Volvo 164, 1970 Service Manual Download Page 202

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Summary of Contents for 164, 1970

Page 1: ...SERVICE MANUAL VOLVO 164 1970...

Page 2: ...in the register point to the index marks on the first page of each section The various parts are divided up as follows Tools Desoription Repair Instructions The specifications are to be found in Part...

Page 3: ......

Page 4: ...Part O GENERAL...

Page 5: ...l...

Page 6: ...ignation and chassis number stamped on the front right hand door pillar GROUP 03 DIMENSIONS AND WEIGHT Leng th W idth Height Wheelbase Ground c1earance Track front rear Turning ci rde Curb weight appr...

Page 7: ...ubricant type Normal oper ating tCr 1p of oil Oil capacity FINAL DRIVE Lubricant type without differen tial brake with differential brake viscosity above 10 C 14 F below 10 C 14 F Oill capacity MECHAN...

Page 8: ...e GUDGEON PINS Floating fit Circlips at both ends in pistan Fit In conneoting rod In piston Diameter standard overs izes 05 CYLINDER HEAD Height rrieasured from cylinder head contact face to face for...

Page 9: ...Inlet valve shoul d then open at CAMSHAFT BEARING Bearing diameter TIMING GEARS Cr ankshaft drive number of teeth Crankshaft gear fibre number of teeth Baokl ash End Hoat camshaft 0 4 63 451 63 464 m...

Page 10: ...ilter Oll FilTER Type Oll PUMP Oi l pump type nu mber of teeth on each gea r wheel end float radial clearance backlash RELIEF VAlVE SPRING IN Oll PUMP Length unloaded approx I oaded wi th 5 0 4 kg 11...

Page 11: ...g 175CD 2SE 2 41 3 mm 1 63 800 r p m 700 r p m Bl AM Automatic Transmission Fluid Type A Sealed system 7 kg cm2 10 0 Ib sq in approx 12 4 litres 2 73 Imp galls 3 27 US galls expansion tank of wich 1 5...

Page 12: ...s minimum len9 th Tigh ening torques ANaching screws Pulley nut TEST VALUES Field winding resistance Voltage drop acrossir nsulation diode Rated test VOLTAGE REGULATOR Typ e Contml vol age cold regula...

Page 13: ...e thread spark plug gap tightening torque Pre enga ging resistance to ignition coil DISTRIBUTOR Type Direction of rotaif ion Bre aker poin ts g ap contact pressure dwell ang le Capacitor Centrifl lgal...

Page 14: ...eth 381033 6 380682 6 235810 6 Socket Number p 45 t 2 P 14 5 s 2 Ba 15 s 2 Ba 15 s 2 Ba 15 s 4 Ba 15 s 2 Ba 15 s 2 SV 8 5 2 Ba 15 s 4 SV 8 5 1 Ba 9 S 1 SV 8 5 2 W 2 2 d 2 W 1 8 d 3 W 1 8 d 5 W 1 8 d 1...

Page 15: ...et gear short planet ge ar llolng ring gear Size of converter Torque roNo in convertrer Norma151tall speed Weights G earbox Converte r aase Converter Total without fluid Weight of fluid To a l with fl...

Page 16: ...nual voO lve shaft oo oo o o oo oo o Pressure pOlint o o o o oo oooo o oo ooo Oil pan drain plug ooooo ooo ooooo o o ooooo o oo o oo Oil tube oolledor lower body ooo o oooooo Governor li ne plate lowe...

Page 17: ...on1 ditioned Warp Brake linings Number per whe el Thiokness new Effective a rea Wheel unit cylinders Num be r per wheel Diameter O 12 Tubu lar divided three un iversal joints support bearings Fitted w...

Page 18: ...1 5 10 12 2 5 3 5 Lb ft 65 70 45 50 70 100 3 6 5 8 8 7 10 8 3 0 4 5 12 15 10 15 8 11 70 85 18 25 FRONT END AND STEERING GEAR WHEEL ALlGNMENT UNLOADED VEHICLE aster amber King p in indinati on at a ca...

Page 19: ...4 5 l m 8 Imp pints 9 5 US pintslminute 5 8 l m 9 Imp p ints 10 5 US pints 14 Imp pints 17 US pints minute With belt l l Oil approved as Automatic Tra nsmission Fluid Type AU Approx 1 2 litres 2 11 I...

Page 20: ...Type Ra di al throw Warp Imbalance com plete wheel Tightening torque for wheel nuts TYRES Type Size Double act ing hydraulic telescopic approx 223 mm 8 78 approx 340 mm 1 3 39 approx 279 mm 10 98 app...

Page 21: ......

Page 22: ...Part 1 SERVICING AND MAINTENANCE...

Page 23: ...o o 1 2 FinaI drive o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o 1 3 Steering box mechani cal steering o o o o o o o o o o o o o o o o o o o 0 0 o 1 3 Servo steering o o...

Page 24: ...is shown above an engine oil with grade For Service MS is used for subsequent topping up Con cerning viscosi ty muHigrade oil SAE 10 W 30 is pri marily recommended At ve ry low temperatures be Fig l...

Page 25: ...s The oil should be drained off immediately affer the car has been driven and while the oil is still warm To do this remove the plugs marked 1 and 2 in Fig 1 3 as weH as the cover for the oil strainer...

Page 26: ...applies also when flushing the final drive After the drain plug or cover has been re fitted fill with new oi The oil should rench up to the filler hole and the oil capacity is about 1 6 litres 2 82 Im...

Page 27: ...ake fluid whi ch meets the requi rements a ccording to SAE 70 R3 Clean the hra ke fl uid container cap betore removal and observe max imum cleanliness when filling with oil Avoid spHling brake flu id...

Page 28: ...Oil Oil See Fig l B Oil Paraffin wax Lock oil ParaHin wax No Lubricating point Lubricant 8 Luggage compartment l id hing es Oil 9 Luggage compartment lid lock Oil KeyhO les Lock oil 10 Door stops Par...

Page 29: ...t e leveli in th e battery is about 5 mm 3 16 above the plates Fig 1 19 If necessary fill with distilled wa er Also oheck that the ba ttery and battery terminals are secure 2 Check to make sure tha t...

Page 30: ...be removed de aned and then lubricat ed with high class durable grease according to the in structions in Groups 46 and 77 respectively Subseque nt fiHing or replocement of grease in a ddi tion to the...

Page 31: ...Part 2 ENGINE...

Page 32: ...a r oH seal Replaaing oil seal timing gea rea 1ing Replaoing the timing gears Posiltive crankoase ventilation Group 22 Lubricating System De cription Repa i r InSlt rudions Group 23 Fuel System Deseri...

Page 33: ...r removing and fitting valve tappets SYO 2435 Dowel pin 2 for fitting cylinder head SYO 2814 Puller for polygon hub SYO 2815 Press tool for fitting crankshaft drive and polygon hub SYO 2816 Drift for...

Page 34: ...h tools SYO 2811 and SYO 2812 SYO 2811 Lifting lug for attaching lifting beam 2810 or 2727 in engine front end SYO 2812 Lifting arm for attaching lifting beam 2810 in rear end of engine SYO 2813 Suppo...

Page 35: ...ositive crankcO se ven ti btion The Fig 2 4 Engine B 30 A viewed from left Hk Bhp SAE DIN 1 If 1 1 f 1f 1 I I I v i 1 80 f j kgm Ibft ffJ I rl d I 60 r _ 20 145 50 j 40 r lrl 4 _ __i I 2000 4000 6000r...

Page 36: ...ve the throttle controi shaft f rom the pedal shaft Iini rads and brack et emove the choke wire from the carbu rettor and the vacuum hose for The brake servo from the manifoid Dis connect the water ho...

Page 37: ...9 Connect the vacuum hose Ftt the throtHe controi shaf t the choke wire alS we U as the ok de aner ca sfng Conneot he hoses rto the air intake and prehea ting pla te respedively 10 W rre the electnk c...

Page 38: ...s T ight en securelly the dra in plug 2 6 2 Place the reinforcing braoket lin position and Nghten 01 1 f1he bo l f s manUa lily Then tigruten seculrely iiirst he bolts for the l ilywheel ca sing anld...

Page 39: ...of a stee 1 backing with indium pla te leadbronze bearing mel ta 80th front and rear crankshaft oil seals are rubber lip type seals with metal frame CAMSHAFT AND VALVE TAPPETS The camsha t 61 is made...

Page 40: ...m in the rocker arm casing and cmnkcase through I the hose 5 Fresh air is supplied to the rocker a rm casing through the air cleaner via the hose 3 Plates in the rocker arm casing see Figure ensure th...

Page 41: ...r seaHng Hange oil pump and con necting rods with pistons Repl ace the caps cor redly on the respective connecting rods 6 Invert and turn the engine Remove the crankshaft Place the caps correctly in t...

Page 42: ...help ef guide dowe ls SVO 2435 The belts must be tightened in a Fig 2 18 Oil hole in cylinder head 2 10 VOLVO 103364 Fig 2 19 Rear end of engine 1 Dowel pi n 2 Core plug 3 Sea ling fla nge 4 Circli p...

Page 43: ...e Fill if necessary with coolant Adjust the valve dearance if required The cylinde1 r head bolts need not be subsequenttly tightened CYLINDER HEAD AND VALVES Dismantling l Remove the va lve spr ings b...

Page 44: ...nary irrespective of whether the en9 ine is cold or warm T he cleamnce is the same for both the inlet and exhaust valve When adjusting use two feelergauges one Go 50 mm 020 thick and the other No Go 5...

Page 45: ...e Use a reversed piston to ensure tha f the rings comeinTo the correct position 2 Measure the ring gap with a feele r gauge The gap shoul d be AO 55 mm 016 022 If neces sary the gap can be increased w...

Page 46: ...een cleaned its journals mu st be measwed with a micrometer Measuring 2 14 A Fig 2 27 Bearing journal VOI VO 22902 sh Ou ld be carried out at sevem l poin ts round the circumference a nd along t he lo...

Page 47: ...d off Fig 2 28 Fitting oil seal Fig 2 29 Fitting sealing flange Pilot bearing for clutch shaft The pi lot bearing 6rcl ip and proteoting walsher are remeved the pilot bealring pullled out with teol SV...

Page 48: ...Fig 2 32 Centre spindle position on SVO 2816 be fMed in its outer position position 1 Wi th a wear ma rk on the polygon hub fit the seal in position 2 11 4 turns of centre holt screwed out With two w...

Page 49: ...s not damaged 4 Remove the camshaft nut and plJ H off the cam shaft geor with pUlller SYO 2250 see Fig 2 34 5 Pull off the crankshaft gear with plJlUer SYO 2822 see Fig 2 35 Screw OUit the oi 1 nozzle...

Page 50: ...it to a torque of 13 15 kgm 94 108 Ib ft The measu ring va lues for the tooth flank clearance and the camshaf t aX le dearance wh ich is deter mined by the spacing ring behind the camshaft gear are gi...

Page 51: ...tted drredly en the pump and cens sts ef a spring Ioaded ball The baH has a cyl indricall guide with a step at the end pesitien and there ere operates flexibly Even 0Jt idling speed there is a certain...

Page 52: ...hould be repla ced eve ry 10 000 km 6 000 miles when the old ffl ter is discarded l Remove the old filter with the help of chai n tonges see Fig 2 43 2 Coa t the rubbe r gasket l Fig 2 42 of the new f...

Page 53: ...riving shaft with g ear is replaced as a single unit The new bushes should be reamed afte r pressing in with arealmer provide1 d with a pil ot guide The sealing rings at i the ends of the deliv ery pi...

Page 54: ...plugs 2 22 Fig 2 47 Delivery pipe sealing rings FITTING THE Oll PUMP When NO l cy linde r is at tep dead cen re fit the eil pump drive and dis ribu ter T he sma1 jl part at the greeve is tu med abliq...

Page 55: ...rettor has been designed with a view to the exhaust emission cO n rol system It is provi ded with a fixed je t pressed into the carburettor housing the fuel flow ortfice area of which is varied by mea...

Page 56: ...The positiv vacuum connection for the ignition distribu tor is locate d on the rear carburettor FLOAT SYSTEM Fuel flows into the floatchamber via the Hoat va lve 4 Fig 2 51 The float l which is made...

Page 57: ...controI On the same spindle outside the cover 5 there is a cam disc 6 Fig 2 52 with con nection for the choke contral pull wire When the cold start device is engaged the valve di sc turnsand this lin...

Page 58: ...Carburettor housing middle section 15 Metering needle 16 Floatchamber 17 Rubber ring 18 Floatchamber plug 19 Drilling for cold start fuel Iocated in carb opposite wall 20 Drilling for extra air throu...

Page 59: ...de of the va Ive w here there is vacuum ca uses the va lve to lif from the bridge This also lifts the tapered me tering need le 15 Fig 2 55 w hich is attached to the plunger out of the jet The effecti...

Page 60: ...floatchambe r 9 Fig 2 60 is led via the valve 4 to the venting filter when the engine has been switched on or during idling Throttling shuts off the connection between the venting filter and the valv...

Page 61: ...front carburettor 5 Hose to hof start valve 6 Hot start valve 7 Hoses to float chambers VOLVO 104445 VOLVO 10446 Fig 2 64 Hot slart volve function idling l Th r J ttl e lever 10 A ir cleaner housing...

Page 62: ...by a new one The e ngine is fitted with an air preheater see Fig 2 67 Not however on vehicles with right hand steering The air preheating device consists of a flap housing S a hose 6 for cold air and...

Page 63: ...a ins the preswre in the line to the f loatchamber REPAIR INSTRUCTIONS The carb urettors are specially set by the manufacturer and f ine a djusted with a CO meter at the factory In orde r not do d ist...

Page 64: ...methods results in unsatisfactory running of the engine and it has been established that the fault is due to an overrich carburettor or loo lean fuel mi ture the carb urettor nozzle should be adjusted...

Page 65: ...nt thermostat has opened Warming up should be done with a completely cold engine When mea suring with a CO meter it is impol1tant that the carburettor temperature is the cerrect e ne When the engine i...

Page 66: ...against the ca rburettor lever with the valve pistonin the upper position and the throttle contral at idlet See Figs 2 64 and 2 65 Lubricate the contact surface with Mo lykote and 2 34 11 10 9 8 Fig...

Page 67: ...e with a carburettor withoult a by pa ss valve When conect funation is obta ined that is even the fundion according to B turn the screw a further 1 2 turn to the Ieft B The valve does no open Normally...

Page 68: ...ing surface see Fig 2 80 If the level is incorrect adjust by bending the tag at the f10at valve N B Do not bend the arm between t he f1oa t and the pin 2 36 Fig 2 80 Float level A 9 13 mm 35 51 B 15 1...

Page 69: ...that the flat surface faces rthe lock sorew The needle shoUlld inofine from the hol es in the a ir valve i e in towards the air c1eaner flange The needrle shoulld be inserted so far that the plastic w...

Page 70: ...observe tha t the ther mostat is Iocated in the centre of the air flow and the tightening screw for the hose clamp is on the upper side of the flap housing AIR CLEANER The inseTt shoul d be replaced...

Page 71: ...parts for wear Replace damaged or worn parts YSSY Fig 2 88 Location of inlet valve Assembling l Fit the inlet va lve see Fig 2 88 and the stop arm Tighten the screw but only sufficiently so that the s...

Page 72: ...eed a certain speed even if the engine speed is exceeded See Fig 2 96 The five fan blades are mounted asym mertricalrly to keeip down the noise level The fan coupl1 ing cons ists of the cO sing 11 Fig...

Page 73: ...radia tor and expansion tank shou l d be flushed with clean water If Volvo anti frost for cars is used it is red in colour it should not be mixed with othe r types of anti frost COOLlNG SYSTEM INNER...

Page 74: ...e There is also a va lve which opens when there is apartial vacuum in the system and admits air into the expansion tank REPAI R INSTRUCTIONS TOPPING UP WITH COOLANT Topping up wi th coolant consistin...

Page 75: ...an belt tension F 1 9 kg 1 5 O Ib A 10 mm approx 3 8 6 Fi JI with coolant see under Fillingempty system with coolant Start the eng ine and check for leakage REPLACING THE WATER PUMP Remove the radia t...

Page 76: ...UPLlNG The fan coupling function can be checked with a stroboscope w ith variable blinking freq uency Make a ma rk on the fan a nd onethe water pump pull ey Find out the speed re lation ship between f...

Page 77: ...ustment 35 Rocker orm casing 36 Ignition cable to ignition coil 37 Cylinder head 3 3 Distributor 39 Oil dipstick 40 Vacuum governor 41 Valve lappet 42 Retainer 43 Cylinder block 44 Gear wheel 45 Bush...

Page 78: ...Part 3 ELECTRICAL SYSTEM...

Page 79: ...ctions Headlights 3 26 Replacing the headllight insert 3 26 Replacing the bulb 3 27 Checking and ad justing the headlights 3 28 Fog lights 3 28 Parking and flasher lights 3 29 Rear lights 3 29 N umber...

Page 80: ...bar and lift up the battery 3 Clean the battery with a brush and rinse it with dean tepid water 4 Clean the battery shelf and cable terminals Use a special steel brush or pliers for the cable ter mina...

Page 81: ...er 3 2 5 Stator 6 Rotor 7 Drive end shield 8 Fan The alternator has a rotating field rotor and statio nary generating windings stator The rotor is of the claw pole type with the field wind ings fed ov...

Page 82: ...Remove the bolt holding the alternator to the engine block 5 Remove the fan belt and lift the alternator for wards Fig 3 5 Alternator fitted VOLVO 104469 DISMANTLING THE ALTERNATOR l Release the two...

Page 83: ...iodes with a diode tester see Fig 3 10 If any of the rect ifier diodesis raul ty the entire diode holder with three diodes must be replaced Fig 3 8 Removing the drive end shield 3 4 VOLVO 104472 Fig 3...

Page 84: ...cking the brush holder VOLVO 103 01 5 frame brush The lamp should 9 ive a Slteady light even if the brush or the termin a l I ea d is moved If the brush ho lder does not meet the above require me nts...

Page 85: ...FiHing 1 Place the support plate on the rotor shaft with the three elevations facing the rotor winding 2 Press the bearing in with the hel p of a tubular sleeve whi ch presses on the bearing inner ri...

Page 86: ...the isolation diode put on the nuts and washers Fit the brush holder Fig 3 19 Checking the alternator 6 Fit the spacer washer key fan pulley washer and nut Tightening torque 4 kpm 29 0 Ib ft 7 Connect...

Page 87: ...d the d i rem ourr ent produced is re fed via the regu lator to the field wind ing until the regulating voMage has been reached 3 8 0 61 I o EXC O F 0 VOl vo IU 1376 Fig 3 21 Inner wiring of regulator...

Page 88: ...ult in the lead or contact which must be remedied imme diately After repairing the leads or contacts measure once aga in With the same load as above measure the voltage drop between the negative pole...

Page 89: ...emperatures see Fig 3 25 volt age should also lie on this occasion between 6 r__ ___r r__ ___r _ _ _ r_____ 13 1 14 4 volts For ambient temperatures other than 250 C 770 F see the diagram in Fig 3 24...

Page 90: ...ting in one or several rectifier diodes Breakage in a diode reduces the cha rging current about 5 amps Short circuiting in a diode limits the alternator charging current to 7 8 amps and causes a rumbl...

Page 91: ...VOLVO 103299 The starter motor Fig 3 27 is fitted on the flywheel housing on the left hand side of the engine It con sists of a 4 pole s eries wound motor The pinian on the starter motor rotor shaft...

Page 92: ......

Page 93: ...he washers are as shown in Fig 3 34 When the bridge is removed the _ brushes follow also but brushes will remain in the field winding Fig 3 29 Starter motor installed 3 14 VOLVO 103300 6 Unscrew the n...

Page 94: ...LVO 103302 Fig 3 33 Starter motor with bearing shield removed The commutator shou ld be checked with a dial gauge after turning A radial throw of 08 mm 003 can be considered permissible The insulation...

Page 95: ...moved from the starter Fig 3 36 Removing the sealing washer 3 16 VOLVO 10 1 082 Fig 3 37 Rotor with pinion VOLVO 101 080 motor If on the other hand it engages satisfactorily examine the starter switch...

Page 96: ...e out the worn bushes with the help of a suitable tool 2 Clean the hole for the bushes and cut away any burr 3 Press in the new bushes with the help of a suit able drift N B Before a self Iubricating...

Page 97: ...a thin layer of grease on the rotor shaft 5 0 1 1 V 13 Place th e bushes in o il for 1 ho ur before fitti ng 6 Ft 2 V 3 Lubrica te the engag ing lever jo in ts and the iron co re of th e so leno id w...

Page 98: ...g of the distributor in relation to engine speed is regulated by a centrifugal governor fitted under the breaker plate Adjustment in relation to loading is controlled by a vacuum regulator mount ed ou...

Page 99: ...trifugal governor spring 2 Distributor arm 8 Cap clamp 14 Flange 20 Breaker cam 3 Contact breaker 9 Rubber seal 15 Lubricator 21 Washer 4 Lock screw for breaker 10 Fibre washer 16 Primary connection 2...

Page 100: ...connection 3 Slacken the screw 3 Fig 3 47 and pull up the distribufor DISMANTLING 1 Pull off the dist ributor arm Remove the cirdip fo r the pull rod from the vacuum regulator Remove the vacuum regul...

Page 101: ...ate must not be loose worn or have burr on Distributor shaft l The play between the distributor shaft and the breaker camshaft must not exceed 1 mm 004 2 The cams on the breaker camshaft must not be s...

Page 102: ...contact may be bent Wash the contacts with trichlorethylene or chemica lly pure gasoline Run the distributor on a test bench and check according to the Specifications REPLACING THE CONTACT BREAKER The...

Page 103: ...peed and adjust the protrador so that a marki ng lis obtained alf 0 Conned the vacuum hose to the bake lite connec tion on the vacuum regulator the primary d ia phragm Increase the vacuum gradually an...

Page 104: ...the engine does not draw in unwant edair 3 Connect the Stroboscope to No 1 cylinder spark plug and to the bai ttery 4 Start the engine and run it at the r p m given In the Specifications Use a tachome...

Page 105: ...ng wheel This causes the stop relay Fig 3 79 to connect up the lighting Up front the pa rking lights are integrally built wit h the flashe rs and are mounted on the front bumper at the corners The rea...

Page 106: ...REPLACING THE BULB 1 Remove the screw and take off the plastic cover over the space behind the headlight see Fig 3 63 Fig 3 63 Removing the plastic cover VOLVO 103325 Fig 3 62 Headlight l Outer rim 2...

Page 107: ...er 100 200 hou rs of operation The voltage al t the bulb with the headlights switched on and the engine running at chO rging speed should be at least 12 5 volts if sufficient lighting strength is to b...

Page 108: ...rectional fiasher Fig 3 70 Bul b location in rear li ght 1 Directiona l indicator 3 Stop light 2 Back up light 4 Rear light REAR L1GHTS REP LACING THE BULB l Slacken the two screws ho lding the glass...

Page 109: ...R LlGHTS Two flasher ma rking lights are placed on each side of the ear To replace the bulb take off the glass The glass is fitted on the body by means of two screws 3 30 Fig 3 72 Side flasher light V...

Page 110: ...ly built with the steering wheel lock The switch has four positions O Complefe electrical system disconnected and steer ing wheel locked l Current to fusebox Garage position 2 Same as position l but a...

Page 111: ...up one at a time for full and half speed respectively The gear housing for the wiper unit contains an integrally built parking switch The 3 32 I _ _ _ l I L _ 53b 53 1 JJL 31b I J 53a VOLVO 103355 Fig...

Page 112: ...arged when the e ngine is switched off Vehicles with automatic transmission are fitted with a sta rt re lay instead of a controi relay for the back up lights lUGGAGE ENGINE COMPARTMENT LlGHTING The ve...

Page 113: ...the two scnews holding the igni tion switch to the steering wheel lock Replace the ignition switch and fit the new one on the steering wheel lock R e fit tthe plastic covers REMOVING AND ADJUSTING TH...

Page 114: ...eat care with the brushes since the ball bearing has a larger dia meter than t he cummutator When as sembling the motor ad just the axial play of the pl a s ic g ea r whee 1 6 by means of the adjust i...

Page 115: ...NGINE COMPARTMENT LIGHT BULB VOLVO 104490 Remove the plastic cover over the bul b by unscrewing the sorew securing the cover Replace the bul b Re fit the plastic cover a nd scr ew i t on securely Make...

Page 116: ...d 3 92 Fig 3 90 Combined instrument reverse side VOLVO 104406 U09 Fig 3 91 Mounting plate with instruments and warning lamps SPEEDOMETER The spee dome te r is of the eddy current type In the speedome...

Page 117: ...tage stabili er This stabilizer centains a bimetal spring and a centact breaker W hen the ignitien is switched en current f1ews threugh the stabilizer and eut te the instruments This heats the bimetal...

Page 118: ...the switch knob It lights when the heating is engaged for the rea r window Fig 3 94 Wa rning valve VOLVO 103218 REPAI R INSTRUCTIONS During work under the dashboard and instrument panel the negativec...

Page 119: ...ECKING THE SPEEDOMETER CABLE It is most important that the speedometer cable IS correctly fitted if the speedomefer is to fun otion with out trouble It is vitally important that the cable is not bent...

Page 120: ...p and fuel gauge are not repairable and must be exchanged if faulty or damaged The gauge can be removed from the detached instru ment panel when the voltage stabilizer and rheostat Fig 3 98 Pickup for...

Page 121: ...and a constant direct current voltage of 5 1 volts The read ing is then noted After th is th e constant direct current is replaced by a 12 vo lt battery and a voltage stabil i zer Do not omit to conne...

Page 122: ...ighting rheostat SO Light switch 51 Ignition switch 52 Door contod 53 Switch heat reor window 54 Heoted reo r window 55 Switch fo r hondbroke controi 56 Fuel gouge tank unit 57 Reversing light 58 Toil...

Page 123: ...Part 4 POWER TRANSMISSION REAR AXLE...

Page 124: ...18 Dismantling 4 19 Inspeding 4 19 Assembling 4 20 Fitting 4 22 Group 44 Automatic Transmission BW 3S Teels 4 23 Descripti on 4 24 Repair Instructiens 4 27 Che aking fluid level 4 27 Ad justing selec...

Page 125: ...ts mainly of a pressure plate diaphragm spring and a shee1 t metall casing The diaphragm spr ing has a douhle function that of a clutch I ever wh en declutch ing and a pressure spring whe n engaging T...

Page 126: ...ay should be 2 3 mm 08 12 and adjustment is made by aHering the length of the thrust rod REPLACING THE CLUTCH WIRE l Unhook the return spring for the release lever Disconnect the wire from the lev er...

Page 127: ...to the friction surface Check the curvature of the pressure plalte with a 240 mm 9 45 long steel VOLVO 102087 Fig 4 7 Checking the curvature of the pressure plate Fig 4 8 Fitting the clutch ru ler wh...

Page 128: ...i pple 6 Thrust sleeve 10 Lock nu t 3 Piston sea I 7 Circli p 11 Thrust rod 4 Piston 8 Stop ring Fitting Fitting IS In reverse order to removal Fi ll with brake fluid and bleed the system MASTER CYLIN...

Page 129: ...0 SVO 2826 Puller for front bearing on intermediate shaft SVO 2828 Puller for rear bearing on mainshaft M 400 SVO 2829 Device for lifting and installing the mainshaft in gear box SVO 2830 Pu Iler for...

Page 130: ...y out where applicable operations 1 6 under the heading R emoving 2 Release he nut for the flange PuH off the flange with pulrler SYO 2261 see Fig 4 14 3 Pull out the old sea l with p ul1 lelr SYO 403...

Page 131: ...see Fig 4 14 4 Remove the release bearing Release the belts and rem ove the cover fer the input shaft Then release the bolts for the clutch casing and remeve t he ca sing 5 Turn the gea rbex upside do...

Page 132: ...as fOor the M 400 unit see Fig 4 21 9 P ul l out the input shant and remove the syncroni zing ring emove the thrust washer from the mainshaft rear end Fit lifting tOOoI SVO 2829 on the mainshaiit Push...

Page 133: ...eck the baH bea rings especiaHy fOrr scoring or cra cks in the bearing races or on the balls ASSEMBLlNG ASSEMBLlNG THE MAINSHAFT l Assemble 1st 2nd and 3rd 4th speed synchronizers Fit the snap rings c...

Page 134: ...elow Fig 4 29 Fitting the mainshaft rear bearing 4 10 VOLVO 103 112 Fig 4 30 Fitting intermediate shaft bearing A Insert drift VOLVO 103 113 3 Place the intermed iate shaft i n the bottom of the gearb...

Page 135: ...the clutch oasing Fit in shims for the intermediate shaft rear bearing so that they li e evenlly with or up to 05 mm 002 under the rear end see A Fig 4 31 9 Fit on the la rge speedomete r gealr Fit th...

Page 136: ...r for flange SYO 2412 Sleeve drift for fitting front and rear bearings on out put shaft and oil seal at flange SYO 2417 Drift for fitting bush in output shaft SYO 2423 Pu Iler for bush in output shah...

Page 137: ...et g ears are forced to rotate aro und the sunwhe el As a result of this the o utp ut shaft will rotate a t a higher speed th a n the ma inshaft ELECTRICAL SYSTEM The overdriveisengaged by e lectro hy...

Page 138: ...le 2 Channel controi valve relief valve 3 Relief valve 4 Pre filter 5 Oil sump 6 Oil pump 7 Fine filter 8 Gearbax mainshaft VOLVO 103173 Fig 4 37 Oil pump l Mainshaft 2 Eccentric 3 Cannecting rad 4 Gu...

Page 139: ...re to rise The pistons are ther eby displaced in the hy draulic cylinders the c1utch sliding member is puHed forwards and contact made with the brake ring Wi th disengagement of the overdrive the conn...

Page 140: ...ring 21 Output shaft 38 Magnet 6 Clutch member outer lining 22 Oil seal 39 Pre filter 7 Planet gear 23 Coupling flange 40 Fi ne fi Iter 8 Needle bearing 24 Rear casi ng 41 Pump plunger 9 Shaft 25 Sole...

Page 141: ...hoU ld be 4 2 5 5 kgm 30 40 Ib ft CHECKING AND REPlACING THE RELIEF VAlVE 1 Remove the base plat e and the pre filter Collect the oil in an oil contaiiner Warning If the vehicle has belen riven recent...

Page 142: ...non retum body ball spring and plug Tighten the plug to a torque of 2 2 kgm 16 IbJt 4 18 Fig 4 46 Fine filter 1 Fi lter 2 Sea l 3 Plug VOLVO 10 116 5 Re fit the pre filter and base pl at e together w...

Page 143: ...therespeotive fine filt er relief valve and pump check valve See a lso under the heading Work which oan be c trried out with the over drive installed Fig 4 47 Dismantling the overdrive VOLVO 10311 7 3...

Page 144: ...is not worn With replacement change the sunwheell complete with bush The bush must be concentnic with the gear wheel and this is difficult to bring about oUl tside a workshop Check the hrake ring for...

Page 145: ...8 Place the pl anet carrier complete with planet gear in position on the outpu t shaft Guide up the splines into the planet corrier and uni directional el u tch with drift SYO 2835 Fig 4 55 ASSEMBLlNG...

Page 146: ...SYO 2836 The t ighten ing torque is 2 2 kgm 16 I lb ft Fit the pfe f lter magnet gasket and base plate 4 22 Fig 4 57 Fitting the front casing 4 Fit the operating pistons in thei r cylinders VOLVO 103...

Page 147: ...the oi I pressure SYO 2532 Attaching plate for magnetic holder when measuring end float of input shaft SYO 2533 Press tool for compressing clutch when removing and fitting the snap ring SYO 2534 Fitt...

Page 148: ...A three element hydrokinetie torque converter eoupling eapable of torque multipllication at an infinitely variable rate between 2 l and l l 2 A hydraulieally ope rated gearbox comprising a pl anetmy g...

Page 149: ...as follows The impeller isrotated by the engine and converts the engine power into hydrokinetic energy The fluid flows from the impeller vanes to the turbine vanes and retUTnS to the impeller through...

Page 150: ...corred pesitiens relative te the twe sun geajrs and the ring g ear and alse ferms a reactien member in certain 4 26 Fig 4 65 Planetary gear c1utches and brake bands cenditiell s The varieus mechanical...

Page 151: ...HECKING THE FLUID lEVEL Normally oil changing i s only required when the gearbox has been reconditioned However the oil level should be checked every 10000 km 6000 miles When checking the oil I evel t...

Page 152: ...cle fill with oi ADJUSTING THE SELECTOR CONTROlS l Disconnect the pull rod from the lever on the selector shaft Set the selector lever to N see Fig 4 69 4 28 Fig 4 69 Ad justing selector eontro ls 2 S...

Page 153: ...rise is more than 20 Ib j sq in 1 4 kg cm2 the effective length of the oQuter cable should be decrease d N B On vehicles with an exhaust emission controi system it may be more sui table to measure th...

Page 154: ...housing and switch with a pencil 4 Connect the controi lamp to both the other ter minals Fig 4 72 B Screw in the switch until the lamp lights agai n and then mark the switch aga in Then screw back th...

Page 155: ...valve bodies assembly with oil tu bes The air used must be clean and dry If the c1u tch and bands operate satisfactorily with air pressu re faulty operation of the kansmis sion must bedue to malfunct...

Page 156: ...T axles 2 Dmin the oi 1 into a clean container see Fig 4 76 N B The oil may be very hot causing scalding if contact is made with the skin 3 Place lifting tool SVO 2727 at the rear end of the Fig 4 76...

Page 157: ...nd withdraw the con verter housing 2 Unscrew t he W eldgl ok screw for the drive f lange on the output shaft Pu I 1 out the drive f1 ange and catch the plairn washer Loosen and withdraw t he rea r ho...

Page 158: ...ody 4 34 27968 Fig 4 81 Main compone tfs of valve bodies assembly A Oil tube collector E Lower valve body B Upper va lve body F Front pump strainer C Governor lin e plate G Rear pump strainer D Separa...

Page 159: ...shift and throttle valve C Primary regulator valve D Se condary regulator va lve E Servo orifice controi valve F Modulator va lve A I __ B VOLVO 102640 Fig 4 84 Upper valve body A 1 2 shift valve and...

Page 160: ...ackwards and forwards and read off the end float Th is should be 010 030 25 75 mm Note the amo unt of play 22 Unscrew the six bolts which re t ain the front pump to the body Withdraw the pump and remo...

Page 161: ...emove the thr ee oil r ings from the clutch body hub 30 Remove the snap ring and take out the pressure plate finner and outer plates Fig 4 89 Withdrawing front clutch assembly VOLVO 27970 VOLVO 27668...

Page 162: ...otted screw early prod Use a t hin wa lled or ground diameter socket for the hexagon bolls Withdraw the pump housing and driven gear Mark the gear on the outside ace so that it can be re fitted corre...

Page 163: ...CV or correspon ding is used for the flange boM ond Loctite AV for the nipples for the oil cooler conneections Note Items not described in this section are assembled in the reverse order to di smanHi...

Page 164: ...ate acing t he rear Fit the snap ring Fig 4 98 Insta Jling driven shaft o il rings 4 40 VOLVO 27994 Fig 4 99 Gear train components A Input shaft and front clutch group B Rear clutch and forward sun ge...

Page 165: ...centre support upwards and fit the assembled unit into the trans mission case Note that the holes point down wards when the transmission is turned the right way up se e Fig 4 92 Fig 4 101 Governor and...

Page 166: ...e Fig 4 91 14 Install ifhe c1utch pl ates Note tha t the outer plates are coned and that all the plates should be fitted with the cone facing in the same direction Begin Fig 4 106 Front servo assembly...

Page 167: ...tes and hub Fit the thrust wash er for the clutch hub clnd input shaft into the front c1utch see Fig 4 114 Fit the snap ring Fig 4 111 Front clutch dismantled VOLVO 28004 Fig 4 112 Front clutch detail...

Page 168: ...Line Fig 4 116 Installing speedometer gear VOLVO 28022 up thecomponent par ts of the valve bodies as sembly by using two of the re alining bolts Check the free movement of all valves in their bores C...

Page 169: ...b le for revers in g lig ht E Ig ni tion sw itc h c VO LVO 102744 The converter convert er ho using and gearbox are fitted in th e reverse order to removing Conn ect the leads for the sta rter inhibit...

Page 170: ...12 Boot 13 Lever 14 Ball socket 15 Stop bracket 16 Spacer sleeve 17 Lever on gearbox 18 Link rad 19 Lever at achment 20 Lever arm 21 Controi rod 4 46 REPLACING THE SELECTOR CONTROL INDICATOR l Disconn...

Page 171: ...through the rear wheels indicating tha t the rear oil pump of the transmission i s operating 6a Stop and restart using full throttle acceleration Check for 1 2 and 2 3 shifts according to the shift s...

Page 172: ...full throttle take off in D Loss of performance and overhe ating in D 3 seized stator Cont inue as for test 4above Transmission downshif ts too easily Tra nsmission will not downshift As tes t 6a abov...

Page 173: ...uid leve l is cerred befere the stall speed test The test must net take p lace lenger tha n ten secends etherwise the tra nsmi ssi en wil 1 everheat Fault tracing en the cenverfer is carried eut as fe...

Page 174: ...al joint The rear end of the front section of the propeller shaft is carried in a ball be aring The ball bearing is con tained in a rubber bearing housing which is attached to the propeller shaft tunn...

Page 175: ...suppert bearing and take dewn the prepeller shaft cemplete Fig 4 124 Removing the bolts Fig 4 125 Removing the snap ring veLve 103227 DISMANTLING DISMANTLING THE PROPELLER 5HAFT l Bend back the leck w...

Page 176: ...n easily wi thout binding at any point If it does not scrap the bearing and repla ce it wi h a new one Check needle bearings and spiders Worn Of damaged parts shou1 ld be replaced ASSEMBLlNG ASSEMBLlN...

Page 177: ...drive SVO 2595 Adjusting rings for differential SVO 2597 Brake for crown wheel used when checking tooth mesh SVO 2599 Drift for removing outer ring front pinia n bearing SVO 2600 Measuring fi xture f...

Page 178: ...l are jour nalle d in the final drive housing by means of two taper roller bearings The crown wheel is bolted to the differential carrier The differential gears them 4 54 selves in the differential ca...

Page 179: ...e o il seal Fig 4 131 Removing the d rive shaft Fig 4 132 Removing the drive shaft bearing VOLVO 10178 1 VOLVO 103 175 5 Fi 11 the space between the seal lips on the new oil with grease The n p lace i...

Page 180: ...e Fig 4 136 Pull out the oldoil sea 1 wi th pul ler SYO 4030 3 Fiit the new ail seal with tool SYO 2806 When fitting the oil seal lubricate the seal lips with grease At the same time apply a Iaye r of...

Page 181: ...the pinion is pointing downwa rds Remove the brake pipes 2 Release the bolts for the hrake backing plates and brake shoe retainers They are slackened thro ug1 h t he h 0 les in the drive shaft flanges...

Page 182: ...and remove the crown wheel 2 Dl1ive out the lock pin see Fig 4 145 and then the shaft for the differenti al gears Take out the differential 9 ears and the thrust washers 3 Pull off the differential c...

Page 183: ...time this sHt Ioses its lock ing effediv e ness For this reason the nut should be repla oed if it has been removed a couple of time s The washer under the nut s hould also be replaced if it has become...

Page 184: ...ocation of the pinlon use a dia I indicator indi cator re1ainer SVO 2284 and a measuring 1 001 SVO 2393 which consists of two parts a pinion gaug e and an a djusting jig Checking is as fo llows Place...

Page 185: ...g 4 154 N B It is almost im possibl e to obta in a snim with exactly the correct thickness However they must not be 03 mm 0012 thicker than the measured value but up to 08 mm 0032 thinner Fig 4 153 De...

Page 186: ...ial carrier The ring with the black oxidize d adjuSltin g ring should be placeld on the orown wheel side Also I ubricate the bearing locail ion in the aarrier PI aee the differential calrl1i er and t...

Page 187: ...e nut with the flat side facing downwards Toe Reverse side Heel Fig 4 160 Correcf tooth contact VOLVO 20196E VOLVO 24269 Fig 4 16l Faulty tooth contact RotaJt e the plate orwards and ba okwa rds sever...

Page 188: ...seal The oil seall is fitted with tool SYO 2806 see Fig 4 137 When fitt ing the oil sea I smear the seal lips with g rease Art the same time apply a Iay er of grease to the spring coil Thi s bst ment...

Page 189: ...o o o o o o o o o o o o o o o 2 2 34567 65891011 2 3 8 3 7 9 10 11 No push start Overheating The numbers indicate the recommended sequence of fault investigation A Fluid level incorrect B Downshift v...

Page 190: ...ort ri ngs 12 Pressure spring 13 Release bearing 14 Clutch wire 15 Washer 16 Rubber bush 17 Washer 18 Nut 19 Rubber stop 20 Stop brocket 21 Pedal shaft 22 Clutch pedal 23 Adjusting nuts 24 Cover gearb...

Page 191: ...lever lower 35 Washer 36 Cover 37 Spring 38 Protective casi ng 39 Oil seal 40 Mainshaft 41 Speedometer drive 42 Rear cover 43 Speedometer pinion 4 Sh ift lever section section 45 Gear wheel 1st gear...

Page 192: ...iston 55 Spring 56 Washer 57 O ring 58 Cylinder 59 O ring 60 Plug 61 Spring 62 Ball body 63 Non return 64 O ring d 65 Pump bo y er 66 Pump plung 67 Wash r 2 68 Fine filter 69 Seal 70 Plug 71 Data plat...

Page 193: ...aring 36 Key 37 Reverse sun gear 38 Needle 1hrust pla te 39 O il rings 40 Forward su n gea r 41 Oil ring 42 Centre bea ring 43 Servo strut 44 Brake band 45 Needle thrust bearing 46 Thrust plate 47 Sna...

Page 194: ...ear 8 Lock pin 9 Differential pinion 10 Crown wheel 11 Shaft 12 Thrust was her 14 Flange 13 Rear axle casing 15 Dust cover plate 16 Oil slinger 17 Oil seal 18 Shims 19 Front pinion bearing 20 Pinion 2...

Page 195: ...Part 5 BRAKES...

Page 196: ...er cylinder Warning valve Brake valve Brake lines Venting the hydraulic system Adjusting the brake light switch Brake pedal Group 54 Auxiliary Brake System 5 17 5 20 5 20 5 23 5 23 5 24 5 25 5 27 5 27...

Page 197: ...ing to Fig 5 3 A hose connection see 2 Fig 5 4 is required for removing the pistons in the rear brake ca lipers For venting the system aventing unit of the type shown in Fig 5 5 is used A connection c...

Page 198: ...he left rear wheel With such an arrangement braking effect is ensured should one of the brake lines fai l The servo brake cylinder S is directly influenced by the brake peda l and with vacuum assistan...

Page 199: ...ms should be avoided When the container of the master cylinder is being filled likewise with all work concerning connections etc the greatest clea nliness should be o bserved in order to prevent dirt...

Page 200: ...e unit From the point of view of leakage the brake valve is not defective if the pressure remains unaitered for at least 15 seconds Outgoing pressure I 30 I 50 I 100 kg cm2 I b sq in 427 711 1 422 Inc...

Page 201: ...uit fades The rear wheel brakes fade A wheel brake fades Faultily set val ve Blocked equa lizing hole in master cylinder HancJbrake cable chafes Faultily adjusted handbrake Faulty brake valve Darnaged...

Page 202: ...is not blocked CHECKINiG THE B RAKE PADS Every 10000 km 6000 miles check the wear on the linings The brake pade should be replaced when the linings are worn down to a thickness of about 3 mm 5 6 1 8 U...

Page 203: ...ded facings and are held in position by means of retaining pins 13 Fig 5 7 Brake componenls front wheel 1 Hub 3 Brake disc 2 Front bra ke ca Iiper 4 Cover plate VOLVO 101 858 6 5 7 __ 8 3 2 Fig 5 8 Fr...

Page 204: ...spring moves on the pin with a certain amount of friction The sealing rings 1 have a square section and press against the piston from the slightly oblique groove in the housing The function of the se...

Page 205: ..._ Secondary circuit pressure above 34 kg cm2 484 Ib sq in Secondary circuit reduced pressure f Primary circuil pressure above 34 kg cm2 484 Ib sq in Primary circu it reduced pressure Fig 5 12 Brake a...

Page 206: ...REPLACING THE BRAKE PADS The brake pads should be replaced when about 3 mm 1 8 of the lining thickness remains On no account must the linings be worn down to below 1 5 mm 1 16 Front wheel brake units...

Page 207: ...arefully clean the cavity occupied by the pads If any of the rubber covers is damaged replace it If dirt has penetrated into the cylinder due to a damaged cover recondition the brake unit 5 Press the...

Page 208: ...Fig S 19 Disconnecf the con nection 2 and the lower hose 4 from the bracket Place the protective casing on the brake lines to prevent unnecessary leakage Discon nect the connection 6 for the upper ho...

Page 209: ...lips Check that the pads are movable 6 Fit the venting nipples and also the brake lines FITTING l Place the ca liper in position Check that the con tact surfaces of the retainer are clean and not dama...

Page 210: ...out one of the retaining pins while keeping the damping springs in position Remove the springs and then the other retaining pin Pu ll out the pads and the spacers see Fig 5 18 2 Remove the dust cover...

Page 211: ...e sure that the piston does not come at a slant and is scored or that it da mages the pin for the AS B device Press in the piston with tool SYO 2809 Check the AS B device for stiffness with a tor que...

Page 212: ...ove mentioned inspection the brake disc should be replaced When 5 16 Fig 5 32 Removing the brake d isc VOLVO 101876 doing this the brake ca li per should first be re moved The n unscrew the lock bolts...

Page 213: ...03184 When the system is at rest Fig 5 34 the pistons are kepi pressed back by the force of the springs When the pistons are in this position the connections be tween the brake fluid container and whe...

Page 214: ...End piece 8 Sealing washer 9 Sprir g 10 Connection front wheel brakes 11 Thrust washer 12 O ring 13 Piston 14 Housing VOLVO 102454 Fig 5 39 Normal position VOLVO IC2J J two brake circuits exceeds abou...

Page 215: ...cylinder and front wheel cylinders the hydraulic force Fig 5 41 Brake valve construction 1 Plug 12 Adjusting screw 2 O ring 13 Locknut 3 Cylinder 14 Spring housing 4 Valve 15 Retainer 5 Valve spring 1...

Page 216: ...e brake fluid spill over 2 Remove the electric cables from the master cy linder and fit plastic plugs as the lines are dis connected Fig 5 45 Removing the container 5 20 VOLVO 103188 4 5 VOLVO 1031 89...

Page 217: ...an 23 66 mm 931 Each time reconditioning is carried out replace the primary piston 3 Fig 5 48 and the secondary pislon 4 Fig 5 48 complete as weil as the stop screw 2 with washei and circlip 5 also th...

Page 218: ...ll the con tainer w ith brake f luid and vent the cylin der Place plastic plugs in the cylinder Check to make sure that the venting hole in the cap l is open and fit the strainer 2 and cap in position...

Page 219: ...i nder secondary circuif 4 Secondary circuit front whee ls 5 Secondary circuit rear whee ls 6 Primary c ircu it rear whee ls 4 Fig 5 57 Bra ke va lves fitted l Adjusting screw 2 Left brake valve secon...

Page 220: ...d check that there is nO ension in the hose Fit the attaching screws and connect up the bra ke pipe Tighten the connec tions Vent the brake system ADJUSTING The adjusting screw 12 Fig 5 41 is not inte...

Page 221: ...rectly it should be adjusted manually before being fitted Bending a pipe already connected often results in deformation at the connections The front brake hoses must only be fitted according to Fig 5...

Page 222: ...to prevent air from sneaking in via the threads of the nipple 7 Fig 5 64 Venting diagram 5 26 5 VOLVO 103199 Fig 5 65 Venting the front wheel brake un it VOLVO 103 265 When venting remove the protecti...

Page 223: ...er 5 Venting should be carried out in the order shown in Fig 5 64 and as fo llows Remote the marking cap a nd fit the ring spanner a nd plastic hose on to the venting nipple Allow the opening of the p...

Page 224: ...he new bushes 3 and 9 and lubricate them with a light layer of bal l bearing grease Fit the bearing sleeves 2 and 8 and the return sp ri ng 10 5 28 10 9 8 7 6 t 4 5 4 3 2 11 12 13 r t f 14 15 16 J Ll...

Page 225: ...shown in Fig 5 70 The servo cylinder function as follows 17 Relainer 18 Filter 19 Silencer 20 Sealing ring 21 Cylinder 22 Return spring 23 End 24 Reac1ion disc 25 Valve piston 33 Valve spring 26 Slop...

Page 226: ...o be moved further for wards than the valve piston and results in the seat of the piston reaching the valve shutting off the air 5 30 supply The pressure behind the diaphragm remams constant and is th...

Page 227: ...Remove the split pins and the split pin bolts 6 and 13 5 Lift up the brake pedal Remove the rubber cover 35 Fig 5 70 6 Remove the protective washer see Fig 5 75 from the cylinder 7 Remove the damper...

Page 228: ...m the brake pedal Remove the bracket with clutch pe dal stop from the cowl 3 Remove the 4 nuts securing the servo cylinder to the cowl 4 Pull the servo cylinder forwards and disconnect the fork from t...

Page 229: ...rake shoes are self centring and both the shoes are partly self apply ing Duo Servo The brake drum is fitted on the drive shaft and so designed that it also serves as a brake disc for the footbrake Wh...

Page 230: ...e wheels Release the handbrake 3 Check that the brake pads are not stuck to the brake disc To prevent the lever when adjusting from influencing the shoes and thus give mi sled ing results the spring t...

Page 231: ...the pu ey 7 4 Remove the rubber cover 8 Fig 5 78 for the front attachment of the cable sleeve and the nut as we as the attachment for the rubber sus pension ring on the frame member Remove the cable f...

Page 232: ...oved from the lever 3 Loosen the three attachments for the frame of the seat slide rails and lift the whole seat forwards 5 36 Fig 5 85 Removing the brake drum VOLVO 10 1922 4 Remove the rubber covers...

Page 233: ...t the brake shoes see Fig 5 86 The shorter sleeve on the adjusting device should be turned forwards on the right hand side and backwards on the left hand side see Fig 5 89 4 Hook on the return spring...

Page 234: ......

Page 235: ...Part 6 FRONT END AND STEERING GEAR...

Page 236: ...eel Replacing bearing in steering column jacket Replacing bush for relay arm Mechanical steering gear Steering box Servo steering Work which can be carried out with servo steering in vehicle Checking...

Page 237: ...SYO 2705 Dr ift for removing and fitting rubber bushing in lower wishbone SYO 271 1 Steering wheel puller SYO 2713 Spanner Sfs for upper wishbone shaft bolt wheel adjustment SYO 2715 Drift for removin...

Page 238: ...2719 Sleeve for fitting oil seal pitman arm shaft SVO 2720 Removal too I for pitman arm shaft bush SVO 2721 Reamer for pitman arm shaft bush SVO 2850 Pilot for reamer 2721 6 2 2860 Q 2865 2866 Fig 6 4...

Page 239: ...ds Fa ulty camber causes uneven tyre wear Fig 6 5 Caster VOLVO 23801 VERTleAL LI NE VOLV O 238 02 Fig 6 6 Camber a nd king pin inclina tio n B King pin inclination C Camber KING PIN INCLlNATION King p...

Page 240: ...is measured d irecfly with the wheels pointing straight forwards Caster a nd kin pin inclination cannot be measured directly Instead the a ngu lar a lteration which occurs whe n the wheel is turned fr...

Page 241: ...to have a eamber whieh is al 4 greater than that for the right hand side e g 0 and 1 4 resp This will eliminate the in fluenee of the road surface inclination whieh would pull the vehicle in a eertai...

Page 242: ...0 3 5 3 0 2 5 0 5 0 4 0 3 0 2 0 15 O 6 6 O I i I 1 II ID V l v I Fig 6 9 Diagram for alteration of easter and eamber I Camber II Cas1er A Shims mm B Al1era1ion af angle I v 7 O gO le B VOLVO 101 952...

Page 243: ...ting is done as fo llows Turn the left wheel for a left hand turn as far as it goes Check that the lock angle of the wheels Fig 6 11 Adjusting screw max wheel lock VOLVO i02079 is 45 If it is not then...

Page 244: ...Stabilizer anchorage 3 Steering knuckle 12 Stabilizer 4 Stub axle 13 Stop bolt max wheel lock 5 Outer wheel bearing 14 Lower wishbone bush 6 Inner wheel bearing 15 Frame at1achment for stabilizer 7 L...

Page 245: ...ed in rubber bushes which are jour nalled in the wishbones Camber and caster are adjust ed by means of shims between the upper wishbone shaft and its attachment in the front axle member see Fig 6 8 Th...

Page 246: ...6 19 4 Remove the stabilizer attaching bolts 5 Loosen the brake hoses from the brocket at the support member 6 Remove the lower nuts for the front engine mount ings Fig 6 15 Tool for lifting engine 6...

Page 247: ...ring components are dried with cotton or cloth rags but not waste A new bearing taken directly from its packing container should not be cleaned After the cleaning inspect the parts If the bearing race...

Page 248: ...ken the wheel nuts slightly 2 Jack up the front end of the vehicle under the front jack attachments Remove the wheeL 3 Slacken but do not remove the nut fo r the upper ball joint Tap with a hammer on...

Page 249: ...jack attach ments Take off the wheel Fig 6 24 Removing the ball joint lower wishbone Fig 6 25 Fitting the ball joint lower wishbone Disconnect the steering rod from the steering arm with tool SYO 229...

Page 250: ...pin until it loosens Fig 6 27 FiHing the rubber bush lower wishbo ne 6 14 VOLVO 103 134 Fig 6 28 Position for bush VOLVO 101978 from the axle Remove the nut and suspend the upper end of the knuckle w...

Page 251: ...YO 2705 turned in the opposite direction as weil as counterhold SYO 2701 and press tool SYO 2699 see Fig 6 27 Both bushes should be faced with the flanges rear wards in the vehicle see Fig 6 14 FITTIN...

Page 252: ...6 box by means of aflange 4 with rubber disc Should a frontal collision involving the indentation of the front end occur it is possible for the lower section of the steering column to break away and t...

Page 253: ...ich is secured in a withdrawn position At position I the vehicle can be moved with the ignition switched off At position II the ignition is connected up and in position III the starter motor can be en...

Page 254: ...the tooth segment of the pit man arm shaft 20 The axial movement of the piston which determines the direction the wheel turn is obtained via steering cam S and ball nut The recircu lating balls 4 are...

Page 255: ...lowing description of the function applies to both FUNCTION The location of the steering valves as weil as that of the oil floware shown schematically in Figs 6 33 6 34 and 6 35 In order to illustrate...

Page 256: ...the turning movement the greater will be the valve displacement One of the controi valves 9 is then displaced to the 6 20 right and opens the intake port 8 wider while at the same time the other cont...

Page 257: ...Oil at the right hand section of the cylinder is pressed by the piston via the annular groove 19 through the return groove 6 of the controi valve 10 back to the oil container 13 Servo pump The servo p...

Page 258: ...line and a lso to the right of the piston W hen the spri ng pressure is overcome the piston is therefore displaced to the rig ht And whe n the speed is sufficie ntly hig h in relation to the counte rp...

Page 259: ...nd fit the horn ring so that the holes come opposite the attaching screws Fit the screws 2 and 3 Fig 6 39 Check the function of the horn ring 4 Fit both parts of the directional indicator switch housi...

Page 260: ...see Fig 6 44 6 Place the relay arm in position fit the washer 7 and the nut Tighten the nut to a torque of 7 0 8 5 kgm 50 60 Ib ft 6 24 SYO 26 9 Fig 6 43 Removing the rubber bush relay arm VOLVO 10207...

Page 261: ...ims 6 Guide spring 8 Stop pla1e VOLVO 103149 8 6 4 Fig 6 48 Removing the pitman arm shaft 5 Pitman a rm shaft 10 Nu1 guide 11 Ball nut VOLVO 103 150 5 Pull out the steering cam with bearing and screw...

Page 262: ...steering cam bearing is pulled out with an a ngle screwdriver Measure the diameters for the bush in the housing and cover as weil as the pitman arm shaft For new parts the clearance is 025 063 mm 001...

Page 263: ...e for this purpose that is the same type as used for the wheel bearings Fig 6 55 Fitting the oil seal 2719 VOLVO 103229 Fig 6 56 Ball nut l Press the lower ball bearing race 2 Fig 6 30 in position in...

Page 264: ...6 28 VOLVO 103 159 thickness of 127 mm 005 and the shims are available in thicknesses of 05 127 and 254 mm 002 005 and 010 Tighten the three bolts to a torque of 1 7 2 1 kgm 1 2 15 Ib ft N B Check to...

Page 265: ...Clamping bolt 10 Drain plug 5 Return line 1l Attach ing bolt 6 Delivery line early prod VOLVO 103 162 Jack up the front end Screw out the drain plug lO Fig 6 62 Turn the steering wheel to the left to...

Page 266: ...he indicated maximum pressure of the pump that is at least 67 kg cm2 953 Ib sq in If pressure less tha n this is obta ined examine the pump and drive as fo llows a Check the tension and condition of t...

Page 267: ...lower steering column section to the one side Fig 6 65 Removing the sealing ring VOLVO 103 165 Fig 6 66 Filling the sealing ring 2 Mark up the location of the flange 3 on the controi spindie Slacken t...

Page 268: ...he tension ing bolt 1 and the attaching bolt 2 Pro teet the nipples and conneetions from dirt 4 Unscrew and remove the pump FITTING 1 Place the pump in position and conneet the oil lines with new seai...

Page 269: ...Part 7 SPRINGS SHOCK ABSORBERS WHEELSJ...

Page 270: ...Repair Instructions Checking shock absorbers Replacing front shock absorbers Replacing rear shock absorbers Replacing support arm bushes Replacing track bar bushes Replacing support stay bushes Group...

Page 271: ...724 Drift for fitting outer ring outer front wheel bearing and removing outer ring inner wheel bearing SVO 2725 Drift for removing outer ring outer front wheel bearing SVO 2726 Puller for front wheel...

Page 272: ...which limit the downward movements of the wishbones The upper ends of the rear springs 5 Fig 7 5 are bolted to the rear side members 8 and at the lower ends to the support arms 15 behind the rear axle...

Page 273: ...of the upper shock absorber attach ment Place the shock absorber in position and tighten its attachment 4 Point the wheels straight forwards with the lower wishbone unioaded and damp firmly the brake...

Page 274: ...Screw iower spring atlachment 4 Hollow rubber spring 14 Wash r 5 Rear spring 15 Support arm 6 Bracket 16 Shock absorber 7 Track bar 17 Lower shock absorber attachment 8 Rear side member 18 Front supp...

Page 275: ...tom to the support arms The rear axle is attached to the body thro ugh two flexibly mounted support arms 1 S Fig 7 S Forces acting long itudinal y are taken up by two support stays 2 and the latera l...

Page 276: ...into the cylinder 2 on the underside of the piston REPAI R INSTRU CTI ONS CHECKING THE SHOCK ABSORBERS Accurate checking of the shock absorbers can only be carried out with special checking devices A...

Page 277: ...remove the ja ck 2 Disconnect the shock a bsorber at the lower attachment Re move the lowe r screw of the spring and then lower the jack until the spring releases from the support arm Move the spring...

Page 278: ...ess out the small bushes with SYO 2730 using SYO 2733 as a counterhold Fig 7 13 Pressing in the bushes can be done with the same tools only in this case SYO 2730 is reversed Fig 7 14 Fig 7 11 Removing...

Page 279: ...ctly on the bush and with tool SYO 2733 as a counterhold see Fig 7 15 Before pressing in the rubber bush coat it with oil so that it slides easily in position and is not damaged When fitting the bushe...

Page 280: ...the hub must be replaced 3 Insert a new oversize wheel stud and press it in by hand as far as possible 4 Place the accessory part the pin in the press tool 5 Place the sleeve on the outer end of the w...

Page 281: ...ng with the help of a pressure greaser If there is not one available pack the bearings by hand with as much thick grease as there is room for between the roller retainer and inner ring of the bearing...

Page 282: ...that the wheel rotates easily without any play 11 Fill the grease cap half full of grease and fit it with tool SYO 2715 12 Fit the front wheel brake unit according to Part 5 13 Lift on the wheel afte...

Page 283: ...Part 8 BODY...

Page 284: ...o o Removing door frames o o o o o o o o o o o o o o o o o o o o o o o o o Removing winding windows o o o o o o o o o o o o o o o o o o o o o o Removing ventilation windows o o o o o o o o o o o o o...

Page 285: ...ring luggage compartment lid SVO 2891 Rule for measuring height of side member SVO 2848 Arm for measuring height of side member SVO 2893 Holder for fixing measuring rule SVO 2847 Holder for securing f...

Page 286: ...le The floor plates are welded together at the rear seat support The tunnel which accomodates the propeller shaft is spot welded to the f loor plates The rear floor plate has a longitudinal reinforcin...

Page 287: ...mediate pillar rear pilktr inner and outer cantrails roof former windscreen pillar rear wheel arch with wheel arch member rear mudguard back plate and joining plate The inner cantrail is manufactured...

Page 288: ...rch plates and the front cross member When removing first take of the plastic cover over the headlights and also the headlights see Part 3 and any extra lights if fitted Then remove the grille the hor...

Page 289: ...ition by means of a lifting arm from the toothed segment with the assistance of a helper arm The luggage compartment lid is built up of an outer and inner plate bonded together with adhesive The catch...

Page 290: ...and hinges are fitted in the reverse order Concerning fitting the door stop see under Remov ing and fitting door stops Since the holes in the hinges and in the attachment between the door hand hinges...

Page 291: ...er handle pressed in when the door latch should slide correctly into the latch plate The latch plate should have an inward inclination of 1 5 for the front doors and 2 50 for the rear do rs see Fig 8...

Page 292: ...e lock The two screws for Fig 8 12 Front door lock 1 Outer handle 2 Pull rod for inner lock knob 3 Lever 4 Lever 5 Lever 6 Pull rod for ouler handle 7 Locking device 8 Inner door opener 8 8 3 r 4 I H...

Page 293: ...e rail and remove the braeket 4 Remove the sealing strip which runs round the door frame Fig 8 13 Rear door lock l Oufer hand le 2 Pull rod for oufer handle 3 Lever 4 Lever 5 Pull rod for lock knob 6...

Page 294: ...ve the attaching screws between the front guide ro il and brocket between the door and brocket Remove the braeket 4 Remove the locking springs and washers for the lifting arm Begin by removing the spr...

Page 295: ...scribed above The lid is then removed Fig 8 17 Lock for luggage compartment lid 1 Lock calch filled in lid 2 Lock mecha nism filled in rea r seclion 3 Lock knob filled in rear sec1ion VOLVO 10 1845 fr...

Page 296: ...ldings The waist mouldings are attached with plastic clips The mouldings are removed with the help of a wooden puttY knife with which they are carefully levered off The clips can be removed by careful...

Page 297: ...ing the trim moulding for rear window Moisten a 4 0 mm 5 32 1 leather cord in soap solu tion or paraffin and place it in the groove of the rubber strip for the trim moulding Place one half of the trim...

Page 298: ...ng before being placed aga inst the tape Once the w indshield has been placed in position then adjusting possibilities are very small The w indshield must not lie aga inst any clip 9 Fit the fixture S...

Page 299: ...mes be necessary to adjust the position of the rear window with the palm of the hand If the Fig 8 24 Fitting the rear window VOLVO 2 822 cord is difficult to pul l out this may damage the strip in wh...

Page 300: ...s case the seat has a wooden frame Door upholstery The door upholstery consists of wood fibre sheeting lined with non woven padding and covered with up holstery material It is secured to the door by m...

Page 301: ...em and resulting in a lesser flow of coolant This means that the temperature of air flowing through the unit wil be lower and the sensitive body will be again effected The result wiU be an increased f...

Page 302: ...s to damage the roof plate 5 Fit the stretchers in the new headlining Make sure that they are provided with rubber caps at the ends as shown in Fig 8 31 6 Fit the headlining by first inserting the str...

Page 303: ...to the braekets and loosen the draining hose Lift out the heater unit and controi valve carefu lly Fig 8 32 Heater unit dismantled l Heat controi valve 2 Heater casing 3 Cell system 4 Fan casing 5 Fa...

Page 304: ...he dashboard Fit the controi wires to the shutters and controi valve Fit the defroster hoses and replace the mat on the trans mission tunnel Fasten the panel in position below the 8 20 dashboard Fit t...

Page 305: ...e front side members and the rear ones fitted directly in the body Removing and fiHing The front bumber is removed by unscrewing the bolts inside the bumper The support bars are removed at the front f...

Page 306: ......

Page 307: ...2 0 Illustration 8 A Controi for body flor A Max deviation from theoretical position for hole g roup 1 5 mm 0 06 B 227 1 mm 8 9 O 04 L 200 mm 7 9 plane of steering box C Max deviation between these f...

Page 308: ......

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Summary of Contents for 164, 1970

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Volvo 164, 1970, Service Manual

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Summary of Contents for 164, 1970

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