📚 Vehicle Manual Information

1995 Volvo 850 Factory Service Repair Manual

🏷️ Basic Information

Make:

Volvo

Model:

850

Year:

1995

Body Styles Covered:

Sedan (LS, GLT, T-5R), Wagon (LS, GLT, T-5R)

Chassis Codes:

LS (Low Pressure Turbo), GLT (Gasoline Luxury Touring), T5-R (Performance Variant)

Engine Codes:

B5252S (2.5L 10-valve), B5254S (2.5L 20-valve), B5234FT (2.3L Turbocharged 20-valve)

👋 Introduction

Segment:

Premium compact executive car, known for safety, durability, and distinctive Scandinavian design.

Competitors:

BMW 3 Series (E36), Mercedes-Benz C-Class (W202), Audi A4 (B5), Saab 900 NG.

Safety Focus:

Early adoption of side-impact protection (SIPS), reinforced chassis, driver and passenger airbags, seatbelt pretensioners.

Design Philosophy:

Practicality, comfort, and robust build quality, with a distinctive boxy yet aerodynamic profile.

Performance Variants:

Introduction of the turbocharged T-5 and the iconic T-5R models, offering significant performance upgrades.

📋 Manual Details

Comprehensive Systems:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Drivetrain, Suspension, Steering, Brakes, ABS, Body, Electrical System, Climate Control, Safety Systems (Airbag, Seatbelt Pre-tensioners)

Total Pages:

Approximately 1500+

Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (PDF) - Searchable, Printable

📖 Manual Coverage

Engine Mechanical:

Engine removal/installation, cylinder head assembly, piston and connecting rod installation, crankshaft installation, timing belt replacement, lubrication system, oil pump operation, engine overhaul procedures.

Fuel And Emissions:

Fuel injection system (Motronic 1.8), fuel pump and filter replacement, injectors testing and replacement, evaporative emission control system, catalytic converter operation.

Ignition System:

Ignition coil testing and replacement, spark plug specifications, ignition timing adjustment (if applicable), ECU diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch replacement, transmission removal/installation, gear synchromesh operation, shift linkage adjustment, internal transmission component inspection.

Transmission Automatic:

AW50-42 Automatic Transmission. Transmission removal/installation, fluid level and condition checks, valve body operation, torque converter testing, solenoids testing, overhaul procedures, electronic control module (ECM) diagnostics.

Drivetrain And Axles:

Front wheel drive axle shafts, CV joint inspection and replacement, differential maintenance, propeller shaft (if AWD variant), rear axle assembly (if applicable).

Suspension And Steering:

Front strut and coil spring replacement, rear shock absorber replacement, control arm bushings, ball joint inspection, wheel bearing replacement, power steering system operation, steering rack diagnosis and repair, alignment specifications.

Brakes And ABS:

Front and rear disc brake inspection, pad and rotor replacement, brake fluid flush and replacement, ABS hydraulic unit testing and repair, wheel speed sensor diagnosis, ABS modulator operation.

Body And Interior:

Door panel removal, seat adjustment and removal, dashboard disassembly, exterior trim replacement, panel gap adjustments, rust prevention and repair guidance.

Electrical System And Diagnostics:

Wiring diagrams, fuse and relay locations, component testing (alternator, starter, battery), lighting system troubleshooting, power window and lock diagnostics, instrument cluster repair, immobilizer system (if equipped).

Climate Control HVAC:

Air conditioning system operation, refrigerant charging, blower motor replacement, heater core diagnosis, climate control module testing.

Preventative Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, coolant flushes, spark plug replacement, brake fluid flushes, timing belt inspection/replacement.

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common drivability issues, electrical faults, cooling system problems, and braking system malfunctions.

Component Replacement:

Detailed instructions for replacing all major components, including engines, transmissions, suspension parts, brake assemblies, and electrical modules.

Rebuild Procedures:

Overhaul procedures for engines, transmissions, and other key mechanical assemblies, including torque specifications and clearances.

Diagnostic Codes:

Listing and explanation of OBD-I (On-Board Diagnostics) trouble codes for the 1995 model year, along with diagnostic strategies.

Torque Specifications:

Comprehensive list of all critical torque values for engine, chassis, and drivetrain fasteners.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including lighting, engine controls, ABS, power accessories, and more.

Depth:

Comprehensive factory-level repair and diagnostic information suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

Quality:

High-resolution scans, clear text, bookmark navigation for easy access to sections.

Searchability:

Full text search enabled for quick location of specific procedures or specifications.

Digital Version:

Printable pages, allowing users to print specific sections or the entire manual.

Physical Equivalent:

Digital PDF, mimicking the layout and content of a professionally bound factory service manual.

Digital Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Options:

Inline 5-cylinder, naturally aspirated and turbocharged.

Displacement Na:

2.5 Liters (2435 cc)

Displacement Turbo:

2.3 Liters (2319 cc)

Horsepower Na:

140 hp (103 kW) @ 5200 rpm (20-valve), 115 hp (85 kW) @ 5000 rpm (10-valve)

Horsepower Turbo:

222 hp (165 kW) @ 5200 rpm (T-5R), 205 hp (151 kW) @ 5200 rpm (T-5)

Torque Na:

153 lb-ft (207 Nm) @ 3700 rpm (20-valve), 130 lb-ft (177 Nm) @ 3000 rpm (10-valve)

Torque Turbo:

232 lb-ft (315 Nm) @ 2500 rpm (T-5R), 200 lb-ft (271 Nm) @ 2000 rpm (T-5)

Induction:

Electronic Fuel Injection (EFI), Motronic 1.8

Fuel Type:

Unleaded gasoline, 91 octane (95 RON) recommended for turbocharged models.

Turbocharger:

Garrett AiResearch T25 (on turbocharged models), intercooled.

🔧 Transmission

Transmission Type:

5-speed Manual (M56H) / 4-speed Automatic (AW50-42)

Transmission Options:

Automatic transmission was optional on most trims, standard on some higher trims.

AWD Availability:

All-Wheel Drive (AWD) was not available for the 1995 model year 850.

Gear Ratios Manual:

Refer to manual for specific gear ratios by model/trim. (e.g., M56H typical final drive 3.77)

Gear Ratios Automatic:

AW50-42 ratios: 1st: 2.76, 2nd: 1.55, 3rd: 1.00, 4th: 0.70, Reverse: 2.05. Final Drive: 3.77

Transmission Fluid:

AW50-42: Volvo Dexron III or equivalent. Manual: Volvo Manual Transmission Fluid (MTF) 75W-90.

📐 Dimensions

Length:

Sedan: 187.3 inches (4758 mm); Wagon: 190.1 inches (4828 mm)

Width:

70.1 inches (1780 mm)

Height:

Sedan: 55.7 inches (1415 mm); Wagon: 56.4 inches (1432 mm)

Wheelbase:

104.9 inches (2664 mm)

Track Width Front:

59.5 inches (1511 mm)

Track Width Rear:

58.9 inches (1496 mm)

Wheel Bolt Pattern:

5x108mm

Wheel Size:

Typically 15-inch or 16-inch alloy wheels (17-inch for T-5R)

Tire Size:

e.g., 205/60R15, 205/55R16 (17-inch for T-5R: 205/45ZR17)

Passenger Volume:

Approx. 96 cu ft (Sedan) / 100 cu ft (Wagon)

Cargo Volume Wagon:

Approx. 36 cu ft (behind rear seats)

Curb Weight:

Approx. 3100-3300 lbs (1406-1497 kg) depending on configuration.

🛡️ Safety Features

NHTSA Rollover Rating:

Not rated specifically, but Volvos of this era generally had high rollover resistance due to low center of gravity.

ABS:

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Traction Control System (TRACS) was an option on some models, particularly turbocharged variants.

Airbags:

Driver and front passenger airbags.

Sips:

Side Impact Protection System (SIPS), including reinforced door structures and energy-absorbing materials.

Seatbelts:

Three-point seatbelts for all occupants, with front seatbelt pre-tensioners.

Child Safety:

Integrated child booster seat (optional on wagons), rear door child safety locks.

💡 Technology Features

Audio System:

Factory premium audio systems with cassette player and AM/FM radio. Optional CD player available. Sound system diagnostics and repair included in manual.

Cruise Control:

Standard electronic cruise control system. Troubleshooting for speed sensor and actuator issues.

N A:

No modern connectivity features like Bluetooth or USB. Relies on analog systems and basic electronic controls.

🔧 Maintenance

Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Use synthetic oil for turbocharged models.

Timing Belt:

Replace every 60,000 miles (96,000 km) or 4 years. Critical replacement interval to prevent engine damage.

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Spark Plugs:

Replace every 30,000 miles (48,000 km) for standard plugs, or consult manual for specific iridium/platinum recommendations for turbocharged variants.

Engine Oil Capacity:

5.3 US quarts (5.0 Liters) for 2.5L, 5.8 US quarts (5.5 Liters) for 2.3L Turbo. API Service SJ or SL, SAE 5W-30 or 10W-30.

Coolant Type:

Volvo Blue Coolant or equivalent (ethylene glycol-based) with a 50/50 mix of coolant and distilled water.

Brake Fluid Type:

DOT 3 or DOT 4.

Pcv System:

Clogged Positive Crankcase Ventilation (PCV) system can lead to oil leaks, rough idle, and engine sealing failures.

ABS Module:

ABS control module failure is a common issue, often indicated by the ABS warning light.

Rear Main Seal:

Leaking rear main engine seal can occur, especially on higher mileage vehicles.

Engine Mounts:

Worn engine mounts can lead to increased vibration and noise.

Automatic Transmission:

AW50-42 can experience occasional harsh shifting or torque converter issues. Regular fluid changes are crucial.

Suspension Components:

Front control arm bushings and sway bar links are common wear items.

📚 Vehicle History

Volvo Legacy:

Volvo's long-standing reputation for safety, durability, and innovative engineering dating back to its founding in 1927.

850 Introduction:

The 850 was a significant departure for Volvo, introducing front-wheel drive and a transverse-mounted inline-5 engine, replacing the rear-wheel-drive 240 series.

Platform:

Built on Volvo's Type II platform, shared with the subsequent S70/V70 and C70 models.

Performance Development:

The 850 line served as the basis for Volvo's foray into high-performance turbocharged vehicles, culminating in the acclaimed T-5R and R variants.

Production Years:

1991-1997 (850 model designation). 1995 represented the mid-cycle update with revised styling and features.

Manufacturing Locations:

Primarily produced in Ghent, Belgium, and Kalmar, Sweden.

🏆 Awards & Recognition

Safety Awards:

Consistently recognized for safety by various automotive organizations due to Volvo's inherent design principles.

Performance Recognition:

The T-5R variant, in particular, received accolades for its performance and distinctive styling, often considered a 'cult classic'.