Volvo 164 1969 Service Manual Download

Page: 1 / 266

Summary of Contents for 164 1969

Page 2: ...he index marks on the first page of each section The various parts are divided up as follows Tools Description Repair Instructions The specifications are to be found in Part O General The instructions given in this book generally as sume that special tools are used and are based on experience gained from method studies The same results may be obtained with other working me thods but we are convinc...

Page 3: ......

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

Page 5: ...j ...

Page 6: ...pe designation and chassis number stamped on the front right hand door pillar GROUP 03 DIMENSIONS AND WEIGHT Length Width Height Wheelbase Ground c1earance Track front rear Turning circle Curb weight approx 4715 mm 186 1735 mm 68 3 1440 mm 56 7 2700 mm 106 3 180 mm 7 0 1350 mm 53 2 1350 mm 53 2 9600 mm 31 6 ft 1360 mm 2992 Ib 4 Engine type designation part number and manu facturing serial number 5...

Page 7: ...apacify SERVO STEERING Lubricant type Oil capacity approx ENGINE GENERAl Type desiglnation Output h p at r p m SAE DIN Max torque kgrm lbJt at r p m SAE DIN 0 2 Engine oil Service MS Multigrade Oil SAE10 W 30 SAE 10W SAE 20 20 W SAE 30 5 2 litres 9 15 Imp pints 10 97 US pints 6 0 litres 1 0 56 Imp pints 12 66 US pints Oil for Automatic Transmissions Type A Gear oil SAE 90 SAE 80 Engine oil SAE 30 ...

Page 8: ...n each piston Height Piston ring clearance in g roove GUDGEON PINS Floating fit Circlips at both ends in piston Fit In connecting rod In piston Diameter standard oversizes 05 10 20 CYLINDER HEAD Height measured from c ylinder contact face to face for bclt heads Cylinder heod gasket CRANKSHAFT Crankshaft end float Main bearings radial clearance Bigi end bearings radial clearance 11 13 kg cm2 156 18...

Page 9: ...m 2 4876 2 4882 62 933 62 946 mm 2 4777 2 4782 62 679 62 692 mm 2 4677 2 4682 62 425 62 438 mm 2 4577 2 4581 62 171 62 184 mm 2 4477 2 4482 38 930 38 970 mm 1 5327 1 5342 39 031 39 072 mm 1 5366 1 5383 39 133 39 173 mm 1 5407 1 5422 39 235 39 275 mm 1 5447 1 5463 39 336 39 376 mm 1 5487 1 5502 39 438 39 478 mm 1 5528 1 5542 1 985 l 991 mm 0782 0784 2 112 2 118 mm 0832 0834 2 239 2 245 mm 0882 0884...

Page 10: ...ng of 66 0 3 5 kg 145 7 7 Ib LUBRICATING SYSTEM Oil capacity including oil filter excluding oil filter Oil pressure at 2000 r p m with warm engine and new oil filter Lubricant viscosity all year round or viscosity above 30 C 8r F between 10 C and 30 C 14 and 87 F below _ 10 C 14 F l When cold s1ar1ing difficul1ies are 10 be expec1ed below _200 _4 0 F mul1igrade oil SAE 5 W 20 can be used Oll FilTE...

Page 11: ... head Main bearing s Big end bearings Flywheel Spark plugs Camshaft nut Bolt for crankshaft belt pulley Nipple for oil fi lter Sump bolts WEAR TOLERANCES CYLINDERS To be rebored when wear amounts to if engine has abnormal Gear 9 20 10 mm 0008 0040 08 014 mm 0032 0055 15 35 mm 0060 0140 39 0 mm 1 54 26 25 mm 1 03 21 0 mm 83 Pierburg PV 3025 min 15 kg cm2 2 1 Ib sq in max 25 kg cm2 3 5 Ib sq in Hori...

Page 12: ...sequence for cylinder head bolts tighte ned in 2 stages 1st stage 2 5 3 6 kgm 1 8 22 Ib ft 2nd stage 8 5 9 5 kgm 6 IbJ t 5 9 13 ELECTRICAL SYSTEM BATTERY Type Grounded System voltage Battery capacity Specific gravity of electrolyte Fully charged battery When recharg ing is necessary Recommended chargiing current ALTERNATOR Type Wattage Max continuous current Max spe ed Direction of rotation Ratio ...

Page 13: ... Clockwise Approx 1 h p 4 05 3 mm 002 012 1 150 1 300 kgl 2 53 2 86 Ib 1 2 4 4 mm 047 173 2 5 4 0 kgcm 2 1 7 3 81 Ib in 1 3 1 8 kg cm 1 13 1 56 Ib in 35 45 mm 014 018 33 mm 1 3 14 mm 6 12 0 Vand 40 50 A 6900 8100 r p m Loaded starter motor 9 Vand 185 200 A Locked starter motor 6 Vand 300 350 A CONTROL SOLENOlD 1050 1350 r p m Cut in voltag e Max 8 V IGNITION SYSTEM Firing order Ignition timingl at...

Page 14: ...rent 5 A ELECTRICALLY HEATED REAR WINDOW Output at first position of switch Output at second position of switch 12 1 distr graduation 425 525 r p m distr 625 725 r p m distr 1150 1000 r p m distr 1850 r p m distr 5 1 distr graduation 6 10 cm Hg 9 5 14 cm Hg 14 5 16 cm Hg 3 So distr graduation 16 25 cm Hg 2 31 cm Hg 28 32 5 cm Hg Watts 45 40 5 4 cp 32 CP 5 4 cp 25 32 cp 15 32 cp 5 10 2 18 3 1 2 1 2...

Page 15: ...gls Lubricant viscosity Oil capacity TIGHTENING TORQUES Flange Caps Crown wheel O 10 3 14 l 1 97 l 1 34 l l l 3 54 l 11 0 14 0 kgm 80 101 Ib ft Gear oil SAE90 SAE 80 Engine oil SAE 30 or SAE20W 40 approx 6 litre 1 1 Imp pints 1 3 US pints 0 797 l Approx 1 5 kg cm2 21 Ib sq in 36 39 kg cmf 510 55O Ib sq in 11 0 14 0 kgm 80 101 IbJt Eng ine oil SAE or SAE 20 W 40 Service ML or higher approx 1 4 litr...

Page 16: ...m 004 2 10 mm 394 174 cm 27 0 sq in 4 36 12 mm 1 422 Disc brakes with AS B device 294 6 mm 1l 6 9 6 mm 378 min 9 1 mm 358 max 15 mm 006 2 10 mm 394 93 cm2 1 4 4 sq in 2 36 12 mm 1 422 23 81 mm 94 Max 23 92 mm 95 Min 23 66 mm 93 3 16 Make Ate Operating pressure 50 2 kg cm2 711 28 4 Ib sq in SERVO CYLINDER Make Ate Designation Bromsgerät T 51 TJGHTEN ING TORQUES Attaching bolts front brake caliper A...

Page 17: ...l type Oil changing quantity TIGHTENING TORQUES Attaching bolt for upper wishbone shaft Nut for upper wishbone shaft Nut for steering wheel Nut for pitman arm Lock nut for tie rod Mechanical steering gear Screw for steerin9 box screw cover Screw for stop plate o 12 oto 1 O to 0 50 7 50 Oto 4 mm O to 0 16 15 mm 006 50 mm 020 1 0 mm 039 3 0 mm 11 8 6 0 mm 236 423 mm 1 6 6 4 8 Burman Cam and bal l nu...

Page 18: ...shock a bsorbe rs compressed unloaded rear shock absorbers compressed WHEELS WHEEL RIMS unloaded Type Designation Radial throw Warp Imbalance com pl ete wheel Tightening torque for wheel nuts TYRES Type Size He lical spring 15 5 mm 611 125 7 mm 4 951 65 6 61 9 65 9 kg 136 145 Ib max 127 mm 5 01 195 mm 7 61 Helical spring 12 0 mm 471 127 0 mm 4 91 82 3 15 7 16 7 kg 34 5 36 7 Ib max 114 mm 4 51 201 ...

Page 19: ...Part 1 SERVICING AND MAINTENANCE ...

Page 20: ... l Gearbox without overdrive l l Gearbox with overdrive l 2 Automatic transmi ssion l 2 Final drive l 3 Steering box mechanical steering l 3 Servo steerin g l 3 Checking the brake fluid leve l l 4 Instructions for lubricating l 4 Distributor l 4 Body l 4 Lubricating chart ...

Page 21: ...p As is shown above an engine oil with grade For Service MS is used for subsequen t topping up Concerning viscosity multigirade oil SAE 10 W 3D is primarily recommended At very low temperatures Fig l l Drain plug on sump VOLVO 103239 VOLVO 103240 Fig 1 2 Checking the oil level in centre spindle be low 20 0 C _40 F or when co l d startin9 difficul ties are anticipated multigrade oil SAE 5 W 20 is r...

Page 22: ... the ear has been driven and while the oil is still warm To do this remove the plugs marked l and 2 in Fig 1 3 as weil as the cover for the oil strainer see Fig 1 4 Also clean the oil strainer as indicated in group 43 B Fil l with new oil after the drain plugs have been 1 4 Also clean the o il strainer as indicated in G roup the oi l an opportun ity of flowing over into the ove r drive The oil sho...

Page 23: ...er the section Gearbox without overdrive applies also when flushing the final drive After the drain plug or cover has been refitted fill with new oi The oil should reach up to the filler hole and the oil capacity is about 1 6 litres 2 82 Imp pints 3 38 US pints For chang ing the oil in the final drive hypoid oil SAE 90 is normal y used Where the air temperature is continuously below _ 100 C 140 F ...

Page 24: ...ements accord ing to SAE 70 R3 Clean the master cylinder cap before removal and observe the g reatest clean liness when filling Avoid spilling brake fluid on the paintwork since th is wi ll damage ii Check to make sure that the venting hole in the cap is not blocked INSTRUCTIONS FOR LU BRICATI NG DISTRIBUTOR After every la 000 km 6000 miles the distributor shaft cam and ignition advance mechanism ...

Page 25: ...1 l3 O il Petrol eum jelly O il Petroleum jeIly No Lubricating point 8 Luglg age compartment lid hinges 9 Luglgag e compartment lid lock Keyholes la Door stops 11 Door hinges 12 W indow winders Locks Accessible after the door uphols tery panels have been removed 13 Front seat slide rails and catches OLVC 102965 Lubricant Oil Oil Oil la Petroleum jelly O il O il and grease Si icon g rease Petroleum...

Page 26: ... clutch fluid con tainer is almost full 3 That the coolant leve is between the Max marks on the expansion tank 4 That the fluid container for the windscreen washer is filled About every other week the following checks should be carried out 1 The tyre pressure 2 The e lectrolyte level in the battery NOTES Note 1 In connection with such workshop ope ra tions involving uncovering the wheel bear ings ...

Page 27: ... Note l Steeri ng gear Note 2 Brake fluid container Note 3 Distributor Note 4 Gearbox Note 5 Wheel bearings _____ Note l i I O Lubricafe after evety E O ö E c O Q V 00 Wheel bearings Note l Carburettors Note 6 Oil filter Note 7 Engine Ndlte 8 Final drive Note 9 Wheel bearings Note l ...

Page 28: ......

Page 29: ...Part 2 ENG IN E ...

Page 30: ...pins 2 13 Connecting rods 2 14 Crankshaft 2 14 Replacing crankshaft rear o il seal 2 15 Replacing oil seal timing gear casing 2 16 Replacing the timing g ears 2 17 Positive crankease ventilation 2 18 Group 22 Lubricating System Description 2 19 Repa ir Instructio ns 2 20 Group 23 Fuel System Description 2 23 Repair Instructions 2 29 Periodical checking 2 29 Adjusting the carburettors 2 30 Remedyin...

Page 31: ...ool for removing and fitting valve tappets SYO 2435 Dowel pin 2 for fitting cylinder head SYO 2814 Pu er for polygon hub SVO 2815 Press tool for fitting crankshaft drive and polygon hub SYO 2816 Drift for fitting crankshaft oil sealon engine front end SYO 2817 Drift for fitting crankshaft oil sealon engine rear end SYO 2818 Drift for removing valve guide SYO 2819 Drift for fitting valve guide SYO ...

Page 32: ...ols 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 Support for lifting arm SYO 2811 for lifting engine with cylinder head removed SYO 2821 Support for lifting tool SYO 2727 for lifting end of engine VOLVO 103 358 Fig 2 3 Engine stand 2 2 SYO 2520 Stand Used to...

Page 33: ...rankcase venti lation The Fig 2 4 Engine B 30 A viewed from left Hk Bhp N_E v v t t 11 100 1 f Cf 1 90 14 1 1 BO l1 k bo r r _ I _ 60 r _ 20 145 j l 19 137 50 I 18 1 30 f 1000 4000 6000rpm VOLVO 103273 Fig 2 6 Output and torque curves B 30 A VOLVO 103385 fan is of the slip coupling type The seven bearing crankshaft has a flywheeL damper mounted on its front end The output figures for the engine ar...

Page 34: ...move the throttle controi shaft from the pedal shaft link rods and bracket Remove the choke wire from the carburettor and the vacuum hose for the brake servo from the manifoid Dis connect the water hoses for the heater element from the engine 10 Fit lifting arm SYO 2811 to the front end of the eng ine as shown in Figt 2 9 and lifting arm SYO 2812 on the engine rear end as shown in Fig 2 10 Jack up...

Page 35: ... Connect the vacuum hose Fit the throttle controi shaft the choke wire as weil as the air cleaner casing Connect the hoses to the air intake and preheating plate respectively 10 Wire the electric cables to the starter motor and connect the fuel hose Fig 2 12 lifting tool SYO 2727 VOLVO 103 131 11 Fit the ignition coil the distributor cap and the ignition leads as weil as the electric cable 12 Fit ...

Page 36: ... the bolts Tighten securely the drain plug 2 6 2 Place the reinforcing bracket in position and tighten al the bolts manual y Then tighten securely first the bolts for the f1ywheel casing and then those for the cylinder block 3 Raise the front axle member and tighten securely the front bolts Remove the auxiliary bolts fit and tighten the rear bolts 4 Fit the nuts for the engin e mountings 5 Lower t...

Page 37: ...f a steel backin91 with indium plate lead bronze bearing meta 80th front and rear crankshaft oil seals are rubber liptype seals with metal fra me CAMSHAFT AND VALVE TAPPETS The camshaft 61 is made of special alloy east iron and has case harde ned cams It is driven from the crankshaft througrh a gear train which has a ratio of 1 2 The camshaft is carried in four bearing s all of which have the same...

Page 38: ...n the rocker arm casing and crankcase through the hose 5 Fresh air is supplied to the rocker arm casing thro ugh the air c1eaner via the hose 3 Plates in the rocker arm casing see Figure ensure that the fresh air is given sufficient circulation in order to mix with the crankcase gas es As the fresh air supply passes through the carburettor air c1eaner impurities are prevented from g etting into th...

Page 39: ... sump rear sealing Hange oil pump and con necting rods with pistons Replace the caps cor rectly on the respective connectin g rods 6 Invert and turn the eng ine Remove the crankshaft Place the caps correctly in their respect ive posi tions CLEANINlG After dismantling wash the parts thorougrhly Parts made of steel or cast iron can be washed in a de greasing tank with a caustic soda solution Light a...

Page 40: ...ed in a Fig 2 18 O il ho le in cylinder head 2 10 VOLVO 103364 Fig 2 19 Rear end of engine 1 Dowel pin 6 Sealing ring 2 Care plu g 7 Crankshaft 3 Sea ling flange 8 Plu g 4 Circlip 9 Dowel pin 5 Pi lot bearing certain sequence see Fig 2 17 to avoid unnecessary stresses The bolts should be tightened in two stag es Check that the oil hole Fig 2 l8 for lubricatingt the rocker arms is open The pilol be...

Page 41: ...eakage Fill if necessary with coolant Adjust the valve dearance if required The cylinder head bolts need not be subsequently tiglhtened CYLlNOER HEAD AND VALVES Disma ntling l Remove the valve springs by first compressing them with valve pliers and removing the valve collets after which the pliers are released Place the valves in order in a volve rack Remove the valve guide seals 2 Measure the dea...

Page 42: ...pective of whether the engine is cold or warm The clearance is the same for both the inlet and exhaust volve When adjusting use two feeler gaug es one Go 50 mm 020 thick and the other No Go 55 mm 022 1 thick The clearance is adjusted so that the thinnest g au9le can be inserted easily whi le the thicker one must not enter When the piston in No l cylinder is at top dead centre the compression strok...

Page 43: ... position 2 Measure the ring gap with a feeler gauge The glap should be 40 55 mm 016 022 If neces sary the gop can be increased with the help of a special fil e 3 Check the piston rings in their re spective grooves rolling then in the groove Also measure the r i Fig 2 25 Fitting the piston 1 Fi1fing ring SYO 2823 clearance ot a few points See Specifications for measurements IN A WORN CYLINDER BORE...

Page 44: ...AFT After the crankshaft has been cleaned its journals must be measured with a micrometer Measuring 2 14 A Fig 2 27 Bearing journal VOLVO 2 29b2 sho uld be carried out at several points round the circumfe rence a nd olong the lo ng1itudino l axis of ea ch journal O ut of roundness on the ma in beoring journa l should not exceed 05 mm 002 1 and 07 mm 003 1 on the big end bea ring journals Taper sho...

Page 45: ...O 2817 Fig 2 28 Fitting oi l seal VOLVO 103367 Fig 2 29 Fitting seali ng fla nge Pilot bearing for clutch shaft VOLVO 103366 The pilot bearing circlip a nd protecting wmher are removed the pi lot bearing pulled out with tool SYO 4090 and checked after having been washed in white spirit If the bearing is worn it should be replaced with a new one Before fitting pack the bearing with heat resistant b...

Page 46: ...03368 Fig 2 32 Centre spindle position on SYO 2816 be fitted in its outer position position 1 With a wear mark on the polygon hub fit the seal in position 2 11 4 turns of centre bolt screwed out With two wear marks on the hub fit the sea ling in position 3 centre bolt screwed out fu ll y W ith three wear marks the polygon hub should be replaced with a new one 5 Fit the polygon hub with tool SYO 28...

Page 47: ...ged 4 Remove the camshaft nut and pull off the cam shaft glear with puller SYO 2250 see Fig 2 34 5 Pu ll off the crankshaft gear with puller SYO 2822 see Fig 2 35 Screw out the oil nozzle blow it c ean and refit it see Fig 2 38 The gears are lubricated from th is nozzle 6 Refit the crankshaft with tool SYO 2815 see Fig 2 36 SYO 2822 Fig 2 35 Removing the crankshaft gear VOLVO 103275 3 SYO 2815 Fig...

Page 48: ...to a torque of 13 15 kgm 94 108 Ib ft The measuring valu es for the tooth flank c1earance and the camshaft axle c1earance which is deter mined by the spacing ring behind the camshaft gear are given in the Specifications 2 18 8 Refit the timing giear casing with gasket The timing g ear casingl is located in position by means of the dowe l pin Corry out operations 5 7 from the previous section POSIT...

Page 49: ...d directly on the pump and conSlists of a spring Ioaded ball The ball has a cylindricall g uide with a stop at the end position and therefore operates flexibly Even at idling speed there is a certain amount of overflow so that the oil pressure is then relatively low the oi l fi lter and then throughoilways out to the various lubricating points All the o il supplied to the lubricating points theref...

Page 50: ... be replaced every 10 000 km 6 000 miles when the old filter is discarded l Remove the old filter with the help of chain tong es see Fig 2 43 2 Coat the rubber gasket l Fig 2 42 of the new filter with oil and make sure that the contact surface for the oil filter is free from dirt By smearing it with oil the gasket slides into better contact with the sealing surface Screw on the filter by hand unti...

Page 51: ...e driving shaft with gear is replaced as a sing le unit The new bushes should be realmed after pressing in with areamer provided with a pilot g uide The sealing rings at the ends of the delivery pipe are made of special rubber and are manufactured to very c ose tolerances see Fig _ 2 47 Use only genuine Volvo spare parts The delivery pipe must be c amped in its correct position first in the oil pu...

Page 52: ...ug s 2 22 LJ Fig 2 47 Delivery pipe sealing rings FITTING THEOll PUMP When No l cylinder is at top dead centre fit the oil pump drive and distl ibutor The small part at the groove is turned obliquely upwards backwards and the groove set ot an ang le of 35 to the longitudinal axis of the engine see Fig 2 46 A Make sure that the shaft goes down into its groove in the pump shaft N B When the timing g...

Page 53: ...6 Drilling for fuel air mixture from by pass valve 7 Throttle spindle cam for regulating secondary throttle 8 Floatchamber plug 9 Floatchamber 10 Fuel inlet The upper section consists of a suction chamber cover which forms a suction chamber together with a diaphragm fixedin the air valve The suction cham ber regulates the air vallve lift and thereby the loca tion of the need le in the jet By means...

Page 54: ...onditions FLOAT S YSTEM Fuel flows into the floatchamber via the float valve 4 Fig 2 52 The float 1 which is made up of twin expanded rubber floats is carried on a bridge on the lower side of the carburettor housing As the fuel level rises the float lifts and by means of the float arm 2 and ta9 closes the needle on its seating when the correct level has been attained The fuel goes through four hol...

Page 55: ...loses the inlet to the channel At the s am e time as the cam disc is operated the throttle flap opening is also influenced in such away that turning the cam disc opens the throttJe through the fast idle stop screw 4 Fig 2 50 and the lever before any of S 6 7 t 8 9 t _0I 10 Ilrut l ll 12 13 r T f1E IR __1 4 15 16 1l I jI f 17 1 _18 VOLVO 103347 Fig 2 54 Cold starting principle l By pass valve 2 Idl...

Page 56: ...plung er to the suction chamber which is sealed from the main body of the carburettor by the 2 26 Fig 2 56 Normal running VOLVO 103349 diaphragm The pressure difference between the un derside of the air valve where there is pressure in the carburettor inlet port and the upper side of the valve where there is vacuum causes the valve to lift from the bridg e This olso lifts the tapered me tering nee...

Page 57: ...ts of carbon monoxide and hydrocarbons in the exhalust gases to an acceptable leve This is achieved mainly by a modified induction system that enables a more exact and leaner mixture ratio between fuel and air to be used How the system works is illustrated in Fig 2 58 For a description of the mon ifo ld branch see page 2 7 The intake manifold is fitted with a secondary throttle 3 at each carburett...

Page 58: ... flap housing S a hose 6 for cold air ond heat resistant hose 7 for warm air as weil as oheater plate 8 which is secured to the exhaust pipe The thermostat 2 fitted in the flap housing is inserted in the air cleaner housing and regulates the flap 4 by meam of the flap controi 3 The warm air taken at the exhaust pipe and the cold air taken at the front of the ve hicle are regulated by the flap mixe...

Page 59: ...nufacture r and fine adjusted with a CO mete r at the factory In order not to disturb the setting of the carburettors it is absolute ly essentia i that the following repair in structions are accurately followed when any work is to be done on the carbureHors 4 n 3 J 2 1 1 6 7 8 9 11 VOLVO 103401 Fig 2 62 Upper sectio n d isma ntled 1 Spring 2 Suc1ion chamber cover 3 Sealing plug 4 Screw 5 Hyd rauli...

Page 60: ...earance of about 1 mm 004 between the lever and the flange of the prim ary throttle spindie See Fig 2 64 6 Setting the rapid idle pull out the choke controi 23 25 mm 15 16 so that the mark on the rapid idle cam comes opposite the centre line of the rapid idle screw See Fig 2 65 Then adjust the rapid idle screws so that the engine speed is 1150 1200 r p m 2 30 Fig 2 65 Fast idle FAULTY CARBURETTO R...

Page 61: ...rst check that the throttle controi is correctly adjusted or if the valve does not open then adjust as follows A Engine does not reduce 5peed at idle Turn the adjusting screw 8 Fig 2 68 to the left until the engine reduces idling speed Check the function by running the engine briefly up to about 2 000 r p m The engine should then return to idling speed When correct function is obtained turn the sc...

Page 62: ...ng 4 Fit the floatchamber with a new gpsket Before checking the float level remove the carburet tor invert it and take out the floatchamber The float is removed by carefully breaking the float spindle from the bridge The float is fitted with the flat side facing away from the carburettor housing At the correcf float level the top point on the float should lie 15 17 mm S B and the rear edge 9 13 mm...

Page 63: ...ne every 40 000 km 25 000 miles if the vehicle is driven in areas with moderate a ir pollution With driving in very dusty areas replacement may have to be done more ofte n No cleaning of any type should be carried out bet ween the replacements The insert on no condition must be moistened or oiled 1 2 3 4 5 6 7 8 9 10 11 17 fY if 1 j1 16 B 12 VOLVO 103375 Fig 2 73 Fuel pump dismantled 1 Upper pum p...

Page 64: ...age and the moving parts for wear Replace damaged or worn parts Assembling 1 Fit the inlet valve see Fig 2 74 and the stop arm TigMen the screw but only sufficiently so that the spring lies weil ag1 ainst the pump body 2 Fit the spring 8 and guide 9 Prise on the rubber seal 1 0 with the flange facing inwards towards the guide 3 Fit the diaphragm unit in the upper section of the pump Press downward...

Page 65: ... speed even if the engine speed is exeeeded See Fig 2 81 The five fan blades are mounted asymmetrieally to keep down the noise leve The fan coupling consists of the easing 11 Fig 2 76 in whieh the plastic fan blades 12 are secured with the bolt 2 The easing 11 has two halves which however cannot be separated for repairs the fan coupling then being replaced complete The hub 8 has a light fit on the...

Page 66: ...rotection against frost down to minus 35 C minus 32 F and should be chang ed every other year on wh ich occasion the engine radiator and expansion tank should be flushed with dean water COOLlNG SYSTEM INNER CIRCUIT BY PASS The cooling system consists of two circuits an inner and an outer one When the engine is warming up and in very cold weather when large quantities of 2 36 Fig 2 78 Coolant flow ...

Page 67: ... whieh opens when there is apartia l vaeuum in the system a nd admas a ir i nt the expansion tank REPAI R INSTRUCTIONS TOPPIN G UP WITH COOLANT Topping up with coolant consisting of 50 gr lyco and 50 water al year round is done in the ex pansion tank when the level has fallen to the Min mark N B Never top up with water only DRAINIING THE COOUNG SYST EM To drain the cooling system open a cock on th...

Page 68: ...e under Filling empty system with coolant Start the engine and check for leakag e 2 38 Fan speeds r p m 4000 V 3000 V 2000 10 00 1000 2000 3000 4000 5000 Ingoing speeds r p m water pump s Fig 2 81 Curve for fa n coupling slip REPLACING THE WATER PUMP VOLVO 103258 Remove the radiator according to the instructions given under Replacing the radiator and screw off the water pump Clean the sealing surf...

Page 69: ... Rocker arm casi ng 36 Ignifion coble fo ignition coil 37 Cylinder head 38 Distribufor 39 Oil d ipstick 40 Vacuum governor 41 Valve tappet 42 Retainer 43 Cylinder block 44 Gear wheel 45 Bush 46 Rubber lip seal 47 Flywheel 48 Sealing flange 49 Main bearing bolt 50 Delivery pipe 51 Cover plate 52 Oil pump 53 Sump 54 Cap 55 Connecfi ng rod 56 Splash plate 57 Main bearing 58 Bush 59 Gudg eon pin 60 Ci...

Page 70: ...Part 3 ELECTRICAL SYSTEM ...

Page 71: ...gnition System Description Ignition coil Distributor Repair Instructions Distributor Removing Disma ntling Inspecting DiSltributor plate Distributor shaft Distributor housing Assembling Replacing the contact breaker Testing the distributor in test bench Fittin g Ignition setting Group 35 Lighting Description Repair Instructions Headlights Rep lacing head light insert Repl acing bulb Checking and a...

Page 72: ...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 minals FITTING l Place the battery in position 2 Fit the securing bar and secure the battery 3 Tighten the cable terminals on to the terminal studs Coat the cable terminals and terminal studs with vaseline SERVIC...

Page 73: ...rotates and the generating wind ings stator are stationary see Fig 3 3 The rotor is of the claw pole type with the field wind ings fed over the slip rings The eonstruetion of the rotor has made it possible for the alternator to have a max speed of 15000 r p m The insulation diode 2 Fig 3 3 whieh is plaeed on the outside of the alternator has two funetio ns It Fig 3 3 Exploded view of alternator 1 ...

Page 74: ...esistance see wiring dia gram Fig 3 21 If the voltage rises in spite of this the armature is d rawn further down and the movable contact meets the lower contact so that the field wind ing is grounded at both ends and this results in a rapi d drop in the voltagle The procedure is repeated con tinuously and this maintains the voltage constant REPAI R INSTRUCTIONS SPECIAL INSTRUCTIONS FOR WO RK ON AL...

Page 75: ... be wrongJy installed when assembling Remove the four attach ing screws Fig 3 7 Removing the insulation diode 3 4 VOLVO 103006 Fig 3 8 Dismantling the alternator VOLVO 103009 Remove the rotor ond the drive end shie ld with the help of two screwdrivers which are inserted in the two recesses between the stator and the drive end shield see Fig 3 8 N B The screwdrivers may not be inserted deeper than ...

Page 76: ... V D C or A C lamps must NOT be used This applies to all the components in the alternator Fig 3 11 Checking the diodes VOLVC 103012 Fig 3 12 Checking the insulation diode VOLVO 103013 Check the diodes with the diode tester see Fig 3 11 If any of the redifier diodes is faulty the entire diade holder with three diodes must be replaced If the insulation diode is fau lty replace the holder complete wi...

Page 77: ...ed Replacing the rectifier diodes Mark the cables connecting the stator to the diodes Solder loose the cables Place the new diode holder exactly in the same po sition occupied by the old one Hold the outgoing cable of the diode with a pair of flat pliers This is to conduct heat from the soldering point in order not to damage the new diode 3 6 Solder on the diodes see Fig 3 15 N B The entire u or U...

Page 78: ...r oil or mineraloi The O ring should be replaeed eaeh time the alter nator is disassembled ASSEMBUNG THE ALTERNATOR Fit the stator and the diode holders in the slip ring end shield Do not forget the insulating washers for the positive diode holder Fit the nuts and washers on the neg ative diode holder serews Press the rotor intothe drive end shield Fit the three screws for the drive end shield sup...

Page 79: ...ical two contact regulator provided with a temperature compensating thermistor REPAI R INSTRUCTIONS Fig 3 20 Voltage regulator REMOVING VOLVO 103297 1 Remove the lead terminal from the battery nega tive pole stud 2 Disconnect the electric leads from the voltage reg ulator 3 Remove the voltage regulator from the wheel arch 3 8 FITTING 1 Mount and secure the voltage regulator on the wheel arch 2 Con...

Page 80: ... and tightened Load the alternator with about 10 amps Suitable load Switched on mainbeam lights With the engine running and the alternator de live ring about 10 amps measure with a suitable voltmeter the voltage be tween the plus pole of the battery and B on the alternator If at this test the voltage drop exceeds 0 3 volt there is a fault in the lead or contact and must be remedied immediately Aft...

Page 81: ...tor sho uld be replaced VOLVO 103039 Fig 3 23 Wiring diagra m for testing the voltage regulator A Alternator B Ba11ery 60 Ah C Vol10meter 0 20 volts D Amme1er 0 50 amps E Vol1age regulator F Wiring lomp 12 vol1s 2 wa11s 3 10 o 20 40 80 VOLVO 103040 Fig 3 24 Voltage temperature diagram for eold voltage regulator If the voltagle regulator is to have a more accurate test install it in the vehicle and...

Page 82: ...ting in one or several rectifier diodes Breakage in a diode reduces the charging current about 5 Amps Short circuiting in Q diode limits the alternator charging current to 7 8 Amps and causes a buzzing noise in the a lternator Partiai short circuiting in the rotor Break or short circuit ng in stator Faulty regulator Fa ulty reg ulator Fa ulty connections on regulator or alternator Short circuiting...

Page 83: ...EF2649 VOLVO lOJ 299 The starter motor Fig 3 27 is fitted on the flywheel housing on the left hand side of the engine It eon sists of a 4 pole series wound motor The pinion on the starter motor rotor shaft moves axially to engage with the flywheel ring gear The pinion is controlled by a solenoid An extra eontact is built into the solenoid for by pass eonneeting of the pre eoupling resistanee on th...

Page 84: ......

Page 85: ...he washers are as shown in Fig 3 34 When the bridge is removed the U _ brushes follow a lso but u brushes will remain in the field winding Fig 3 29 Starter motor installed 3 14 VOLVO 103300 6 Unscrew the nut which holds the field terminal connection to the controi solenoid 7 Unscrew the attaching screws for the controI solenoid Remove the solenoid 8 Remove the drive end shield and rotor from the s...

Page 86: ...302 Fig 3 33 Starter motor with bearing shield removed The commutator should be checked with a dial gtauge after turning A radial throw of 08 mm 003 can be considered permissible The insula tion between the laminations shou ld be milled down to 4 mm 016 below the surface of the laminations see Figs 3 38 and 3 39 This work i s carried out in a special ap paratus or if such is not available with a g...

Page 87: ...d 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 enga ges satisfactorily examine the starter switch a nd leads W hen the controi solenoid has been removed it sho uld be wiped clean Then press the armature in several times a nd test again by connecting it to a battery If the controi solenoid does not f...

Page 88: ...Drive 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 bush is fitted it should lie in light oil for at least 1 hour Fig 3 40 Testing the rotor Fig 3 41 Checking the stator REPLACING THE FIELD WINDING S 1 If the starter motor hos not been dismantled t...

Page 89: ... a thin layer of grease on the roto r shaft 5 01 1 V 13 Place the bushes in oil for l hour before fitt ing 6 Ft 2 V 3 Lu bricate the e ngaging lever joi nts a nd the iron co re of the solenoid with a th in laye r of g rea se 2 Fit the starte r pinion on the rotor shaft and the wear washe r a s weil as the circlip Secure the wear wGsAer in position 3 Fit the engaging arm on the pinion Fit the rotor...

Page 90: ...etting of the distributor in relation to engine speed is reg ulated by a centrifugd governor fitted under the breaker plate Adjustment in relotion to loading is controlled by a vocuum reglulator mount ed outside the distributor 4 Fig 3 47 Fig 3 47 Distributor 1 Primary connection wilh capacilor 2 Lubricalor 3 Al1aching boll 4 Vacuum regulalor VOLVO 103313 The vacuum regulator has two diaphragms an...

Page 91: ...regulafor 1 2 3 4 5 6 8 e Fig 3 48 Distributor 7 Disfribufor housi ng 13 Spring ring 19 Centrifugal governor spring 8 Cap clamp 14 Flange 20 Breaker cam 9 Rubber seal 15 lubricafor 21 Washer 10 Fibre washer 16 Primary connecfion 22 Circlip 11 Steel washer 17 Disfribufor shaf1 23 Breaker plafe 12 lock pin 18 Cenfrifugal weighf 24 Rod brush carbon ...

Page 92: ...e connection 3 Slacken the screw 3 Fig 3 47 and pull up the distributor DISMANTLING l Pull off the distributor arm Remove the circlip for the pull rod from the vacuum regulator Remove the vacuum regulator according to Fig 3 50 2 Mark up how the lock clamps for the cap are located and remove them Fig 3 50 Removing the vacuum regulator Disconnect the lead from the breaker contacts and remove the pri...

Page 93: ...ct plate must not be loose wom 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 camsha ft must not be scored or worn down so that the dwell ang le is altered 3 The holes in the centrifugal weights must not be oval or deformed in any other way 4 The centrifug al weig ht spring s must not be de form...

Page 94: ...ixed contac t may be bent Wash the contacts with trichloroethylene or chemically pure g asoline Run the distributor on a test bench and check according to the Specifications REPLACING THE CONTACT BREAKER The contact breaker can be replaced with the distri butor fitted but it should be done with the distributor dismantled 1 Remove the distributor rotor arm 2 Disconnect the electric lead at the prim...

Page 95: ...speed and adjust the protractor so that marki ng is obtained at 00 Connect the vacuum hose to the bake lite connec tion on the vacuum regulator the primary dia phragm Increase th e vacuum gradually and read off the values on the prescribed graduations The difference between the rising jfa lling vacuum must not exceed 1V2 o A certain adjustment of the max reading can be obtained by slackening the s...

Page 96: ...the engine does not draw in unwanted air 3 Connect the Stroboscope to No l cylinder spark plug and to the battery 4 Start the engine and run it at the r p m g iven in the Specifications Use a tachometer for this purpose Point the ignition setting lamp at the graduation on the flywheel damper Slacken the distributor 3 Fig 3 47 and turn it until the firing position agrees with that g iven in the Spe...

Page 97: ... lights stop lights back up lights and directiona l indicators see Fig 3 61 Fig 3 61 Rear light VOLVO 10332 t REPAI R INSTRUCTIONS HEADLlGHTS REPLACING HEADLlGHT INSERT 1 Remove the screw and take off the plastic cover over the space behind the headlig ht see Fig 3 63 2 Remove the connecting contact by pulling it straight backwards 3 Remove the outer rim by pressing it downwards forwards so that i...

Page 98: ...nd take off the plastic cover over the space behind the headlight see Figl 3 63 2 Remove the connector by pulling it straight out backwards 3 Remove the rubber cover and the spring holding the bulb pull out the bulb see Fig 3 66 4 Fit the new bulb Make sure that the bulb collor fits into the socket in the insert N B Do not touch the bulb globe with your fingers 6 Adjusting screw 7 Plastic cove r 8...

Page 99: ... Screws for inner rim 3 28 Fig 3 66 Removing the bulb VOLVO 103379 other way the insert sho uld be re placed The inside of the bulb must not be oxidized to a black or brown col our The lighting effect normally deteriorates to such an extent that the bulbs should be replaced after 100 200 hours of operation The voltage at the bulb with the headlights switched on and the eng ine running at charging ...

Page 100: ...rews Check th at the sealing is fitted correctly REAR LlGHTS REPLACING THE BULB l SIneken the two screws holding the gla ss and lift off the glass VOLVO 103327 Fig 3 69 Number plate light with bulb glass removed 2 Rep lace the damaged bulb N B Do not touch the globe of the new bulh with yo ur fingers 3 Refit the glass and the screws NUMBER PLATE LIGHT REPLACING THE BULB 1 Remove the screw holding ...

Page 101: ...oi solenoid on starter motor starting posi tion When ignition key is released in position 3 it returns automatically to position 2 3 30 HORN The horn is mounted on the support irons for the front bumper One of the horns has a low frequency and the other a high frequency The horns can be engaged via a controi reloy by the horn ring mounted inside the steering wheel WIN oSHIELD WIPERS The windshield...

Page 102: ... the Light is switched off completely in the second position the light is on when any of the front doors is opened and in the third position the lig ht is on continuously CONTROl RElAYS As standard the car is fitted with four controI relays Three of them are mounted on a holder situated on the left hand wheel arch see Fig 3 73 One of these relays is a controI re lay for the horn another is a contr...

Page 103: ...NG THE DIRECTIONAt INDICATOR LEVER SWITCH Remove the screws ho ding the p astic covers one screw for the upper cover three screws for the ower cover and remove the covers Remove the screws ho ding the switch f the vehic e is fitted with a n overdrive the bracket ho ding the switch for the overdrive must first be removed Rep ace the switch and secure the new one firm y Fit the p astic covers 3 32 F...

Page 104: ...inter mediate defroster nozzle and its hoses Remove the wiper motor Disconnect the controi cables for the heater Remove the fusebox and disconnect the ground cables Re move the choke controI Rel ase the attaching screws for the wiper frame and carefu lly pull out the frame Fig 3 76 Removing the switch nut DISMANTLING THE WIND SHIELD WIPER MOTO R VOLVO l o 1 29 Remove the nut on the outgoing shaft ...

Page 105: ...he glass at the short side opposite the switch Pull out the bulb The g lass is re fitted by hooking it securely at the side where the switch is situated and then pressing in the glass firmly 3 34 Fig 3 78 Luggage or engine compartment light REPLA CING LUGGAGE OR ENGINE COMPARTMENT LIGHT BULB Remove the plastic cover over the bu lb by un screwing the screw securing the cover Replace the bu lb Re fi...

Page 106: ...creen washers 46 Interior lamp 47 Switch for heater head 48 Switch fo r windscreen wipers and wosher 49 Instrument lighting rheostat 50 Light switch 51 Ignition switch 52 Door contact 53 Switch heat reor window 54 Heated reor window 55 Switch for handbrake controi 56 Fuel gauge tank unit 57 Reversing light 58 Brake stopl ight 59 Tail light 60 Number plate lighting 61 Overdr controi lam p 62 Switch...

Page 107: ...screen wipers 44 Hea ter 45 Wi ndscreen washers 46 Interior lam p 47 Switch for heater 48 Switch for windscreen wi pers a nd washer 48 Instrument light ing rheostat 50 Light switch 51 Ignition switch 52 Door contact 53 Switch heat rea r window 54 Heated rear window 55 Switch for handbrake controi 56 Fuel gauge tank unit 57 Reversi ng light 58 Brake stopplight 59 Tail light 60 Number plate lighting...

Page 108: ...Part 4 POWER TRANSMISSION REAR AX LE ...

Page 109: ...the orifice nozzle Checking and replacing check valve Cleaning th e filter Removing Dismantling Inspecting Assem bling Fitting Group 45 Propeller Shaft Description Repair Instructions Replacing the support bearing Removing Dismantling Inspecting Assemhling Fitting Group 46 Rear Axle Toois Description Repair Instructions Replacing bearing and oil seals for drive shaft Replacing pinion oil seal Remo...

Page 110: ...nsists mainly of a pressure plate diaphragm spring and a sheet metal casing The diaphragm spring has a double function that of a clutch lever when declutch ing and a pressure spring when engagling The clutch operation takes place by means of the clutch pedal and on left hand steered vehicles its movements are transferred to the clutch via a wire a lever and a release bearing On right hand stee red...

Page 111: ...onding play shou ld be 2 3 mm 08 12 and adjustment is made by altering the length of the thrust rod REPLACING THE CLUTCH WIRE l Unhook the return spring for the release lever Disconnect the wire from the lever 2 Unscrew the rear nut and remove the wire sleeve from the clutch casing 3 Disconned the wire from the clutch pedal Un screw the nut for the wire sleeve and remove the wire 4 Fit the new wir...

Page 112: ...amage to the friction surface Check the curvature of the pressure p ate with a 240 mm 9 45 long steel VOLVO 102087 Fig 4 7 Checking the curvature of the pressure plate Fig 4 8 FiHing the c1utch ruler which is placed diagonally over the friction surface of the pre ssure plate Then measure the di stance between the straight edg e of the ruler and the inner diameter of the pressure plate This me asur...

Page 113: ... Thrus1 sleeve 10 Lock nu1 3 Piston seal 7 Circlip 11 Thrust rod 4 Pis10n 8 S10p ring FiHing Fitting is in reverse order to removal Fill with brake fluid and vent the system MASTER CYLINDER Removing Disconnecl the pipe from the hose Re lease the hose from the container Unhook the return spring Slacken the bolts and lift off the master cylinder Dismantling Remove the rubber cover and the thrust rod...

Page 114: ... SYO 2826 Puller for front bearing on intermediate shaft SYO 2828 Puller for rear bearing on mainshaft M 4CO SYO 2829 Device for lifting and installing the mainshaft in gear box SYO 2830 Pu II er for reverse shaft SYO 2831 Press tool for fitting bearing on intermediate shaft and rear bearing on mainshaft SYO 2832 Puller for rear bearing on mainshaft M 410 Used together with SYO 2828 SYO 2833 Fixtu...

Page 115: ...l SEAL 1 Carry out where applicable operations 1 6 under the heading Removing 2 Release the nut for the flange Pull off the flange with puller SVO 2261 see Fig 4 14 3 Pull out the old seal with puller SVO 4030 Fit the new oil seal with the help of sleeve SVO 2412 Fig 4 13 Gearbox M 400 Fig 4 14 Removing the flange 4 6 VOLVO 22 720 4 Press on the flonge with tool SVO 1845 see Fig 4 15 Fit the other...

Page 116: ... 2261 see Fig 4 14 4 Remove the release bearing Release the bolts and remove the cover for the input shaft Then release the bolts for the clutch casing and remove the calSing 5 Turn the gearbox upside down Pull out the front bearing of the intermediate shaft with tool SYO Fig 4 18 Removing intermediate shaft front bearing Fig 4 19 Removing intermediate shaft rear bearing VOLVO 103 103 2826 see Fig...

Page 117: ...s for the M 400 unit see Fig 4 21 9 Pull out the input shaft and remove the syn chronizing ring Remove the thrust washer from the mainshaft rear end Fit lifting tool SYO 2829 on to the mainshaft Push the englagingr sleeve for l st and 2nd rearwords Lift up the mainshaft as shown in Fig 4 22 10 Pull out the reversing shaft with puller SYO 2830 see Fig 4 23 and remove the reverse gear 11 Pull out th...

Page 118: ...ball bearings especially for scoring or cracks in the bearing races or on the ba lls AS s EMBLING ASSEMBLlNG THE MAINSHAFT l Assemble ht 2nd and 3rd 4th synchronizers Fit the snap ringt s correctly see Fig 4 26 2 Place ring SYO 2852 in a press Place on 3rd 4th synchronizer synchronizing cone 3rd speed gear l i VOLVO n727 Fig 4 26 Assembling the synchronizing wheel and needle bearing Make sure that...

Page 119: ... below l l i_ Fig 4 29 Fitting the mainshaft rear bearing 4 10 VOLVO 103112 Fig 4 30 Fitting intermediate shaft bearing A Insert drift 3 Place the intermediote shaft in the bottom of the g earbox housing Fit the mainshaft in the housing Take off the lifting too l and place the thrust washer on to the mainshaft 4 Fit the rear ball bearing on to the mainshaft Fit press tool SYO 2831 over the bearing...

Page 120: ...against the eluteh easing Fit in shims for the intermediate shaft rear beoring so that they lie evenly with or up to 05 mm 002 under the rear end see A Fig 4 31 9 Fit on the larg e speedometer gear Fit the rear eover with a new gasket When fitting eompress the gasket and ensure that the intermediate shaft has the eorreet elearanee 20 25 mm 008 010 10 Press on the flange with tool SYO 1845 Fit the ...

Page 121: ...ller for flange SVO 2412 Sleeve drifl for fif1ing front and rear bearings on out put shaft and oil seal at flange SVO 2417 Drifl for fitting bush in output shafl SVO 2423 Puller for bush in output shaft SVO 2834 Pressure gauge for checking oil pressure SVO 2835 Centring mandrel for splines in planet carrier and uni direction clutch SVO 2836 Socket for removing and fitting plugs for fine filter oil...

Page 122: ...anet g ears are forced to rotate around the sunwheel As a resu lt of this the output shaft will rotate at a higher speed than the mainshaft ELECTRICAL SYSTEM The overdrive is engaged by electro hydrau lic means On the gearbox cover there is a contact which cuts in when 4th speed is engaged Thus the overdrive can only be engaged when this speed is en9 aged It is switched on by means of a switch pla...

Page 123: ...zle 12 Channel from controi valve 13 Plug 14 O ring 5 Piston 6 Cyl inder 7 Ball 8 9 10 11 12 13 Fig 4 38 Function with direct drive l Nozzle 2 Channel controi valve relief valve 3 Relief valve 4 Pre fi Iter 5 Oil sump 6 Oil pump 7 Fine filter 8 Gearbox mainshaft 9 Eccentric 10 Channel relief valve mainshaff 11 Piston 12 Channel oil pump hydraulic cylinder controi and relief valves 13 Controi valve...

Page 124: ... to rise The pistons are thereby displa ced in the hydraulic cylinders the c1utch sl iding member is pulled forwards and contact mode with the brake ring With disengagement of the overdrive the connec tion between channels12 and 2 is c1osed Instead the connection between channel 2 and the sump is opened This permits oil under the large piston of the relief valve to flow out into the sump the press...

Page 125: ...ring 21 Output shaH 38 Magnet 6 Clutch member outer lining 22 Oil seal 39 Pre filter 7 Planet gear 23 Coupling flange 40 Fi ne fi Her 8 Needle bearing 24 Rear casing 41 Pump plunger 9 ShaH 25 Solenoid 42 Connecti ng rod 10 Planet carrier 26 Piston seal 43 Front casi ng 11 Oil thrower 27 Piston 44 Input shaft 12 Uni directional clutch 28 Operating valve gearbox mainshaft rollers 29 Orifice nozzle 4...

Page 126: ...ghtening torque shoul d be 4 2 5 5 kgm 30 40 Iq ft CHECKING AND REPLACING THE RELIEF VALVE l Remove the base plate and the pre filter Collect the oil in an oil container Warning If the vehicle has been driven recently the oil may be hot and cause damage if it comes into contact with your skin 2 Remove the plugl under the relief valve with tool SYO 2836 se Fig 4 43 PuU out the large piston SVO 2834...

Page 127: ...the non return body ball spring and plug Tighten the plugl to a torque of 2 2 kgm 16 Ib ft 4 18 Fig 4 46 Fine filter l Filler 2 Seal 3 Plug VOLVO 103 116 5 Re fit the pre filter a nd base plate toglether with a new g asket Do not forget the magnet on the bottom plate Fill with oi CLEANING THE FILTER l Remove the base plate and the pre filter Collect the oil in an oil container Warning If the vehic...

Page 128: ... respective fine filter re lief valve and pump check valve See olso under the heading Work which can be carried out with the over drive ins faned Fig 4 47 Dismantling the overdrive VOLVO 103117 3 Press down and pull out the pump cy linder Then take out the connecting rod and pump plunger DISMANTLING THE CLUTCH UNIT 1 Remove the circlip for the sunwheel Pull out the sunwheel backwards 2 Remove the ...

Page 129: ...worn W ith replacement change the sunwheel complete with bush o The bush must be concentric with the gear wheel a nd this is difficult to bring about outside a workshop Check the bra ke ring for abrasion cracks or we ar Check to make sure that the linings on the clutch sliding member are not burnt or worn ASSEM BUNG THE OVERDRIVE Use new gaskets O rings lock washer and seals whe n assembling Obser...

Page 130: ...ainer and bolt 8 Place the planet carrier complete with pl anet gear in position on the output shaft Guide up the splines into the planet carrier and uni directional clutch with drift SYO 2835 Fig 4 55 ASSEMBLlNG THE CLUTCH UNIT 1 Press the ball bearing into the retainer and fit the circlip Fig 4 53 FiHing the uni directional c1utch Fig 4 54 Fitting the oil thrower 1 Oil thrower plate 2 Circlip VO...

Page 131: ...l SYO 2836 The tightening torque is 2 2 kgm 16 Ib ft Fit the pre filter magnet g asket and base pla1 te 4 22 Fig 4 57 Fitting the front casing 4 Fit the operating pistons in their cy inders VOLVO 103119 5 Install the brake ring on the front casing Place the front casing on the rear one Fit wa hers and nuts see Fig 4 57 Note that both the copper washers should be fitted on the upper bolts Tigh ten ...

Page 132: ...The rear end of the front section of the propeller shaft is carried in a ball bearing The ball bearing is con tained in Q rubber bearing housing which is a ttached to the propell er shoft tunnel with a cover see Fig 4 59 The propeller shoft is fitted with three universal joints Em h joint consists of a spider with four ground frunnions carried in flange yokes by means of needle bearings 5 Intermed...

Page 133: ...port bearing and take down the propeller shaft complete VOLVO Fig 4 60 Removing the bolts 103227 r Fig 4 61 Removing the snap ring 4 24 DISMANTLING DISMANTLING THE PROPELLER SHAFT l Bend back the lock washer and unscrew the nut for the support bearing Remove the rear section of the propeller shaft Pull off the support bear Ing 2 Remove the support bearing from the housing DISMANTLING THE UNIVERSAL...

Page 134: ...hout binding at any point If it does not scrap the bearing and replace it with a new one Check needle bearings and spiders Worn or damaged parts should be replaced ASSEMBLINiG ASSEMBLlNG THE UNIVERSAL JOINTS l During possibly the fitting of the old needle bear ings check that they are filled with grease and that the rubber seals are not damaged New bear ings shou ld be half filled with grease Fig ...

Page 135: ... SYO 2595 Adjusting rings for differential SYO 2597 Brake for crown wheel used when checking tooth mesh SYO 2599 Drift for removing outer ring front pinion bearing SYO 2600 Measuring fixture for adjusting rings 4 26 SYO 2601 Holder for expander tool SYO 2394 fitted on tool SYO 2709 Puller for drive shaft SYO 2714 Fixture for rear axle used on garage jack fOT re moving and fitting rear axle see Fig...

Page 136: ...wn wheel are jour nalled in the final d rive housingl by means of two taper roller bearings The crown wheel is bolted to the differential carrier The differential gears them selves in the differentia l carrier consist of two bevel pinions on a trunnion and two side gea rs in whieh drive shafts are earried by means of internai splines The differential gears are journalled so that they can rotate an...

Page 137: ...ve the oil seal Fig 4 67 Removing the drive shaft Fig 4 68 Removing the drive shaft bearing 4 28 VOLVO 101781 VOLVO 103175 5 Fil the space between the seal lips on the new oil with grease Then place it on the drive shaft Fit the bearing and lock ring Turn the bearing correctly see Fig 4 70 N B Always use a new lock ring Place fitting ring SYO 2839 against the bearing and the I ock ringr Close the ...

Page 138: ...2261 see Fig 4 72 Pull out the old oil seal with puller SYO 4030 3 Fit the new oil seal with tool SYO 2806 When fitting the oil sea lubricate the seal lips with grease At the same time apply a layer of girease to the springi coi See Fig 4 73 This last men tioned measure is made to prevent the spring coil from jumping out during fitting 4 Press on the flange with the help of pre ss tool SYO 1845 se...

Page 139: ...support when the pinion is pointing downwards Remove the brake pipes 2 Release the bolts for the brake backing plates a nd brake shoe retainers They are slackened throug1h the ho les in the drive shaft flanges Pull out the drive shafts with puller SYO 2709 see Figl 4 67 3 Remove the inspection cover 4 If the fina l drive is being reconditioned because of noise the mesh pattern should be checked be...

Page 140: ...ng gear bolts and remove the crown wheel 2 Drive out the lock pin see Fig 4 81 and then the shaft for the differential gears Take out the differential geers and the thrust washers 3 PuJl off the differential carrier bearings with puller SVO 2483 see Fig 4 82 Take care of the shims INSPECTING First dean all the parts thoroughly Check the bear ing races and bea rings The races rollers or roller reta...

Page 141: ... In time this slit loses its locking effectiveness For this reason the nut should be replaced if it has been removed a couple of times The washer under the nut should also be replaced if it has become de formed Check the oil seals and replace them if they are damaged or worn Make sure that there are no cracks in the rear cas 4 32 23318 Fig 4 83 Fitting the differential gear inge Check that the bra...

Page 142: ... the location of the pinion use a dial indicator indicator retainer SYO 2284 and a measuring tool SYO 2393 which consists of two parts a pinion gauge and an adjusting jig Checking is as follows Place the pinion gouge on the ground surface of the pinion and the adjusting jig in the diffe re ntial bearing positions as shown in Fig 4 86 Place the indicator retainer on the drive pinion carrier and zer...

Page 143: ... 4 90 N B It is almost im possible to obtain a shim with exactly the correct thickness However they m ust not be 03 mm OO12 thicker than the measured value but up to 08 mm OO32 thinner Fig 4 89 Determining the shim thickness l Adjusting ring 2 Dial indicator 3 Bearing complete 4 34 Fig 4 90 Measuring the shim VOLVO 101797 4 Press the rear bearing on the pInlon with sleeve SVO 2842 see Fig 4 91 Fit...

Page 144: ... the d ifferential carrier The ring with the black oxidiz ed adjusting ring should be placed on the crowrn wheel side Also lubri cate the bearing location in the carrier Place the differential cOf rier and jihe edjustin g rings in the final drive housing see Fig 4 94 Use the dial indicator and adjust in the dngs so that the cor reet tooth flank clearanc e 1 20 mm 005 Fig 4 93 Fitting the pinion VO...

Page 145: ...Fit the nut with the flat side facing downwards Toe Reverse side Heel Fig 4 96 Correct tooth contact 4 36 VOLVO lO 9 VOLVO 24269 Fig 4 97 Faulty tooth contact Rotate the plate forwards and backwards several times Put on the dial indicator and retainer SYO 2284 lero set the indicator to the adjusting ring and then place the measuring point facing the bearing see Fig 4 89 Read off the indicator With...

Page 146: ...sket 3 Fit the drive shafts Tighten the bolts for the thrust washers to a torque of 5 kgm 36 Ib ft Gre lse the bearing 4 Then fit the brake discs and brake caliper Finally fit the brake pipes FITTING THE REAR AXLE 1 Place the rear axle on fixture SYO 2714 which is mounted on a garage jack see Fig 4 99 Move the rear axle in under the vehicle and fit on the bolts for the support arms and torque rods...

Page 147: ... 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 gearbox 25 Lever and release shaft 26 Release fork 27 Return spring 28 Washer 6 5 4 3 2 7 8 9 10 11 12 13 19 ______ 18 17 16 15 U 24 25 26 27 28 VOLVO 103222 Illustration 4 Ä Clutch a nd clutch controls ...

Page 148: ...sh 34 Gear lever lower scetion 35 Washer 36 Cover 37 Spring 38 Protective casing 39 Oil seal 40 Mainshaft 41 Speedometer drive 42 Rear cover 43 Speedometer pinion 44 Shift lever 45 Gear wheel 1st gear 46 Needle bearing 47 Reverse gear 48 Bush 49 Slide register SO Engaging sleeve and gear wheel for reverse gear 51 Circlip 52 Reverse gear shaft 53 Needle bearing 54 Gear wheel 55 Gearbox housing 56 S...

Page 149: ... Piston 55 Spring 56 Washer 57 O ring 58 Cylinder 59 O ring 60 Plug 61 Spring 62 Ball rn body 63 Non relu 64 O ring d 65 Pump bo y 66 Pump plunger 67 Washer 2 68 Fine filter 69 Seal 70 Plug 71 Data plate 72 Screw r and carrier 73 Planet gea 74 Sunwheel d member 75 Clufch sil mg 76 Pre filter 77 Gasket 78 Magnet 79 Base plate 80 Bol washer 81 Resd lent 84 Bush her 85 Thrust was 86 Oil thrower 87 Ci...

Page 150: ... side gear 8 Lock pin 9 Differential pinion 10 Crown wheel 11 Shaft 12 Thrust washer 13 Rear axle casing 14 Flange 15 Dust cover plate 16 Oil slinger 17 Oil seal 18 Shims 19 Front pinion bearing 20 Pinion 21 Rear pinion bearing 22 Shims 4 5 6 7 8 22 21 20 19 18 Illustration 4 0 Final drive 9 10 11 17 16 12 15 14 13 I l LVO TD2 ...

Page 151: ...Part 5 BRAKES ...

Page 152: ... cylinder o Warning valve o Brake V llve o Brake lines o Venting the hydraulic system o Adjusting the brake lig ht switch o Brake pedal o Group 54 Auxiliary Brake System 5 17 5 20 5 20 5 23 5 23 5 24 5 25 5 27 5 27 Description o 5 29 Repair Instructions o 5 31 Replacing the air cleaner and damper o 5 31 Replacing the check valve o 5 32 Replacing the servo cylinder o 5 32 Group SS Handbrake Descrip...

Page 153: ...A hose connection see 2 Fig 5 4 is required for removing the pistons in the rear brake calipers For venting the system aventing unit of the type shown in Fig 5 5 is used A connection cover see l Fig 5 4 is also required for connecting the unit to the brake fluid container 6 rii iii 4 Fig 5 2 Testing device SVO 2741 YS W 1 Nippl e plug 4 Hose 2 Connection nipple 5 Ye nting d evice 3 Enlorging nippl...

Page 154: ... and the left rear wheel With such an arrangement braking effect is ensured should one of the brake lines fail The servo brake cylinder 5 is directly influenced by the brake pedal and with vacuum assistance from the induction manifold of the engine less pedal pressure is required for brakingl The function of the brake valves 10 and 11 is to assist in providing a suitable distribution of braking po...

Page 155: ...should be avoided When the container of the master cylinder is being mled likewise with a ll work concern ing connections etc the gtreatest cleanliness should be observed in order to prevent dirt from gtetting into the system Only clean unused brake fluid should be filled Brake fluid which is expelled during for example venting may not be put back into the system After use over a long period it is...

Page 156: ... brake unit From the point of view of leakage the brake valve is not defective if the pressure rema lns unaitered for at least 15 seconds Incom ing pressure I 45 I 65 I 100 kg cm2 I b sq in 640 924 1422 Outgoing pressure I 45 I 52 57 I 62 69 kg cm2 I b sq in 640 739 810 882 981 10 Check the other brake valve in the same way by con necting it to right rear w hee l brake unit and the inner lower nip...

Page 157: ... circuit fades The rear wheel brakes fade A wheel brake fades Faulty set valve Blocked equalizing hole in master cylinder Handbrake cable chafes Faulty adjusted handbrake Faulty brake valve Damaged broke line Blocked hose Worn sealing ring Remedy Remove and blow dean the valve and replace the seal ring If insufficient replace check valve Remove master cylinde r and re place seal Replace servo cyli...

Page 158: ...hould be replaced when the linings are worn down to a thickness of about 3 mm 1 8 Under no circumstances must the linings be 5 6 worn down below 1 5 mm 1 16 For replacement of the pads see pages 5 10 and 5 11 FUNCTION CHECK In addition to the regulator check on the brakes carried out by the driver as result of the driving done the brakes shou ld be checked every 10000 km 6000 miles by a workshop m...

Page 159: ...pads 10 are pro vided with bonded facingJ s and are held in position by means of retaining pins 13 Fig 5 7 Brake components front wheel l Hub 3 Brake disc 2 Front brake caliper 4 Cover plate VOLVO 101 808 Fig 5 8 Front wheel brake cali per 1 Sealing ring 8 Bolt 2 Piston 9 Retaining clip 3 Rubber dust cover 10 Brake pad 4 Retaining ring 11 lower venting nipple 5 Channel 12 Damping spring 6 Outer ha...

Page 160: ...r The spring moves on the pin with a certain amount of friction The sea ling ring s l have a square section and press a gainst the piston from the slightly obliq ue groove in the housing The fun ction of the sealing rings is partly to prevent brake fluid from oozing out and partly to return the pistons to the rest position after braking The rubber dust covers 6 prevent dirt from entering The brake...

Page 161: ...Secondary circuit pressure above 50 kgicm2 711 Ib sq in Secondary circuit reduced pressure f _ Primary circuit pressure above 50 kg cm2 711 Ib sq in Primary circuit reduced pressure Fig 5 12 Brake application disc This means that in the rest position the brake linings are a lways at a certain distance from the brake disc regardless of wear so that the wheel brakes are se lf ad justing Should leaka...

Page 162: ... REPLACING THE BRAKE PADS The brake pads should be replaced when about 3 mm l 8 of the lining thickness remains On no account mlust the linings be worn down to below 1 5 mm 1 l6 Front wheel brake units l Remove the hub ca ps and slacken the wheel nuts slightly 2 Jack up the vehicle and place blocks under the rear axle and front jack attachments Unscrew the wheel nuts and lift off the wheels 3 Remo...

Page 163: ... Carefully clean the cavity occupied by the pads If any of the rubber covers is damaQ1ed replace it If dirt has penetrated into the cylinder due to a damog ed cover recondition the brake unit 5 Press the pistons into the caliper with tool SYO 2809 When pressing in check the function of the pistons in the A S B device see Fig 5 17 The pressing in force should be 20 80 kg cm 17 70 Ib in If the force...

Page 164: ...on 2 and the lower hose 4 from the bracket Place the protective casing on the brake lines to prevent unnecessary leakage Discon ned the connection 6 for the upper hose from the brake 4 Unscrew the attaching bolts 5 and 7 Fig 5 20 and remove the brake caliper see Fig 5 21 DISMANTLING l Remove the hairpin shaped retaining clips for the retaining pins Pull out one of the retaining pins while holding ...

Page 165: ...the hairpin shaped retoining clips Check that the pads are movable 6 Fit the venting nipples and also the brake lines FITTING 1 Place the caliper in position Check that the con tact surfaces of the retainer are clean and not damag ed as it is of vital importance that the caliper takes up the correct position in relation to the brake disc Fit the attaching bolts after they have been coated with a c...

Page 166: ...eping the damping springs in position Remove the springs a nd then the other retaining pin Pull out the pads see Fig 5 18 2 Remove the dust cover retaining rings and the dust covers Place the ca liper in a vice as shown in Fig 5 27 Fit tool SVD 2809 and press one of the pistons down to the boftom Fit a suitab le venting connection see Fig 5 4 in the ca liper Place a hose piece in the caliper and f...

Page 167: ...iper Make sure that the piston does not come at a slant and is scored or that it damag es 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 wrench see Fig 5 29 The force required to press in the piston should be between 20 80 kg cm 17 3 69 3 Ib in If the force required is otherwise the piston must be replaced 4 Fit and test the ot...

Page 168: ...ing the above mentioned inspeetion the brake disc should be replaced When S 16 Fig 5 32 Removing the bra ke disc VOLVO 101876 doing this the brake caliper should first be removed Then unscrew the lock bo lts and lift off the brake dise see Figs 5 32 and 5 85 Tap on the inside of the disc with several light blows from a plastic hammer or similar tool W hen fitting check that the contact surface is ...

Page 169: ... system is at rest Fig 5 34 the pistons are kept pressed back by the force of the springs When the pistons are in this position the connections bet ween the fluid brake container and wheel brake units are open At the moment braking takes place the primary piston to the right is pressed in by the piston rod This c10ses the connection between the container and the wheel brake unit and the pressure i...

Page 170: ... rear 11 Thrust washer wheel brakes 12 O ring 6 Connection master 13 Piston cylinder 14 Housing 7 End piece 5 18 8VOLVO 102454 Fig 5 39 Normal position VOLVO 102455 two brake circuits exceeds abolJt 10 kg cm 2 142 Ib sq in The valve construction is shown in Fig 5 38 and it operates as Tollows If there is no fau lt in the circuits and the brakes are applied the hydraulic pressure on the pistons is ...

Page 171: ...ylinder and front wheel cylinders the hydraulic force Fig 5 41 Drake valve construction 1 Plug 2 O ring 3 Cylinder 4 Valve 5 Valve spring 6 Cylinder 7 Connec1ion fo masfer cylinder 8 Pisfon gaskef 9 Brackef 10 Spring 11 Refainer 12 Adjusfing screw 13 Locknuf 14 Spring housing 15 Refa iner 16 Screw 17 Equalizing valve 18 O ring 19 Connection fo rear wheel brake cylinders 20 Ho sing 21 Pisfon 22 Val...

Page 172: ... brake fluid spill over 2 Remove the electric cables from the master cy linder and fit plastic plug s as the lines are dis connected Fig 5 45 Removing the container 5 20 VOLVO 103188 3 4 5 Fig 5 46 Container parts 1 Filler cap 4 Container 2 Strainer 5 Rubber sea l 3 Rubber seal VOLVO 103 189 3 Remove the two attaching nuts for the master cylinder and lift the cylinder forwards see Fig 5 44 Em pty ...

Page 173: ...less than 23 66 mm 931 Each time reconditioning is carried out replace the primary piston 3 Fig 5 48 and the secondary piston 4 Figl 5 48 complete as weil as the stop screw 2 with washer and circlip 5 also the sealing ring 6 1 More over the rubber seals Fig 5 46 for the container should be replaced Fig 5 49 Secondary piston l Pislon 4 Washer 2 Washer 5 Thrusl washer 3 Pislon seal 6 Spring ASSEMBLl...

Page 174: ...the con tainer with brake fluid and vent the cylinder Place plastic plugs in the cylinder Check to make sure that the venting hole in the cap 1 is open and fit the strainer 2 and cap in position FITTING 1 Place the sealing ring 6 Fig 5 49 on the master cylinder Fit the cylinder in position and then the Fig 5 52 Fitting the primary piston 5 22 VOLVO 103 193 VOLVO lOJ 194 Fig 5 53 Checking the equal...

Page 175: ...er secondary circuit 4 Secondary circuit front wheels 5 Secondary circuit rear wheels 6 Primary circuit rear wheels 4 5 6 7 8 Fig 5 57 Brake va lves fitted l Adjusling screw 2 Left brake valve secondary circuil 3 Screw assembling 4 Brake hose 10 left rear wheel 5 Brake hose to right rear wheel BRAKE VALVE REMOVING 6 Bracket 7 Aftaching screw 8 Right brake valve 9 From the master cylinder primary c...

Page 176: ...ve in position and check that there is no tension in the hose Fit the attaching screws and connect up the brake pipe Tighten the connec tions Vent the brake system ADJUSTING The adjusting screw 12 Fig 5 41 is not intended for adjusting in the normal meaning of the word Its function is to balance the variations in the manu facturing The carefully checked adjustment mode at the initial assembling is...

Page 177: ...correctly it should be adjusted manually before being fitted Bendingi a pipe already connected often results in deformation at the connections The front brake hoses must only be fitted according to Fig 5 19 and always with the linkage arms unioaded Do not forget the clips 4 Vent the brake system according to the instruc tions giiven below Fit the filler cap with venting hole on the container VENTI...

Page 178: ...event air from sneaking in via the threads of the nipple 7 Fig 5 64 Venting diagram 5 26 5 VOLVO 103 199 Fig 5 65 Venting the front wheel brake unit VOLVO 103 265 When venting remove the protective cap and fit the venting tool SYO 2740 See Figs 5 65 and 5 66 Let the other end of the hose hangi down into a collectin g vessel Open the venting nipple and have someone carefully depress the brake pedal...

Page 179: ...a turn Slowly depress the bra ke pedal to the floorboard W hen the pedal has reached the floorboard pause a little and then release the pedal quickly Repeat this procedure until brake fluid free from a ir bubbles flows o ut W hen the fluid is free from air depress the pedal to the floorboard and close the venting nippleol 6 Repeat the venting so that both the circuits a re vented at least twice Re...

Page 180: ... m 6 Press in the new bushes 3 and 9 and lubricate them with a light layer of ball bearing grease Fit the bearing sleeves 2 and 8 and the return spring lO 5 28 10 9 8 7 6 m _ 5 4 3 2 11 12 13 r 14 15 16 Il 4 17 Fig 5 69 Drake pedal suspension components 1 Bolt 10 Return spring 2 Bearing sleeve 11 Brake light switch 3 Bush 12 Bracket 4 Nut 13 Split pin bolt 5 Thrust rod 14 Link 6 Split pin bolt 15 ...

Page 181: ...hown in Fig 5 70 The servo cylinder functions as foII ows 17 Refainer 18 Filter 19 Silencer 20 Sealing ring 21 Cylinder 22 Refurn spring 23 End 24 Reacfion disc 25 Valve pisfon 26 Sfop washer 27 Washer 28 Guide housing 29 Valve guide 30 End 31 Valve plate VOLVO 103201 33 Valve spring 34 Refurn spring 35 Rubber cover 36 Washer 37 Rear fhrusf rod 32 A1faching screw When the system is at rest the par...

Page 182: ...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 remains canstant and is thus unable to overcome the hydrau lic counterpressure in the master cylinder The mov able parts of the servo cylinder therefore rem ain in th is position and constant braking is obtained as long as th...

Page 183: ...witch 4 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 prote ctive washer see Fig 5 75 from the cylinder 7 Remove the damper 1 Fig 5 76 and the air cleaner 2 Fig 5 75 Removing the washer FlTTING 1 Fit the cleaner and the silencer The slots on the cleaner and damper should be displaced 1800 from each other 2 Fit the ...

Page 184: ... from the brake pedal Remove the brocket with clutch pe dal stop from the cowl 3 Remove the 4 nuts securing the servo cylinder to the cowl 4 Pu ll the servo cylinder forwards and disconnect the fork from the link arm FITTING l Check that the rubber cover 35 Fig 5 70 is pressed down properly at the protective washer for the cleaner Secure the fork to the lin k arm Push in the servo cylinder so that...

Page 185: ... of suspension the brake 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 When the handbrake is applied the lever and rod press the shoes against the brake drum When the wheels or drive shaft attempt to turn the drum the shoes accompony the rotation becaus...

Page 186: ...ke off the wheels Release the handbrake 3 Check that the brake pads are not stuck to the bråke disc To prevent the lever when adjusting from influencing the shoes and thus give misled ing results the spring tension acting on the lever should be reduced This can be done by fitting holder SYO 2742 Fig 5 82 or by disconnecting the cable from the lever 4 Set the drum so that its hole coincides with th...

Page 187: ...rn spring is held in position according to Fig 5 82 Bend up the lock and remove the lock pin so that the cable releases from the lever 6 Remove the return spring with washers Loosen the nut for the rear attachment of the cable sleeve Lift the cable forwards after having loosened both sides of the attachmen ts INSTALLlNG 1 Adjust the brake shoes of the rear wheels Check that the brake pads do not s...

Page 188: ... coat of ball bear ing grese Do not forget to lock the pull rod and make sure that the rubber covers seal weil 5 36 Fig 5 84 Removing the brake drum REAR WHEEL BRAKE UNIT HANDBRAKE COMPONENT DISMANTLING VOLVO 101922 1 Apply the handbrake remove the hub caps of the rear wheels and loosen the wheel nuts 2 Jack up the rear end place blocks under the rear axle remove the nuts and take off the wheels R...

Page 189: ...urn spring 5 Fit the brake drum with attaching bolts 6 Place the brake caliper in position Fit the attach ing bolts 1 and 3 Fig 5 25 after smearing the bolts with a couple of drops of Locktite type AV 7 Check that the brake pads move freely from the brake disc and adjust the handbrake see opera tion 4 6 under Adjusting the handbrake 8 Vent the fitted brake caliper see Group 52 9 Fit the wheel see ...

Page 190: ...Part 6 FRONT END AND STEERING GEAR ...

Page 191: ...n 6 16 Mechanical steering 6 16 Servo steering 6 18 Repair Instructions 6 23 Replacing the steering wheel 6 23 Replacing bearing in steering column jacket 6 23 Replacing bush for relay arm 6 24 Mechanical steering gear 6 24 Steering box 6 24 Servo steering 6 29 Work which can be carried out with servo steering in vehicle 6 29 Checking the oil level 6 29 Dmining the oil 6 29 Filling with oil and ve...

Page 192: ...nt upper wishbone SVO 2705 Drift fo r removing and fitting rubber bushing in lower wishbone SVO 2711 Steering wheel puller SVO 2713 Spanner 5 8 for upper wishbone shaft bolt wheel adjustment SVO 2715 Drift for removing and fitting grease eap in hub SVO 2722 Puller inner ring inner front wheel bearing SVO 2723 Drift for fitting ouler ring inner front wheel bearing and oil seal in hub SVO 2724 SVO 2...

Page 193: ...t SYO 2719 Sleeve for fitting oil t e pitman arm shaft SYO 2720 Removal tool for pitm arm shaft bush SYO 2721 Reamer for pitman arm shaft bush SYO 2850 Pilot for reamer SYO 2721 2860 Q 2865 2866 Fig 6 4 Tools for work on the servo steering SYO 2860 Tool for removing oil seal SYO 2863 Tool for fitting oil seal SYO 2864 Testing instrument SYO 2865 Connection nipple for SYO 2864 SYO 2866 Connection n...

Page 194: ...Faulty camber causes uneven tyre wear Fig 6 5 Caster OLVO 23 01 VERTleAL LINE VOLVO 23 02 Fig 6 6 Camber and king pin inclination B King pin inclinalion C Camber KING PIN INCLlNATION King pin inclination means the inclination of the king pin inwards Since this car does not have a king pin the inclination is represented by an angle made be tween a verticle line and a line thiough the centre of the ...

Page 195: ... with the whee l l pointing straight forwards Caster and kin pin inclination cannot be mea sured directly Instead the angu lar a lteration which occurs when the wheel is turned from 20 outwards to 20 inwards is measured on the instrume nt Most types of modern wheel a lignment measuring in struments require that the wheels are locked with for example the help of a pedal jack When meosuring the whee...

Page 196: ...nd side to have a eamber whieh is a l 4 g reater than that for the right hand side e g 0 and l 4 resp This will eliminate the in f1uenee of the road surfaee inclination whieh would pull the vehicle in a eertain direction Also the loea tion of the driver in the vehicle Ieft hand steered right hand steered has a eertain influenee due to the Fig 6 8 Adjusting the easter a nd eamber A Shims VOLVO 10 1...

Page 197: ...A 4 0 3 5 3 0 2 5 2 0 0 5 0 4 0 3 0 2 O 6 6 l II ID O v v 7 I V Fig 6 9 Diagram for alteration of easter and eamber I Camber II Casler A Shims mm B Alteralion of angle I V 3 v ...

Page 198: ...iving Adjusting is done as follows Turn the left wheel for a left hand turn as far as it g oes Check that the lock angle of the wheels Fig 6 11 Adjusting screw max wheel lock is 45 If it is not then adjust to this value with the stop bolt A Fig 6 ot the pitman arm 2 Repeat this procedure with the right wheel ond the stop screw on the relay arm N B Check that the break hoses are c1ear at fu ll whee...

Page 199: ...tabilizer anchorage 3 Steeri ng knuckle 12 Stabilizer 4 Stub a xle 13 Stop bolt max wheel lock 5 Outer wheel bearing 14 Lower wishbone bush 6 Inner wheel bearing 15 Frame attachment for stabiliter 7 Lower wishbone ball joint 16 Front a xle member 8 Lower w ishbo ne 17 Stop bolt max wheel lock 9 Spri ng 6 8 VOLVO 103128 ...

Page 200: ...ubber bushes whieh are jour nalled in the wishbones Camber and easter are adjust ed by means of shims between the upper wishbone shoft and its a ttachment in the front axle me mber see Fig 6 8 The front whee ls are earried in taper roll er bearings 5 and 6 Fig 6 12 The front spring assembly consists of eoil springs 9 inside whieh te leseopie shoek absorbers 10 are fitted In order to inerease its a...

Page 201: ...ering arms with tool SYO 2294 according to Fig 6 19 4 Remove the st Jbilizer attaching bolts Fig 6 15 Tool for lifting engine 6 10 VOLVO 103131 Fig 6 16 Removing the grease cap VOLVO ln1 9AA 5 Loosen the brake hoses from the bracket at the support member 6 Remove the lower nuts for the front eng ine mount ing s 7 Remove the front oxle member attaching bolts lower and remove the front end DISMANTLI...

Page 202: ...tub axle FITTING l Place the inner bearing in position in the hub and press in the oil seal with tool SYO 2723 and standard handle tool SYO 1801 See Fig 6 20 2 Place the stub axle in posiNon and tighten the ball joint nuts If the ball joint twists hold it firmly in position with a screw vice see Fig 6 24 Fit the steering rod on to the steering arm 3 Place the hub on the axle fit the outer bearing ...

Page 203: ... slot A Fig 6 22 and check thot the grease forces its way out If necessary top up with multi purpose grease 2 Press the bo joint into the wishbone with press tool SYO 2699 sleeve 2701 and drift 2704 see Fig 6 23 Make sure that the slot in the bo joint coin cides with the long itudinal shaft of the wishbone either externa y or interna y Fig 6 22 as the pin has maximum movement in the direction of t...

Page 204: ... SYO 2699 and sleeve SYO 2700 see Fig 6 25 Fig 6 24 Upper ball joint securely held by vice Fig 6 25 Removing the ball joint lower wishbone FITTING VOLVO 101 98 1 l Check that the rubber seal is fi lled with grease by breaking the pin to the side so that grease is for ced out If this does not hoppen then fill the seal with grease Before fitting remove any grease that has squeezed out on to the ball...

Page 205: ... lower wishbone 6 14 VOLVO 103134 Fig 6 28 Fitting the rubber bush lower wishbone 2713 Tighten the nuts for the wishbone shaft to a torque of 5 5 6 2 kgm 40 45 Ib ft 2 Fit the upper baH joint in the steeringl knuckle and tighten the nut 3 Fit the wheel and wheel nuts Lower the vehicle and tighten the wheel nuts to a torque of 10 14 kgm 70 100 IbJt Fit the hub cap LOWER WI SHB ONE REMOVING l Remove...

Page 206: ... 7 Place the wishbone in position and fit the wish bone shaft 6 Hold the wishbone roughly vertical and tighten the nut 8 to a torque of 13 15 kgm 95 110 Ib ft 2 Fit the spring Raise the jack and fit the steering knuckle Tighten the nuts for the ball joints If the pins rotate hold them securely with a vice see Fig 6 24 3 Fit the shock absorber according to the instruc tions given in Part 7 4 Fit th...

Page 207: ...ering 6 16 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 colu mn to break away and thus prevent the steering wheel from being forced backwards up wards Also contributing to this effect is a splined joint with clamping sleeve on the upper section of the steering column which...

Page 208: ...secured in a withdrawn position At position I the vehicle can be moved with the ig nition switched off At position II the ignition is connected up and in position III the starter motor can be engaged The ignition switch and steering wheel lock can only be replaced as a sing le unit Fig 6 30 Steering box mechanical l Lower bo II bea ri ng steeri ng ca m 2 Bearing race 3 Guide pin 4 Shims and gasket...

Page 209: ...h segment of the pit man arm shaft 20 The axial movem ent of the piston which determines the direction the wheels turn is obtained via steering ca m S and ball n ut The redrculating baH s 4 are I oca fled in annul ar grooves and form the thread for the nut Movement of the steering cam cornes from the steering column at the contro i spind le 16 and the torsion rod ll se cured in the spindie The st ...

Page 210: ...fo llowing description of the function applies to both FUNCTION The loca tion 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 more clearly how the valves are connected to the part of the housing where the servo piston operates a cross section has been made through the steering valves in addition to the long itudinal se...

Page 211: ...he 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 controi valve 10 is dis placed to the left and closes the intake port 11 The delivery line of tbe controi valve 9 is linked with the annular groove 19 in the valve housing This also applies to the return g ...

Page 212: ...il 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 sel1Vo pump Fig 6 36 is of the vane type It is mounted on a bracket on the left hand side of the engine and is pulley driven by the engine at engine r peed The pump rotor is provided with 10 loose vanes and r...

Page 213: ...r than that in the line and a lse te the right ef the pi sten When the spring pres Sure i S overceme j he pisten is therefore di Sp ace d te f1he right And when the speed is suffi ciently high in relatien te the counterpreswre the pi ston has heen di S P laced se muchthat the surpl us oi l can Hew back to the inlet side ef the pump see Fig 6 37 Since the pump sheuld de iver a q ua ntity sma ler th...

Page 214: ...i t the horn ring so th at the holes come o pposite the nttaching screws Fit the screws 2 a nd 3 Fig 6 39 Check the function of the horn ring 4 Fit both parts of the directional indicator switch housing and the ir attaching screws REPlACING STEERING COlUMN JACKET BEARINrG To replace the upper bearing 11 Fig 6 41 first remove the steering wheel spring 13 and seat 12 If the other bea rings are to be...

Page 215: ...6 44 6 Place the relay arm in position fit the washer 7 and the nut Tigihten 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 102073 SYO SYO 2699 Fig 6 44 Fitting the rubber bush relay arm VOLVO 102074 7 Fit the steering red i n the inner hole on the relay arm and the tie rod Tighten the Nyloc nuts to a torque of 3 5 4 1 kg m 25 30 Ib f...

Page 216: ... Shims 6 Guide spring 8 Stop plate VOLVO 103149 8 6 4 Fig 6 48 Removing the pitman arm shaft 5 Pitman arm shaft 10 Nut guide 11 Ba ll nut VOLVO 103 150 S Pull out the steering cam with bearing and screw off the ball nut at the same time see Fig 6 S0 6 Collect t he 10 balls for the lower ball bearing 7 Remove the upper bearing from the steering cam Collect the 13 balls 8 Remove the balls from the b...

Page 217: ... lowe r steering cam bearing is pulled out with an ang le 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 02 63 mm 0010 0024 If the clearance exceeds 18 mm OO7 replace the bush according to the following Use tool SYO 2720 see Fig 6 51 for pre ssing the bush out of the housing The early prod type housing has afla...

Page 218: ...for this purpose that is the same type as used for the wheel bearings Fig 6 55 Fifling the oil seal J VOLVO 103 229 Fig 6 56 Ball nut l Press the lower ball beoring race 2 Fig 6 30 in position in the housing Fit the 10 balls 7 14 mm Use grease to hold the balls in position 2 Pack the 27 balls 7 93 mm into the hall nut 21 with the help of grease Fig 6 56 Scre w the steering cam 19 into the ball nut...

Page 219: ...xial play 6 28 VOLVO 103159 thickness of 127 mm 005 and the shims are avail abl e in thicknesses of 05 127 and 254 mm 002 005 and 01 O Tighten the three bo lts to a torq ue of 1 7 2 1 kgm 12 15 Ib ft N B Check to make sure that there is axial play on the pit man arm shaft If there is not the ba l ls may be damaged when tig hte ni ng 9 Measure the axia l play Fig 6 59 afte r the bo lts have been ti...

Page 220: ...d out of the container and pump Stop the engine and turn the steering wheel from the stop lock to stop lock until all the oil has run out YS Fig 6 61 Oil level Fig 6 62 Steering box fitted 1 Nut 2 Bolt 3 Fla nge 4 Cla mping bolt 5 Return line 6 Delivery line ea rly prod 7 Venting screw 8 Adjusting screw 9 Steering box 10 Drain plug 11 Attoching bolt FllLlNG WITH Oll AND VENTING NOTE The oil capaci...

Page 221: ...dicated maximum pressure of the pump that is at least 67 kg cm2 953 Ib sq in If pressure less than this is obtained examine the pump and drive as fo llows a Check the tension and condition of the drive bell Replace the be lt if defective b Remove the pump controi valve see Fig 6 64 Observe the utmost cleanli ness Wash and blow clean before screwing o ut the plug 4 6 67 wh ich should be done from u...

Page 222: ... nd lower steering column section to the one side Fig 6 05 Removing the sealing ring VOLVO 1031 65 Fig 6 06 Filling the sealing ring 2 Mark up the location of the flange 3 on the controi spindie Slocken the c1amping bolt 4 and pu ll off the flange 3 Remove the rubber cover as weil as the circl ip for the sealing ring 4 Carefully apply tool SYO 2860 to the sealing ring Tighten the screw Fig 6 65 Th...

Page 223: ...he tensioning bo lt l and the attaching bo lt 2 Pro tect the nipp les and connections from dirt 4 Unscrew and remove the pump FITTING l Place the pump in position and connect th e oil lines with new seals 2 Fit the attaching bolts and other components see Fig 6 67 Tension the drive belt so that it can be pressed in about 5 mm 3 16 in the middle Tighten the bolts and the connections 3 Fil with oil ...

Page 224: ...Part 7 SPRINGS SHOCK ABSORBERS WHEELS ...

Page 225: ... 5 General 7 5 Shock absorbers 7 5 Repair Instructions 7 6 Checking shock absorbers 7 6 Replacing front shock absorbers 7 6 Replacing rear shock absorbers 7 7 Replacing support arm bush s 7 7 Replacing track bar bushes 7 8 Replacing support stay bushes 7 8 Group 71 Wheels Repair Instructions 7 9 Changing wheels 7 9 Replacing wheel studs 7 9 Replacing and adjusting front wheel bearings 7 9 ...

Page 226: ...heel bearing and sea SYO 2724 Drift for fitting outer ring outer front wheel bear ing and removing outer ring inner wheel bearing SYO 2725 Drift for removing outer ring outer front wheel bearing SYO 2726 Puller for front wheel hub SYO 2730 Drift for removing and fitting bush track bar small bush in torque rod and support arm SYO 2733 SYO 2731 Drift for removing and fitting large bush torque rod SY...

Page 227: ...g The fro nt axle memher is fitted with rubber buffers 4 wh ich limit the downward mo vements 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 Any impacts from spring depression is absorbed by the rubber buffers 4 mounted in the rear side members 7 2 Fig 7 2 Front spring a nd shock ...

Page 228: ...ttachment and rubber bush l and 7 Fig 7 7 Place the shock absorber in position and tighten its attachment 4 Point the wheels straight forwards with the lower wishbone unioaded and clamp firmly the brake hoses to the screw of the stabilizer 5 Fit the wheels and wheel nuts Lower the vehicle Tighten the nuts REAR S IPRINGS REMOVING l Remove the hub cap and loosen the wheel nuts a couple of turns Jack...

Page 229: ...et 13 Screw lower spring altachment 4 Rubber buffer 14 Washer 5 Rear spring 15 Support arm 6 Brocket 16 Shock absorber 7 Track bar 17 Lower shock absorber attachment 8 Rear side member 18 Front support stay altachment 9 Upper shock absorber attachment 19 Front bush support arm 10 Washer 7 4 ...

Page 230: ...to the support arms The rear axle is arttached to the body th rough two flexibly mounted support arms 15 Fig 7 5 Forces acting long itudinally a re ta ke n up by two support stays 2 and the latera l forces are absorbed by a track bar 7 The support arms are fore mounted in rubber bushes 19 The support stays ond track bar are attached to the rear axle frame through the rubber bushes SHOCK ABSORBERS ...

Page 231: ...into the cyli nder 2 on the underside of the piston REPAIR INSTRUCTIONS CHECKING SHOCK ABSORBERS Accurate checking of the shock absorbers can only be carried out with special checking devices A rough check however can be made in order to see that the shock absorbers are functioning on the whole by noting the damping effect when rocking the ear up and down and then releasing it Testing can also be ...

Page 232: ...he jack 2 Disconnect the shock absorber at the lower attachm ent Remove the lower screw of the spring and then lower the jack until the spring releases from the support arm Move the spring backwards so that it runs free from the support arm Raise the jack until the rear axle is in a level position 3 Remove the screw on the support arm at the rear axel bracket 3 Fig 7 S Remove the front screw and t...

Page 233: ... con be done with the same too ls on ly in this case tool SVO 2730 is turned round Fig 7 12 5 Fit the bar with the screw to the fram e brocket 12 6 Place the other end on the rear axle brocket 6 and fit both washer and nut Screw on the frame brocket nut 7 Remove the blocks and lower the vehicle i d VOLVO 102085 Fig 7 10 Removing and fitting the front bush support arm 7 8 REPLACING BUSHES FOR SUPPO...

Page 234: ... 1 before such a bolt is fitted REPLACING AND ADJUSTING FRONT WHEEL BEAR INGS 1 Remove the hub cap and slocken the wheel nuts slightly 2 Jack up the front end place blocks under the lower wishbones Unscrew the wheel nuts and lift off the wheel 3 Remove the front wheel brake according to the instructions gliven in Part 5 under Removing the front wheel brake unit 4 Remove the greOlSe cap with tool S...

Page 235: ... is room for between the roller retainer and inner ring of the bearing Also apply grease to the outer sides of the bearings and on the outer rings pressed into the hubs The cavity in the hub is fi lled with grease a ll ro und up to the smallest diameter of the outer ring of the outer bearing se Fig 7 21 Use a high class bearing g rease for the bearings Place the in ner bearing in position in the h...

Page 236: ...en the wheel and hub and then tighten up the nuts suffi ciently so that the wheel can not be displaced on the hub Lower the vehicle and tighten the wheel nuts firmly Tighten every other nut n little at a time until all of them are finally tightened to a torque of 10 14 kgm 70 100 ft lb Fit the hub cap VOLVO 23808 svo 1801 Fig 7 20 Fitting the sealing ring Fig 7 21 Lubrication of front wheel bearin...

Page 237: ...Part 8 BODY ...

Page 238: ...ing door locks Removing lock handles Fitting and adjusting lock handles Latch plates Removing d oor frames Removing ventilation windows Removing winding windows Removing window winders Luggage compartment lid Sealing strips Bumpers Trim mouldings Windshield and rear window Seats Replacing the headlining Instrument panel Controi drawings of body flooring 8 l 8 l 8 l 8 2 8 2 8 2 8 3 8 4 8 4 8 4 8 4 ...

Page 239: ...sists of the bulkhead wheel arches front upper cross member and lower cross member The bulkhead forms the front transverse wall of the body and has welded end pieces Two front side members project from the front floor section At the front they are joined together by means of a cross member and at the rear they are connected to the front cross member under the front seats The front axle member and ...

Page 240: ...oothed segment with the assistance of a helper arm 8 2 The luggage compartment lid is built up of an outer und inner plate bonded together with adhesive The catch for the locking device is fitted on the r e ar edge of the lugglage compartment lid The hinges are fitted on the front edge of the lid The hinges are bolted to the body The luggage compartment lid is counter balanced by means of a gas sp...

Page 241: ... by means of clips The armrests are made of moulded plastic and are screwed to the inner plate of the door HEADLlNING The head lining consists of plastic fabric stretched on roof ribs and secured in retainerSl fitted on the upper limit of the body sides COVERING FOR BULKHEAD AND FLOOR The sides of the bulkhead are lined with millboard The bulkhead is cove red with se lf adhes ive insulating materi...

Page 242: ...ank and any othe r components which are mounted on the front Fig 8 4 Bonnet lock 8 4 plate Also re move the battery and the hose for th e air c1eaner Disconnec1 the wire for the bonnet lock the bolts between the front plate and mudguard wheel arch and front cross member BONNET AND BONNET LOCK The bonnet is attached in each hinge by means of bolts The bonnet is removed by unscrewing the bolts betwe...

Page 243: ...move the door stop in accordance with the In structions under Removing and fittings door stops Unscrew the bolts between the hinge s and door The bolts are accessible when the door is opened The door can then be taken off Fig 8 6 In order to remove the hing es the panel in front of the door has to be taken off When this has been done the three bol s are unscrewed after which the hinges can be remo...

Page 244: ...e lock cy linder by unscrewingl its attach Fig 8 7 Rear door 8 6 Fig 8 8 Removing winding handle ing Sicrew wh ich is fitted in the rea r edge of the door 3 Remove the locking for the pull rod locking knob a nd take out the pul 1rod 4 Remove the locki ng for the inne r door opener push rod 5 Remove the lock ing for the outer handle pull rod 6 Unscrew the fiwo screws for the re ar winde r rail on t...

Page 245: ... of which is placed inside the door and thet rear one on the edge of the door Fig 8 9 Front door lock l Oufer handle 2 Pull rod for inner lock knob 3 Lever 4 Lever 5 Lever 6 Pull rod for oufer handle 7 Locking device 8 Inner door opener FITTING AND ADJUSTING FRONT DOOR LOCK HANDLE When fiMing the inner door opener this is adjusted as follows Fit the inner door opene r without tightening the screws...

Page 246: ... is fitted with a floating nut plate The latch plate is adjus able since the holes in the body are larger than the diameter of the attaching screws The vertical position of the latch plate is controlled by closing the door with the press button of the outer 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 0 f...

Page 247: ...placed at the upper edge of the door as shown in Fig 8 6 3 Remove the locking springs and washers between the sl ide rail and lifting arms These springs can be removed by press ing them right in and then releasing them after which they can be taken off N B Take care that the window does not fall down into the door Even if the window is placed carelessly at the bottom of the door the slide roil can...

Page 248: ...fter which SYO 2739 Fig 8 14 Tools for gas spring 8 10 Fig 8 1S Lock for luggage compartment lid 1 Lock catch fiffed in lid 2 Lock mechanism fitfed in rear secfion 3 Lock knob fifted in rear section VOLVO 101845 the gas spring can be removed When fitt ing a new gas spring press tool SYO 2744 is used as shown in Fig 8 14 in order to enable damp SYO 2739 to be fitted Fittingl is done in the reverse ...

Page 249: ...oved from the bumper by unscrewin g the boltlS inside the bumper Fitting is done in the reverse order TRIM MOULDINGS WAIST MOULDINGS The waist mouldings are ottaehed with pl astic clips The mouldings O1 e carefully prised off with a wooden VOLVO 24814 Fig 8 17 Removing the trim moulding putty knife The clips can be removed by carefully pulling them off with pl iers W hen fitting begin by placing i...

Page 250: ...n fitting rubber strip A Plywood sheel 15 mm 9 32 B Foom plaslic 25 38 mm 1 1 C Slorag e comparlmenl D Hooks for sealing compound gu n WINDSHIELD AND REAR WINDOW WINDSHIELD Removing the windshield 1 Remove the windshield wiper arms Place protec tive padding over the bonnet front seats and backrests 2 Remove the trim mouldings as described in opera tions 1 3 under Windshield Moulding Removing 3 Rel...

Page 251: ...from inside This wi ll cause the rubber strip to creep over the sheet metal edge as shown in Fig 8 23 It may sometimes be necessary to adjust the position of the windscreen with the pa lm of the hand If the cord is difficult to pull out this may cause dam age to the strip in which case the windshield shou ld be stuck from inside or outs ide with the palm of the hand if the rubber strip does not cr...

Page 252: ... Fit the s retchers in the new headlin ing Make sure 8 14 Fig 8 27 Headlining VOLVO 101848 that they are provided with rubber caps at the ends as Slhown in Fig 8 27 6 Fit the headl ining by first inserting the stretchef s beginning with the front one 7 Stretch the headlin ing fo rwalrds and tuck in the pl astic strip at the front edge 8 Then SJflrefch the he adlining backwards by pulling both ends...

Page 253: ...rawing for body floor A Max deviation from theoretical position for hole group 1 5 mm 0 6 B 227 1 mm l0 9 0 04 L 200 mm 7 9 plane of steering box C Max deviation between these flanges and the Z direction l mm 0 04 600 2800 000 32 0 00 00 lo VOLVO 103344 ...

Page 254: ...Part 9 INSTRUMENTS ACCESSORIES AND OTHER EQUIPMENT ...

Page 255: ...late 9 3 Removing the fixing plate for speedometer and miileometer trip meter 9 4 Cheeking the speedometer eable 9 4 Removing and cheeking the temperature gauge 9 4 Removing and eheeking the fuel gauge 9 5 Cheeking the voltage stabilizer 9 5 Part 94 Heating Systern Deseription 9 6 Repair Instructions 9 7 Removing the unit heater 9 7 DismanHing the unit heater 9 9 Replaeing the fan motor 9 9 Assemh...

Page 256: ...gs 9 3 a nd 9 4 SPEEDOMETER The speedometer is of he eddy current type In the speedometer iS a pe rm anent magnet whlich is me chan ically connect ed with aspeedometer cable driven from a worm gear on he g earbox Surro unding the magnet is a drum coil sp ring and roHe r mounted on a separate shaft Rotation of the magnet generates VOLVO 103 284 Fig 9 3 Mounting plate with instruments and warning la...

Page 257: ...up resistor is in circuit The himefal insflrument us ed here is of the same type as that in the temperature glauge VOLTAGE STABILlZER The emperature and fuel g auges are powe red by a voltag e of opprox 5 1 volts and are fed through a 9 2 voltage Sltabilizer This stabilizer contains a bimetal spring and a contact breaker When thte ignition is switched on current flows through the stabilizer and ou...

Page 258: ...k below the daSlhboard and instrument panel the negative cabl e Slhould de disconnected from the battery to avoid Slhort circuits REM OVING THE COMBINED INSTRUMENT Remove the pand below the dashboaHl1by loose ning the two fixing screws one on the left hand s ide of the body and one beside the g love compartment Then pull the uppe r sedion of the panel re a rwards so that it loosens from the clips ...

Page 259: ...ust be rep laced if damaged Th e indicating instrument can be separated from the detached instrument panel when the vo ltage stabilizer has been removed and the nuts ho lding the instru me nt are accessibl e The ind icating instrument should be checked w ith an ohmmeter The resistance shou ld be approx 12 5 ohms M easureme nt is suitabl y carried out between the nuts on the reverse side of the ins...

Page 260: ...p the pickup should have a resistance of approx 10 ollms and al the lower approx 60 85 ohms Movement of the float arm should not result in a break in the circuit reading Checking of the indicoting instrument by connecting the pickup lead to earth is not permitted as this wil 1 domag e the instru ment excessive loading on the resistor wire and overheating of the bimetal spring If no measuring instr...

Page 261: ...with the cell system so that all coolant which passes thmug h the cell system al so passes through the controi valve The heated coolant wm ms up the air which is fed through the hea er unit by the heater 9 6 fan or the slipstreom If the coolant temperature in creases the sensitive body of the thermostat expa nds thus actin g on the vO lve in the control system and resulting in alesser flow of cool...

Page 262: ...fan motor Remove the two 9crews which hold the fusebox to the heater Remove the cont rol valve and loosen the upper hose to the heater unit Care must be taken with Fhe controi va l ve and the copper tube be fween the valve ond the heater Plug the outlets on the heater so that he remaining coolant does not run into the car on removal Loosen the earth ing cables from the rig ht hand bracket Loosen a...

Page 263: ......

Page 264: ...e the cell system with sensitive body and reassemble the casing halves Replace the spring clips and the rubber bush ings FITTING THE HEATER UNIT Place the heater unit in position and connect th e draining hose Fit th e four screws which hold the heater to the brackets Connect the earthing cables to the rig ht hand bracket Fit the controi valve and the upper hose to the heater Fit the fusebox to th...

Page 265: ......

Page 266: ...Printed in Sweden Gotab Kungälv 74 12597 TP 10473 1 Engelska 3000 10 68 Printed in Swede R 2000 2 74 ...

Search results

Summary of Contents for 164 1969

Reviews:

Related manuals for 164 1969

Brands by name

Popular brands

Volvo 164 1969, Service Manual

Search results

Summary of Contents for 164 1969

Reviews:

Related manuals for 164 1969

Brands by name

Popular brands