVO 25255 to be pushed forwards, measurement C, Fig. 12.
  • Page 10 P 120 Remove the screws in the hinges and lift off the door. The holes in the centre pillar are larger than the diameter of the bolts. When running nuts are used, this enables the door to be adjusted both vertically and laterally.

  • Page 11: Door Locks And Door Handles

    P 120 Remove the door upholstery by carefully app- l ying a screwdriver or similar under the pad- ded edge and then prising outwards, when the upholstery will come away, see Fig. 20. Remove the paper protectors which are fitted over the holes in the inner plate of the door.
  • Page 12 P 120 DISMANTLING THE DOOR HANDLES Unscrew the two screws which hold the press- button and lock plunger to the door handle, see Fig. 23. Press out the locking pins as shown in Fig. 24. Turn the key backwards and forwards a few...
  • Page 13 P 120 Rear door Fit the lock (11, Fig. 27) with remote control (13) in the door without tightening the screws. Adjust measurement A, Fig. 28 to 17±0.5 mm (0.67 ± 0.02") by turning the lock. Tighten the l ock hard. If it is not possible to obtain the...
  • Page 14 P 120 FITTING AND ADJUSTING THE OUTER HANDLES Inner locking knob Front door, early production With the locking knob in the pressed-down posi- tion, measurement C, Fig. 28 should be 12± 1 mm Check that measurement B, Fig. 28=15± 1 mm (0.47 ±...
  • Page 15 P 120 VOLVO 1 01 039 Upper attaching screw for ventilation Fig. 31. window Unscrew the screws which hold the guide rail for the winding window, see Fig. 32. This only Fig. 34. Lifting out the ventilation window applies to the extended guide rail on the front doors.

  • Page 16: Sealing Strips

    P 120 VOLVO VOLVO 23248 23249 Fig. 35. Removing clip for carrier Fig. 36. Removing sprocket STRIPS ATTACHED WITH FASTENING RAIL Sealing strips On late production vehicles the sealing strip is attached by means of a fastening rail which is spot- BONDED STRIPS welded to the door.
  • Page 17 P 120 Luggage compartment lid, 2- and 4-door models The luggage compartment lid is mounted on two hinges, both of which are attached by means of three screws to the inner plate of the lid and with t wo screws to the plate under the rear window.
  • Page 18 P 120 Unscrew the nuts for the hinges and remove the latter. FITTING THE UPPER TAILGATE Place the hinges with packings in position. Screw on the nuts, adjust the position of the tailgate and tighten the nuts. Fold the plastic strip for the headlining as shown in Fig.

  • Page 19: Trim Mouldings

    P 120 TRIM MOULDINGS Waist mouldings The waist mouldings, and the upper trim moulding for the door on the 2-door model, are P 120 attached with clips. The mouldings are removed with the help of a putty knife with which they are carefully unfastened.
  • Page 20 P 120 Fig. 47. Application of masking tape Fig. 50. Position of springs Fig, 48. Removing window moulding Fig. 51. Fitting window moulding Fig. 49. Removing spring Fig. 52. Fitting spring 8--1 9...
  • Page 21 P 120 Trim mouldings, windscreen REMOVING Remove the trim moulding from the rubber strip by inserting a moistened nylon putty knife between the strips and moving it all, round, see Fig. 53. (Do not pull off the trim moulding). Push over the joining pieces to one of the halves of the moulding.
  • Page 22 P 120 Place the upper trim moulding in position and press it up against the rubber strip. Pull out the leather cord and press in the trim mould- i ng at the same time. Fit the angular joining pieces. Press on the side mouldings and push them up into the joining pieces.

  • Page 23: Rear Window

    P 120 Fit a cord (preferably terylene) of a suitable size in the groove of the rubber strip for the sheet metal edge, beginning at the top centre as shown in Fig, 60. Place the windscreen in position with rubber strip fitted.

  • Page 24: Removing The Backrest

    P 120 SEATS Front seats REMOVING, EARLY PRODUCTION Lift out the seat cushion. Press down the catch for adjusting the longitudinal position of the seat and push the seat forwards until the slide rails release from the frame. It may be necessary to lift the pull wire for the catch halfway between the slide rails.
  • Page 25 P 120 To remove the upholstery, undo the lacing at the l ower edge, open the zip-fastener, after which the upholstery can be removed, see Fig. 66. When fitting the backrest, place the nylon washer on the pin and fit the right-hand pin in position.
  • Page 26 P 120 Fig. 67. Inner trim mouldings removed Knocking in the teazel strip Fig. 70. Headlining and trim strip released Fig. 68. Fig. 71. Fitting sun visor Stretching the headlining Fig. 72. Cutting away the headlining Fig. 69. 8-25...
  • Page 27 P 120 REPLACING THE HEADLINING, 2- AND 4-DOOR VEHICLES Remove the interior light, sun visors, rear view mirror and upper part of the trim moulding for the windscreen. Release the side mouldings as shown in Fig. 67. Cut away the old headlining as shown in Fig.

  • Page 28: Removing The Instrument Panel

    P 120 Fig. 76. Stretching the headlining and attaching Fig. 77. Removing trim moulding for windscreen to teazel strip Instrument panel REMOVING THE INSTRUMENT PANEL The instrument panel is secured to the body with screws. These are accessible after the front doors have been opened and the inner trim moulding for the windscreen removed as shown in Fig.

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