SERVICE

MA UAL

VOLVO 164 1971

 o General

1 Servicing and maintenance

VOLVO

2 Engine
FOREWORD

This Manual contai-ns servicing instructions for the

Volvo 164, 1971 model.
The book is divided up into 9 parts as indicated
by the register opposite. The pages and figure
illustrations ineach part are numbered in such a
3 Electtical system and instruments
way that ,t he first group shows the number of the
part concerned while th,e second group shows the
number of the page or figure illustration in ,that
particular part, for example, under the heading
"Electrical system and instruments"; 3-1, 3-2, etc.
A convenient way of finding the particular section
4 Power transmission, rear axle
you are looking for is to bend the right side of the
Manual back so that the arrows in the register
point to the index marks on the first page of each

5
section.

The various parts are divided up as follows: Brakes

Tools
Description
Repair Instructions

The speaifications are to be found in Part O,

General.
The instructions given in this book generally as-
sume that spe,cial 100ls are used and a,re based on
& Front end and steering gear
experience gained from method studies. The same
results may be Qbtai·ned with other working me-
thods, but we a:re convinced that by following the

7
instructions given in this MClnual you will always
achieve the best results in the shortest possible
time. Frame, suspension, wheels
AB VOLVO
Göteborg - Sweden

a
Reprinting permitted if sour·c e quoted.

Body
 Part O

GENERAL
 GROUP 01

TYPE DESIGNATlONS
This Manual deals with the Volvo 164 ear of the following types :
Type designation Engine Gearbox Rear axle
164-134 B30A M 400 3.73 : 1
164-135 B30A M410 3.73 : 1
164-136 B30A BW35 3.31: 1
164-155 B30A M410 3.73 : 1
164-156 B30A BW35 3.31: 1

(ID ®
CD

®
~@L4W

l . Vehicle type designation, 3. Type designation ond 5. Gearbox type designa-

chassis number and code chasiis number (stamped tion, part number and
number for colour and on the front right-hand manufacturing serial num-
upholstery. door pillar). ber.

2. Body number. 4. Engine type de~ignation, 6. Plate on lower part of

part number and manu- inspection cover showing
facturing seria·1 number. number of ,t eeth and re-
duction ratio öf final
drive.

GROUP 03

DIMENSIONS AND WEIGHT

Length . .. . . . . . . .. .. . . 47"15 mm (186")
Width . .. . . 1735 mm (68.3")
Height ..... 1440 mm (56.7")
Wheelbase 2720 mm (107.0")
Ground clearance . . . 180 mm (7.0")
Track, front .. . .. .... .. ..... . .. . .. .. .. . . . .. . ... . ..... . . . 1350 mm (53.2")
rear . ... ... . . . ............ . . .... . ....... . . . . . . ..... . 1350 mm (53.2")
Turning cirde .. . . . . . . . .. ... . . .... . . .. . . . . . .. ....... . 9600 mm (31.6 ft.)
Curb weight ...... . . . . . . . . . . . . . . . ... ..... .. . . . ... . . approx. 1360 mm (2992 Ib.)

O: 1
 LUBRICATION
ENGINE
Lubricant, type ... . .. . . .. .. . .. ... .... . .. ... .. ........ . ... . . Engine oil
grade .. . .... . . . ....... . .... . ....... . ..... . . . . . Service MS
viscosity, all year ,r ound .. ... ...... . .. . .... . . . . . . . Multigrade Oil SAE lOW-30
below -10° C (14° F) . . . . . ........... . SAE 10W
be't ween -10° and +30° C (14 and 90° F) SAE20/20 W
above +30 0 C (90 0 F) .. . ........ ... ..... . SAE 20
Oil capacity, excluding oil fi·lter .. . ..... . ... .. . . ... . . .. . . .. .. . 5.2 litres (9.15 Imp.pints= 10.97 US pints)
including oil filter ........ . 6.0 litres (10.56 Imp.pints= 12.66 US pints)
Oil for carburettor damping cyl'i nder .. . Automatic Transmission Fluid

GEARBOX (WITHOUT OVERDRIVE)

Lubricant, type ..... Gear oil
viscosity SAE 90
at continuous air temperature below _10 0 C
(14° F) .. SAE 80
Alternative lubricant, type ... ......... Engine oil
viscosity, all year round . SAE 40
Oil capacity ... . ......... . 0.6litre (l .l Imp.pints = 1.3 US pints)

GEARBOX WITH OVERDRIVE

Lub~i.cant,
type ..... .. .... . .... .. . Engine oil
grade ..... . Service MS
viscosity, all year round r . ' i. ' SAE 30
alternative . . .. ...... . Multigrade Oil SAE 20 W-40
Oil capacity, gearbox and ?verdrive 1.4 litres (2.46 Imp.pints=2.95 US pints)

AUTOMATIC TRANSMISSION
Lubricant, .t ype ..... . . Automatic Transmission Fluid, Type F
Normaloperating temp. of oil 100-115° C (212-239° F)
Oil capacity ... .. . 8.2 litres (14.43 Imp.pints = 17.30 US pints)

FINAL DRIVE
Lubricant, type, without differential lock ... . . . ... . . . ... . .. .. . Oil according to MIL-L-2105 B
with differential lock .... ... ..... . . . . . ...... . Oil according to MIL-L-2105 B, provided with ad-
ditive for differential lock
viscosity, above -10° C (14° F) .... . ......... . .... . SAE90
below -10° C (14° F) ... . . . . ... . ... . . . . . . SAE80
Oi:1 capacity ' . . . . . . . . . . .......... . .... .. . . ... . 1.6 litres (2.82 Imp.pints=3.38 US pints)

MECHANICAL STEERING GEAR

Lubricant, type' .... .. .. . ............... . .. . ....... . .. . Hypoid oil
viscosity . ........ . .... . .. ............... . .. .. ... . SAE 80
oil capacity .... . . . .. . .. . .. . .. . ..... . ... .. . . .. . .. . 0.6 litre (1.1 Imp.pints= 1.3 US pints)

SERVO STEERING
Lubri·c ant, type ........ . .. .. .. . . ..... .. . .. . . . .. . ...... . .... . Automatic Transmission Fluid, Type A
Oil capacity ...... . ... ... . . . .. . ... .. .. .. . . . . .. ...... approx. 1.2 litres (2.11 Imp.pints=2.53 US pints)

ENGINE
GENERAL
Type designation .. ......... . .. .............. . . .. ... . .. .... . . B30 A
Output, h.p. at r.p.m. (SAE) .. . .... . .... . ........... . . . ...... . 145/5500
(DIN) . ............. . ..... .. . .. . . . .. .. . . 130/5000
Max. torque, kpm (Ib.ft.) at r.p.m . (SAE) ............. . . . .... . . 22.5 (163)/3000
(DIN) .................. .. . . 21 (152)/2500

0:2
Compression pressure (warm engine) when turned over with
starter moto r, 250-300 r.p.m . ... . . 12-14 kp(cm 2 (170-200 p.s.i.)
Co mp ression ra tio . . . . 9.3: l
Numbe r of cyli nden . 6
Bore ....... . 88.90 mm (3.50")
St rok e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... . . . . .. . . . ... . 80 mm (3.15")
Displacement . . . 2.98 lit res
Weight, incl udi ng electrica l equipm e nt an d gearbox . .. 241 kg (530 Ib.)
Weight excluding gearbo x, sta rte r motor, oil and wate r 192 kg (422 Ib. )

CYLINDER BLOCK
Material .... . .. . .... . Special alloy east iron
Bore, standard ... . .. . . .. . . . . . 88.92 mm (3.501 ")
oversize .030" . . . .. . . . . . . . . . . . . . . . . .. . . . . .. . . . . . .... . . 89.68 mm (3.531 ")

PISTONS
Materi'al . ... . .... . .. .. .. . Light alloy
Weight, standard .... . 507 ±5 grammes (1 7.75±0.1 8 oz.)
P.e rmissible weight deviation be,t ween pi ston s In same engine 10 g ra mmes (0.35 oz.)
Height, total ........ . 71 mm (2.79")
Height from piston pin centre to piston crow n 46 mm (1 .81 ")
Pist-on clearance ... 0.04-0.06 mm (0.0016-0.0024")

PISTON RINGS
Piston ring gap, measured in ,ring opening 0.40-0.55 mm (0.016-0.022")
Oversize on piston rings 0.030"

COMPRESSION RINGS
Marked "TOP". Upper ring chromed .
N umber on each piston . . . . 2
Height . .. . .. . .. . ... . 1.98 mm (0.078")
Compression ring c1earance in groove 0.045-0.072 mm (0.0017-0.0028")

Oll SCRAPER RINGS

Number on each piston l
He,i ght . .. . .. . ... . . . ... . . . . . . 4.74 mm (0.186" )
Scraper ring' c1earance in groove .. 0.045-0.072 mm (0.0017-0.0028")

GUDGEON PINS
Floating fit. Circlips at both ends in piston.
Fit:
In connecting rod Close running fit
In piston . . .. . . . Push fit
Diameter, standard . . . . .... . . . . . . . .. . . . . ... . ... .. .. . . . . . . .. . 22.00 mm (0.866")
oversizes .05" 22.05 mm (0.868")

CYLINDER HEAD
Height, measured from cylinder head contact face to face for
bolt heads ........ . . . . .. ......... .. . ... . . . .. . ... . ... . ..... . 86.7 mm (3.41 ")
Distance from top side of head to overflow pipe upper end
(pipe pl'aced under thermostat) . . . . . ...... . ... . ... . 35 mm (1.38")
Cylinder head gasket, thickness standard (unioaded) .. 0.8 mm (0.031 ")
(Ioaded 0.7 mm = 0.028")

CRANKSHAFT
Crankshaft, end float ... 0.047-0.138 mm (0.0019-0.0054" )
Main bea rings, radial clearance 0.028-0.079 mm 1(0.0011-0.0031 " )
Big -end b ear ings, radi a l clea rance 0.029-0.071 mm (0.0012-0.0028")

0:3
 MAIN BEARINGS
Main bearing journals
Diameter, standa,r d . . .. , . ,' . . . . . .... . ' . . . .. .. ', . .. . .. , ... .. ' 63.451-63.464 mm (2.4981-2.4986")
undersize .010" " ..... . ... .. .. . . . , . . ' ... . . ..... . . . 63.197-63.210 mm (2.4881-2.4886")
.020" .... .. ........... .... .. . . .... . ... .. 62.943-62.956 mm (2.4781-2.4786")
Width on crankshaPt for pilot bearing shell
Standard .. " ........ . ..... . .. ...... . .. . . . . .. . .... .. . .. .. . 38.960-39.000 mm (1.5338-1.5351 ")
Oversize 1 (undersize she II .010") .. . . , . .. ... . . . .... . .. .... . . 39.061-39.101 mm 1(1.5438-1.5451")
2 ( " .020") ... .. .. .... .. .. . .. ...... .. . 39.163-39.203 mm (1.5538-1.5551")

BIG-END BEARIN GS
Big-end bE-aring journals
Width of hearing recess . . ....... ... ... .. . ... .... . . . . . . .... . 3l.950-32.050 mm (l.2579-1.2618")
Dj.ameter, standard ., ... , .... . . . . . . .. . ... . . . . .. . .. . .. . . ... . . 54.099-54.112 mm (2.1299-2.1304")
unde,rsize .01 O" .. . . .. . , . . " .. . . ...... .. . . .. . . .. .. . 53.845-53.858 mm (2.1199-2.1204")
.020" ...... , ... .. . . . .. .. . . .. ... , ...... . . 53.591-53.604 mm (2.1099-2.1104")

CONNECTING RODS
End Hoat on crankshaft ..... .. , .... . .. ... . . .. . .. . . . .. ... .. . 0.15--0.35 mm (0.006-0.014")
Leng,th, centre-centre ........ . ..... ' .... . ', ... . . . ... . . . . .. . . . 145±0.1 mm (5.71 ±0.004")
Max. permissible) weight deviation between connectings rods in
same engine . ", . . : . . . , ... .... . . ....... .. . .... ............ . 6 grammes (0.21 oz.)

FLYWHEEL
Permissible axial throw, max. 0.05 mm {0.002") at a diameter of 150 mm (5.9")
Ring gear (chamfer forwards) 153 te,eth

CAMSHAH
Marking ...... . ... . .. ,. , . . . . . .. . ' . , . . . .... , .. .. . . ...... . . . . . C
Number of bearings .. . . . . . .. . . . . . . ... . . . .. . . . . . .. , . . .. . . . . . 4
Joumal, diameter .... . ' . . .. . .. , . . . . . . . . .... . , '., . , . . . , . ... . 46.975-47.000 mm (1 .8494-1.8504")
Radial clearance .. . . . , .. . .. . , . , . .. . . . . , ... .... . . ' , , . . . . . . . 0.020--0.075 mm (0.0008--0.0030")
End float .. . . ........ . . , . ', ...... '., ....... . ............ .. . 0.020--0.060 mm (0.0008--0.0024")
Valve dearance for controi of camshaft setting (cold engine) 1.45 mm (0.057")
Inlet valve should then open at . .... . ....... , . . . .. ... .. ... . . , 0° (T.D.C)

CAMSHAFT BEARING
Bearing diameter ....... . . . ...... . . . .. . . . .. . . .. ... . .... . . .. . 47.020-47.050 mm (1.8512-1.8524")

TIMING GEARS (

Crankshaft drive, number of teeth . . . .. . .... . . , ... , .. , ... . . . 21

Crankshaft gear (fibre), numbe r of teeth ..... . ..... . . . ' . . .. . . . 42
Baokl·ash .... . ... .. .. .. ' . . . ,., ... . .... .. .. , . . ...... . .. . .... . 0.04--0.08 mm 1(0.0016-0.0032")
End Hoat, camshaft " .. .. . . .. . . . .. . ' . , .. , .. ....... . ... . .. .. . 0.02--0.06 mm (0.008--0.0024")

VALVE SYSTEM
VALVES
Inlet
Disc diameter .. . . . .. . . . .. . .... .... . , . . . , .. ...... . .. . .. . . 42 mm (1 .654")
Stem di'ameofer ... . ' . .... . ..... ' .. .... ... , ... . 7.955-7.970 mm (0.3132-0.3138")
Valve face angle .. , .. . .. , .... . ' .. . . . .. . ... .... . . ........ , . . 44.5°
Valve seat angle . . . . . ..... , . .. . . .. . . .... . .... . , .. ' .. . ... .. . 45°
Seat width in cylinder head . .. . ' ... ' . , ... . ..... .. . ' . . . . .. . . . . 2.0 mm (0.080")
Clearance, both wa'rm and cold eng·ine ... . ,' .. .. .. .. . . . " . . . 0.50--0.55 mm (0.020--0.022")

0:4
Exhaust
Disc diameter ......... . . 3.'i mm {1.378" )
St,em diameter ... . . 7.7'25--7.940 mm (0.3120-0.3126")
Valve face angle 445°
Valve seat angle . ..... . ... ... . ... ... .... . . . . . .. . .. . . 4Jo
Sea~ wid~h in cylinder head ... ... . 2.0 mm 1(0.020-0.022")
Clearance, both wa;rm and coldengine 0.50-0.55 mm {0.020-O.022")

VAlVE GUIDES
Length, inlet valve ... 52 mm (2.047")
elGhaust valve 59 mm (2.323")
Inner diameter . . . . . .. . .. .......... . ... .. . . .... .. . . . . . 8.000-8.022 mm (0.32-0.321 ")
H,e ight above upper face of cylinder head ..... . . ... . . 17.5 mm (0.689")
Clearance, valve stem-valve guide, inlet valv,e . .......... . . . 0.030-0.067 mm (0.0012-0.0026")
exhaust valve 0.060-0.097 mm (0.0024-0.0038")

VAlVE SPRINGS
Length, unioaded, approx. . .. . ... . . . . . . . . . . . . . . . ...... . 45 mm {1.77")
with a loading of 25.5±2.0 kp (56±4A Ib) ... . . ...... . 39 mm (l.54")
with a loading of 66.0±3.5 kp (145±l.7 Ib) ... . . . . . . .. . 30.5 mm (1.20")

LUBRICATING SYSTEM
Oil capacity, indudi,ng oil filter . ......... .. ... .. .... ... ... . . 6.0 litres (10.56 Imp.pints = 12.66 US pints)
excluding oil filter ...... .. .... ...... . ...... .. . 5.2litres (9.15 Imp.pims=10.97 US pints)
Oil pressure ,at 2000 r.p.m. (with wa;rm engin'e and new oil filter) 2.5-6.0 kpjcm 2 (36-85 p.s.i.)

Oll FilTER
Type .... .. . Full-How typ.e

Oll PUMP
Oil pump, type ... ..... . Gear
number of t,e e,th on each gea'r wheel 9
end float .... .......... . ..... . 0.02-0.10 mm (0.0008-0.0039")
radial clearance .... . .... . .. . . . . . .. . ... . 0.08-0.014 mm (0.0032-0.0055")
backlash .. . ... . .. . .. .. ... . . .. . . .. . . . . 0.15--0.35 mm (0.0060-0.0140")

RELIEF VAlVE SPRING (IN Oll PUMP)

Length, unloaded . . ....... . .. .. ... .. ..... .. . .. .. approx. 39.0 mm (1 .54")
loaded with 5.0±OA kp (1l.0±88 Ib.) ...... . .. ...... . 26.25 mm (1.03")
7.0±0.8 kp (15A±1.7 Ib.) . ........ . .... . . 21.0 mm {0.83")

FUEL SYSTEM
FUEl PUMP
Diaphragm type pump ...... .... ... ... .... ...... .. ... . .. .. . . Pierburg PV 3025
Fuel pressure, measured at same level ,a s pump ·a t 1000 r.p.m . min . 0.15 kp/cm 2 (2.1 p.s.i.)
max. 0.25 kp/cm 2 (3.5 p.s.i.)

CARBURETTORS
Type ...... . ......... . Horizon~al carburettor
Make and designation Zenith-Stromberg 175CD-2SE
Number .............. . 2
A,ir intake diameter . . . . . ....... . .. .... . . .. ... . 41.3 mm (1 .63")
Idling speed ... .. .... . ....... ... . ... .. ... . .... . .... . . . .... . . 800 r.p.m.
For cars with automatic transmission ..... .. . ... . .. . .... ... . . 700 r.p.m.
Metering needl,e de's ignation .... . . ... . . . ... . . . . .... . . ... .. . . Bl BE
Oil for damping cylinder .. ... . ... . . . . . .. .. . .. .... . .. . . . ... . Automatic Transmission Fluid

0:5
COOLlNG SYSTEM
Type ...... .. .. .. .. . . .. .... .... ..... ... .. . ... .. ... .. . Sealed system
Radiator cap valv'e opens at . ... .. .. . .... . . .... ...... . ..... . 0.7 kp/cm2 (10.0 p.s.i.)
Capacity ..... ..... . ........... .. . . . .... . ...... .. . approx 12.4 litres=2.73 Imp.galls/3.27 US galls
(expansion tank of which 1.5 litres = 2.6 Imp.
pints=3.2 US pints)
Fan belt, designation ... . . .. . .. . . ... . ..... ............... . 7MX875
Fan belt tension : for a force of 11.5-14.0 kp (25-30 I'b.) on the
bel,ts between the pulleys obtained with a depress'ion of 10 mm (0.39")

THERMOSTAT
Type . ........ . .. .... ... . ......... . . . .. ......... . . ... ... . .. . Wax
Marked .. ... . .. . . ..... . . . ....... . .. . .... . .. . .. . ... .... . ... . 82°
Begins to open at .... . . ..... . .. . ...... . .... . .. . ... . .. . ... . . 81-83" C (177-182° F)
Fully open at .... . ... .. .. . .. .. ... .. .. . . ... . .... . .. ........ . 90 C (194 F)
0 0

Kgm Lb.ft.
TIGHTENING TORQUES
Cylinder head .......... ... ......... . ... .. . .... . . . . . ... . .. . . 8.5-9.5 61-69
Main bearings .. .... .... .. . . ..... . . .. . ..... . . . .. . . . ....... . . 12-13 87-94
Big-end bearings ...... .... .. .... . .... . .. ... . . . ..... .... .... . 5.2-5.8 38-42
Flywhee l .. .. . . . .. . . ... . ...... .. .. .. ............... . . ..... . 5.0-5.5 36-40
Spark plugs . ... . .. . ...... . . . .. .. . . .... ............. . .. ... . . 3.5-4.0 25-30
Camshaft nut .. .. .... . .............. .. .. . . .. . .... .. ... . . .. . 13-15 94-108
Bolt for cmnkshaft belt pulley ..... ... ... . . ... . . .. .... .. . . . . 7-8 51-58
Nlipple for oil filter .. .. .. ....... . .... . ... ....... . .. .. ..... . 4.5-5.5 32-40
Sump bolts .. . .. . ..... . . . .. . . . . . ... .......... . .. . . .. .. . ... . 0.8-1 .1 6-8
Alternatar bolt (1//') . .... ........ .... .. ... .. . ....... . .. . . . . 7.1-8.6 50-60

WEAR TOLERANCES
CYLINDERS
To be rebored when wear amounts to (if engine has abno rm a I
oil consumption) ............... . ....... ............. 0.25 mm (0.010")

CRANKSHAFT
Permissible out-of·round on main bearing journals, max. 0.05 mm '(0.0020")
Pe'rmissible out·of-ound on big-end bearing journals, max. 0.07 mm (0.0028")
Crankshaft end float, max. . ................. . 0.15 mm (0.0060")

VALVES
Permissible clearance between valve stems and valve guides,
max. .... .. .... ... .. . ... ..... ......... ..... ... . .. . .. .... . .. 0.15 mm (0.0060")
Valve stems, pe~missible weoar, max. ............ ... . . ... . ... 0.02 mm (0.0008")

CAMSHAFT
Permissible out-af-round (with new berings) max ..... .. .... . 0.07 mm (0.0028")
Bearings, permissible wear ........... . .. ... ...... . ... .... . . . 0.02 mm (0.0008")

TIMING GEARS
Permissible backl ash, max. 0.12 mm (0.0048")

11 7 3 2 6 10 14
Y2~'i:

Tight'ening sequence for cylinde'r head bolts (tightened in 2

stages). l st s~age : 2.5-3.0 kgm (18-22 Ib.ft.); 2nd stage: 8.5-
9.5 kgm (61--69 Ib.ft.)

0:6
 ELECTRICAL SYSTEM

8ATTERY
fype .. . ..... . Tudor 6 Ex 4 F op or equivalent
Grounded . ... . Negative terminal '
System voltage 12 V
Battery, capacity ..... 60 Ah
Spe6fic gravity of eleotrolyte:
Fully charged batf<ery ....... . . . . . . 1.28
When recharging is necessary .. . . . . . .. . . 1.21
Recommended char9'ing current ... ....... ...... ... 5.5 A

ALTERNATOR
Type .. . . . . . . . . .. . .. .. . . . . . .. ... . . ... . ... . . .... . S.E.V.Motorola 14 V-34833
Output ... ... .... . .. . . .. . .. .. . . . .. . . . . . . .. . .. .. . . . . .. .. .. . . 770 W
Max. amperage .. . . . . . . . ... . . .. . . . .. .. . . . . . . . . ... . . . . . . .. . 55A
Max. sp'e ed . . . .. . 15000 r.p.m.
Direction of rotation Optional
Ratio, engine-alternator 1- 2
Brushes, minimum length 5 mm '(0.20")
Tightening torques:
Attaching screws . . . . . .. . . . . . . .. ..... . .. . . . . . . ... . . . . . . . 0.28-0.30 kpm (2.0-2.2 Ib.ft.)
Pulley nut .... .. ..... . .. . .. . . .. . .. .. . . . . .. ... ...... . . . . . . . 4 kpm (29 Ib.H.)

TEST VALUES
Field winding resistance ............... .. . . . .. . . 3.7 ohms
Voltage drop across insulation diode 0.8-0.9 V
Ra~ed test . ' 48 A (min . at 3000 r.p.m. and 'approx. 14 V)

VOLTAGE REGULATOR
Type .. ... . . . . .. . . .. . . . ... . . .. . . . ..... . S.E.v. Motorola 14 V-33544
Controi vo ltage, cold regulator. . . . .. . ..... . . . . . . . 13.1-14.4 V
affer running 45 minutes 13.85-14.25 V

STARTER MOTOR
Type ... Bosch GF 12 V l PS
Voltage .. ' 12V
Grounded .... . ......... . ....... . .... . .. ..... . ... . .... ..... . Negative terminal
Diredio n of rotation .. . .. . . . .. .. . .. . . . . . ... . .. . . ... . .... ... . Clockwise
Output . ... . ............ . . .. .. . . ... . . . . .. . . .. .. .. .. . . .. . . . . Approx. l h.p.
Brushes, number ..... . . . . ..... . . .. . . . . . . . . . ... . . .. . ...... .. . 4

TEST VALUES
Mechanical
Rotor end float 0.05-0.3 mm {0.002-O.012")
Brush spring tension ......... . .... . ...... . . . ......... .. . 1.150-1.300 kg (2.53-2.86 Ib.)
Distance from pinion to ring gear . .. . ..... .. . .. ..... . .. . . 1.2-4.4 mm (0.047-0.173")
Fri ction all torque of rotor brake .... . . .. . .. . . ... . . .. . . .. . . 2.5--4.0 kpcm (2.17-3.81 Ib.in.)
Pin'ion lidling torqve ...... .. . . . .. . . . . ...... .. . . . . .. . . .. . . . 1.3-1.8 kpcm (1.13-1.56 Ib.in.)
Backlash . .... . ........ . . .. .... . ... . .... . .. .. . ........ . . . 0.35-0.45 mm {0.14-0.018")
Minimum diameter of commutaror .... . . .. ... .. . .. ..... . . . 33 mm (1.3")
Minimum length of elec. brushes . ..... . .................. . 14 mm (0.6" )

0:7
Electrical
Unloaded starter motor :
12.0 V ,and 40-50 A 6900-8100 r.p.m.
Loaded starter motor:
9 V ond 185-200 A 1050-1350 r.p.m.
Lockeds~arter motor:
6 V an'd 300-350 A o r.p.m.

CONTROt SOLEN OlD

Cut-in voltag'e ... . . . Min . 8V

IGNITION SYSTEM
Fining order .... .... .... . ... . . .... . . . .... , ... . . . .. . .. .. . .. . . 1-5-3-6-2-4
Ignition timing
(at 600-800 r.p.m. with vacuum governo'r disconn.ected) . . . . 10° before T.D.C.
Spark plugs, type . ..... . Bosch W 200 T 35 OT equivalent
thread .. .. . . . ..... . . . . 14 mm
spa'rk plug gap .. . .... . . 0.7-0.8 mm (0.28-0.032")
tightening torque ..... . . . . 3.5-4.0 kgm (25.3-29.0 Ib.ft.)
Pre-engaging resistance toignition coil ... . .. ... .... . ....... . 0.9±0.05 ohm

DISTRIBUTOR
Type ..... . . . .. . . . Bosch JFUR 6
Din~ction of rotation Anti-dockwise
Br,e aker poin,ts, g,a p ........... . . . ..... . Min. 0.25 mm '(0.010")
contact pressu're 500-630 grammes (1.10-1.40 Ib.)
dwelJ ang'le ...... . . . ... .. . . .. . . .. . . .. . . 40±3°
CapacitoT 0.2 IL F-25 %

Centrifugal governor:
Advance range, fota I .. . . . . .. . . . . ... . . . . .... . . 12±1° (distr. gradua;tion)
Advance begins at .... .. ... .. . .. .. . . . . . . . .. . . . . . . . . . 425-525 r.p.m . (distr.)
Values, 5° . ........ . ... . . . . . . . . .. ... . 625-725 r.p.m. (dis~r.)
10° . .... . , . . 1150-1650 r.p.m. (distr.)
A,dvance finishes at ... 1850 r.p.m. {distr.)

Vacuum governor:
Positive controi (not U.S.A.)
Advance range, total . . .... . . . .. . . . . . .. .. . . . .. ... . ... . , . . . 5±1 ° (distr. graduation)
AdV'anoe begins at .... . ... .. ... . .. .. . . . . . . .... .. . . .. . .... . 6-10 cm Hg
Valu'e, 2.5° . .. .. . ... .. . . .... . ..... . . . .... . . .. . .. .. . ..... . 9.5-14 cm Hg
Advanoe finishes a.f ..... . ...... ... . ..... . .......... . .. . . . 14.5-16 cm Hg

Negative controi
Drop, to~al ......... . . .. . . . . . . . . . . .. . . .. . .. . . 3±OS (distr. graduation)
Drop begins at ... . ....... . ................ . . . 16-24 cm Hg
VlOiues 2° . .... . . . ............. . ..... . ...... ... . .. . .... . 23-31 cm Hg
Drop finishes at ..... . ....... . .. . .... .. .... . ......... . . . . . . 28-32 cm Hg

0:8
 LAMP BULBS Watts Socket Number
Headlights ........ . ..... . . .... ... . . . ........ . 45/40 p 45 t 2
Feglights ....... . ........... . . . ...... . . .. . ........... .. ... . 55 P 14,5 s 2
Parking lights, frent . .. . .... . .... . .... . .. . . . ........ . 5 (4 cp) Ba 15 s 2
rear . .. . .. . ... . .... . .... . .. . . . . . . .... .. .. .. . . 5 (4 cp) Ba 15 s 2
Fla's hers .... .......... .. . . . . . . ... . . . ... .... . .... . . . ... . . . .. . 32 CP Ba 15 s 4
Step Iiglhts ...... .. ....... .. . ..... . . .. . .... . . . . . . . ... ... ... . 25 (32 cp) Ba 15 s 2
Reversing lights ....... . ....... . .. . . . .... . ....... . .. . . ...... . 15 (32 cp) Ba 15 s 2
License plate light . . . . .... . .. . . . . .. . . .. . . . . . . .. ..... . . . .. . . . 5 SV 8.5 2
Side ma,rker lamps .. , ............. . . . . ... . . ..... . 5 Ba 15 s 4
Interier lighting . ... ... . ........... . .. ....... .. . . . . . ... . . . .. . 10 SV 8.5 l
Gleve cempartment light .... .. . . .... . . . . . . ...... ... .. . . .. .. . 2 Ba 9 S l
Engine and luggage cempartments .. .... .. .. . .. .. .. ..... ... . 18 SV 8.5 2
Instrument lighting, cembined instrument ... . . ... ..... .. ... . .. . 3 W 2.2 d 2
Lighting heater centre Is deck ..... . .. . ..... . . . . . .. . ... . . . .. . . 2 Ba 7 s l
Warning lamp, instrument panel .. .. ... . ... . .... . ...... . ... . 1'.2 W 1.8 d 5
Warning lamp, everdrive . . ........ . .. . .... . .... . ...... . ... . 1.2 W 1.8 d l
Warning lamp, el'ec. heated rear windew . . ....... . .. .. . .. .. . 1.2 W 1.8 d
Emergency warning flashers . ..... . ..... . .. .. ... . . . . . ....... . 1.2 W 1.8 d

FUSES Number
Rated current 16A 2
Rated current 8A l
Rated current 5A 4
Rated current 8 A (feglights) . . . .. .. . . .. .. . 4

ELECTRICALLY HEATED REAR WINDOW

Output, at first pesitien ef switch . ..... . Approx. 40 W
Outpu~, at second pesition of switch . . .. . Approx. 150 W

1NSTRUMENTS
SPEEDOMETER GEARS
Tyre 165 SR 15

Final drive Small S-gear Lorg'e S-geer Error

Gearbex Ratie
I red. rotie
I Part NO'. l Teeth I Port NO'. l Teeth I I %
M 400 3.73 : l 380168 18 381033 6 3.0 : l +0.43
M410 3.73 : l 380754 18 380682 6 3.0 : l +0.43
BW 35 3.31: l 380164 16 381033 6 2.66: l +0.38
I
The pe;pcentag·e errer lin the Clbev.e table is calculated fe r a relling radius of 308 mm (12.1 "), whioh is the value
ef the figure established by AB Velve fer tyres at a vehicle speed ef about 80 km.p.h. (50 m.p.h.).
Number ef speedemeter cable revelutions per km (mile) registered : 640 (1024).

TYRE 6.85-15

Finla·1 drive Small S-gear Large S-gem Errer

Gearbex Ratie
I red. fatie
I Part NO'. l Teeth I Part NO'. l Teeifh I I %
M 400 3.73 : l 380168 18 381033 6 3.0: l -l
M 410 3.73: l 380754 18 380682 6 3.0 : l -l
BW 35 3.31 : l 380164 16 381033 6 2.66: l -0.75

The per,c entage errorin the above table is calculated fe'r a r,elling radius ef 312 mm (12.3"), which is the va,lue
ef t.~e figu·re established by AB Ve IvO' fer tyres at (] vehicle speed ef ab,eut 80km.p.h. (50 m.p.h.).
Number ef speedemeifer cable revelutiens per km (mi le) registered : 640 (1024).

0:9
 POWER TRANSMISSION, REAR AXLE
CLUTCH
Clutch, type .. .... .. . . Single, dry-plate, di·aph ragm spring
Size ... . . . .. .. . .... . 9"
Clutch friction area, total .. . .... . .... . 468 cm 2 (72.5 sq.in.)
Release lever play, vehicle with left-hand steeri·ng . ... . .. . . .. . 4-5 mm '( 0.16--0.20")
vehicle with right-hand steering . .. . . . . . . . 2-3 mm (0.08--0.12")

GEARBOX
M 400
Reduction ratios :
l st speed ...... . . .. . . .. . . . .. . . . . .... . .. .. . ... . 3.14 : l
2nd spe~d ... .. . . . . .... . . ...... . ... .... . .. .. .. .... . ... .. l.97 : l
3rd' speed . . . . . . .. . . .. .. .. . . . . . . . .. . ... . . . . 1.34 : l
4th speed . . . . . . . . . . . . . ..... . . . .. . l :l
Reverse . .. . .......... . . 3.54 : l
Flange nut .tightening torque 11.0-14.0 kpm (80-101 IbJt.)
Lubricant ... ..... . ...... . .... . ... . . . Gear oil
viscosity. . . ..................... . SAE 90
at continuous air temper-ature helow
-100 C (14 0 F) .. .. .... .. .. . SAE 80
Alternative lubricant .. . .... . ....... . Engine oil
viscosity, all year round SAE 40
Oil capacity ..... approx. 0.6 litre (l.l Imp.pints = 1.3 US pints)

M 410 (G EA RBOX M 400 WITH OVERDRIVE)

Reduction mtio, overdrive ..... .. . . ...... .. . . 0.797: l
Oil pressure, direct drive .. . .... .... ... . . .. . ... . Approx. 1.5 kg/cm 2 (21 p.s.i.)
ov'e rd rive .. . . ....... . . 36-39 kg/cm 2 (510-550 p.s.i.)
Nut fo r driVling flange ... .. ..... .. .. . .. 11.0-14.0 kpm (80-101 IbJt.)
Lubricant, . .. .. . ... .. . . . . .... .. . . . .... . . Eng1ine oil
viscosity . . . . . . ... . .. ... . .. . ... . ... . . SAE 30 or SA'E 20 W-40
quaiity . .... . ...... . .. . ... . .. . . . .. . . . . " . Service ML ,or higher
Oil capa-city, gearbox and overdrive ... . . . . .... .. . .. .. ... . .. . approx. lA litres (2.46 Imp.pints=2.95 US pints)

AUTOMATIC TRANSMISSION
Make and type . . .. ... ..... . .... . ... . .. . ..... . . . . .. . . Borg-Warner, type 35
Type designation, left-hand drive ...... . . . .. . . . ......... . .. . As 15--35 EN
right-hand drive ..... . .... . .... . ...... .. . . 210
Colour of type plate, left-hand drive ... . . .... . .... . . Light blue
right-hand drive ... . ... . .. . .... . . ... . . Dark blue
Reduction ratios : .. . ........ . .. ....... . .. . ........ .
1st gem. . . . . . . . .. . ....... . . . . . .. . .... . . . 2.39 : l
2nd gear .. . . . .. . ..... .. ... . ....... . 1A5: l
3rd gem. .
Reverse ..
. .. .. .. ... . . . ... . . . . .
. ......... ... . . . .. . .. . . . . .. ..... .. . .
l :l
2.09: l
) X Converter ratios

Number of teeth, front sun gear .. . . .. . . .. . . .. .. . .. . . ..... . . 32

rear sun gear .. .. .. . .. . . .. . . .. . . . . . . . 28
planet gear, short ... . . . .. . . . .. .. ... . ... . . 16
planet gear, l'O'ng .. .. . ............... . .. . . 17
ring gear .. .... .. ... ... .... . .. . . . .. . .... . 67
Size of converter .... ... . .. . . .. . .. . . . .. . . ..... . ....... . .... . . 11" (28 cm)
Torque ra~io ,in conv'e rfer .. . ....... . ... . . . . .. .. .. .. . .. . 2:1-1 :1
Normal 's tall speed .......... . . . . .. .. . ... .. . . . . . .. .. ...... .. . 2100 r.p.m.
Weights : Ib. kp
Gearbox . . .. . . . . .. . . .. . . . .... . . . .. . ...... . ... . . . .... . . 82 37.2
Converter aase 7 3.2
Converter . ............... . .. . . . ...... ... . . . .. . .. . . . ..... . 30 13.6
Total, without fluid .... . .... . .... . .... . .. . . . . .... . . . .. . . . 119 54.0
Weight of fluid .... .. . ......... . ...... . . .. . . . ...... ..... . . 17 7.7
To~al, with fluid ....... . ...... . . .. ..... . . . . . ..... . ... .. . . 136 61.7
Fluid, type ... ... . .. . .. .. ..... . . . . ...... . .... . . . . . .. .. ... . . Automatic Transmission Fluid, Type F
Fluid capacity ... . . . .... . ... . .. .. ..... . . .. .... ... . .. . .. . 14 pints (8.2 litres)
Normall ope'rat ing temperature of fluid .... . . . . . . ... .. ... . .. . approx. 212-240 0 F (110-115 0 C)

O: 10
 Approximative shift speeds, kick down

1-2 shift 2-3 shift 3-2 shift 2-1 shift

I km .p.h . I m.p.h. I km.p.h. I m.p.h . I km .p.h. I m.p.h . I km.p.h . I m.p.h.

Left-hand drive 65 - 117 - 104 - 53 -

Right-hand drive
I 63
I 39
I 112
I 70
I 100
I 62
I 51
I 32

SPRINGS FOR CONTROl SYSTEM

Spring Effedive number
Approximate length of turns Wire diameter
1-2 shift valve 1.094" 27.8 mm 131/2 0.024" 0.61 mm
Convel1ter e >Ghausting v-alve . .... . .. . . 0.70" 17.8 mm 12 0.018" 0.46 mm
Rear pump check valve ........... . 0.617" 15.7 mm 3 0.019" 0.49 mm
Prima ry regulator valve ..... .. ... . . 2.941 " 74.7 mm 14 0.056" 1.42 mm
Servo onifice controi valve . .. .. .. . 1.005" 25.5 mm 17 0.024" 0.61 mm
Modulator valve ............ . . . .... . 1.069" 27.2 mm 19 0.028" 0.71 mm
Seoondary regulator va·lve .. 2.593" 65.9 mm 18 0.056" 1.42 mm
2-3 shift valve (inner spring) 1.59" 40.4 mm 221/2 0.036" 0.91 mm
Throttle valve (inner spri,ng) 0.807" 20.5 mm 28 0.018" 0.46 mm
Throttle valve (outer spring) 1.174-1 .1 85" 29.8-30.1 mm 191/2 0.032" 0.81 mm

TIGHTENING TORQUES
Application Lb.ft. Kpm
Torque converter - drive plate ........ . .. . . . . .. . .. . 25-30 3.5-4.1
Transmission case - convert'e r housing ... . ......... . . . . . 8-13 1.1-1.8
Extension housing - troansmission case . . .. .. . . ......... . . . 30-55 4.1-7.6
Oil pan - transmission case .. . ......... .... . . .. . . . .. . . . . . . . 8-13 1.l-1 .8
Front servo - transmission case ...... . .... . ... .. . ..... .... . 8-13 1.1-1.8
Rear servo - transmission case ...... . .. . . ... .... .. . . .. . . . 13-27 1.8-3.7
Pump adaptor - front pump body .... . ... . ...... . ..... .. . 17-22 2.4-3.0
Slotted screws ........ . ... . 2-3 0.3--D.4
Pump adaptor - transmission ca se .. . . .. ....... . ........ . .. . 8-18.5 1.1-2.6
Re'a r pump - transmission ca se ..... . . .. .... . .. . ..... . ... .. . 4-7 0.6--1.0
Slotted screws ......... .. ... .. ... . . . ....... . . .. . . . .. . .. . . . 1.7-3.0 0.25-0.41
Centre support - transmission case ........ . ........... . .. . . . 10-18 1.4-2.5
Outer lever - manual vO'lve shaft .... ..... .. . . .. . . . ... . .. . . . 7-9 1.0-1.2
Pressvre point . . . ....... . ......... . ... ........... . .... . .. . 4-5 0.6-0.7
Oil pan drain plug .................. . . .. .... . 8-10 1.l-1.4
Oil tube collector - lower body . . . . .. . ................ . . 1.7-2.5 0.25-0.35
Governor li.ne plate - lower body ... . ......... . .. . .. . ..... . . 1.7-2.5 0.25-0.35
Lowe r body end plate - lower body . ............. . . . . .. . .. . 1.7-2.5 0.25-0.35
Upper body end plate front or rear - upper body ... .. ... . . . . 1.7-2.5 0.25-0.35
Upper body - lower body .... . . . . ................. . ..... . 1.7-2.5 0.25-0.35
Valve bodies assembly - transmission ca se .. .. . . .. . ... .. .. . . 4.5-9 0.6--1.2
Front pump strainer - lower body ....... . .. . . .. . . . ... . .. . . . 1.7-2.5 0.25-0.35
Downshift valve cam bracket - valve body ..... .... . .. . .. . . . 1.7-2.5 0.25-0.35

Governor
Inspection cover - 'e xtension housing .... . . . .... . .. .. ....... . 4-5 0.6-0.7
Cover plate - governor body ........ . . . ........ . . ... . . 1.7-4.0 0.25-0.55

Brake band adjustment

Adjusting screw locl<iing nut, rear servo - case 25-30 3.5-4.1

Special threaded parts

Starter inhibitor switch locknut 4-6 0.6-0.8
Downshift valve cable adaptor - transmiss ion ca se .. ... . . .. . 8-9 1.1-1.2
Coupling flang.e - driven shaft .. . ....... . ..... . . . ... . .. . . . . . 35-50 4.8-6.9

O: 11
PROPELLER SHAFT
Type ... . . .. .. ...... . .. . . . .. . .. .. . . . .. .. . . .. .... . . .. . .. . . .. . Tubula r, divided, three universa l ioints,
support hearings
Universal ioints ... .. . . ............. . Fitted with needl·e bearings
luhricant, sliding ioint (when assembling) Molybdenum disulphide .chassis grease
universal ioint ............... . Further addiltion not required

REAR AXLE
Rear axle, type Semi-Hoating
T~ack .. . .. . . .. ..... . .. ... . . . . . . . . . . . ...... . .... .. ..... . ... . 1350 mm (53.15")

FINAL DRIVE
Type .... . .. ..... .. . . .. . . .. . . . . .. . . . .... . . . . . . .. .. . ....... . Spiral bevel (hypoid)
Reduction ratio ...... . . . .. ... .. .. . ... , . .. . ... .. . .. . ...... . . 3.31 : 1 (13 : 43) or 3.73: 1 (11: 41 )
Ba·cklash ...... . ........ . ...... .. .. . .. . .... . . 0.13-0.20 mm (0.005-0.008")
Pre-Ioading on pinion bearings, new bearings . .. . . .. . . . . . . 11-23 kpcm (9.55-20 Ibjn .)
wn-in hearings ...... . .. . 6--11 kpcm (5.21-9.55 Ib.in.)
Precloading on differential bear.ings .. ... . ....... . .. . ....... . 0.13-0.20 mm (0.005-0.008")
lubricant, type, without differential brake .... .. ... . . . . . .... . Oil according to Mll-l-2105 B
with differential brake . .. ... . ....... . ....... . Oil according to Mll-L-2105 B, provided with
additive for differential lock
viscosity, above _10 0 C (14 0 F) .... . . . . . .......... . SAE90
be~ow _10 C (14 F) ... . . . . . . . ... . . . ... .
0 0
SAE80
Oil oapacity .... . ... . .... .. . . . .. . . ... . . . . 1.6 litres (2.82 Imp.pints = 3.38 US pints)

TIGHTENING TORQUES Kpm Lh.ft.

Flange .. . ................ . . . .. . .. . . . . . .. . . . . . . . . . . . . . . . . . . . 28-30 200-220
Gaps ...... . . ... . . .. . . .. . . . . . ... .. . .... . . . . . . . .. . . . . . . . . .. . . 5.0-7.0 35-50
Crown wheel .. . ..... . . . .. . .. . . . . ..... . .. . . . . .. . . . . . 6.5-9.0 45-65

BRAKES
FRONT WHEEL BRAKES
Type ... . ....... . Disc brakes
Brake discs:
Outside diameter 272.2 mm (lO],')
Thickness, new . .......... . . . . . ... . ............. . . . . ..... . 14.34 mm (0.565")
reconditioned .......... . ....... . ...... . .. . ..... . Min. 13.14 mm (0.517")
Warp .... . .. ......... .... . . . . . ..... . ...... . . . . , . ..... . .. . Max. 0.10 mm (0.004")
Brake linings:
Numher per wheel ..... . .... . .... . . . ........ . . . .. .. . .. ... . 2
Thickness, new .... .. . .... . . .. ........... . . .. . . . . . . . . . . . . . 10 mm (0.394")
Eff.ective area .. .. .. . .. . .. , .... . . ... .. . . . ..... . . . . . . ... . . . 172 cm 2 (26.7 sq.in .)
Whe<el unit cylinders:
Number per wheel ... . . . . ... .. .. . . . . . .. _ ......... . .. . . . . . . 4
Diameter ....... . ... . . . . . ..... .. . . .......... .. ... . ....... . 36.12 mm (1.422")

REAR WHEEL ,BRAKES

Type . ..... .... . Disc brakes
Brake discs:
Oufside diameter 295.5 mm (11.6")
Thickness, new ... . .. . .... . ........ . . . .. .......... . . . . ... . 9.6 mm (0.378")
reconditioned .... . .. . .. .... . .. ... .... . ..... . .. . . 8.4 mm (0.331")
Warp .................. . .... . . . .... . . . . .. ..... . .. .... . .. . max. 0.15 mm (0.006")
Brake linings :
Number per wheel ..... . ...... . . . . .. .... . . . .. . .. . . . ... . .. . 2
Thiokness, new .. . .......... . .. . ......... . .. . .. .. . . .. .. . .. . 10 mm (0.394")
Effective area . .. . . ........ . .. .. .. ... .... . .. ....... .. .... . 100 cm 2 '(15.5 sq.in.)
Wheel unit cylinders:
Number per wheel ..... . .... . .. . .. . . .. .. . . .. . . . .. . . . ..... . 2
Diameter .................. . .... . .. . . ... . ... . . . .... . . . . .. . 38.15 mm (1.5")

O: 12
MASTER CYLINDER
Nominal diameter . ...... . . . .. . ..... . . . . .. . . .... . ... . . .. . . .. . 23.81 mm (0.94")
Bore ..... . ......... . ..... . . . . .. ...... . . . . . . . . ... . . . . . . Max. 23.92 mm (0.95")
Piston diameter .. . . . ... . .. ... ... . . . . . . Min. 23.66 mm (0.93")

BRAKE LINE
Outer diame·t er 3/16"

BRAKE VALVE
Make . . .. . . . .. ... . . Ate
Operating pressure 34±2 kg/cm 2 {484±28.4 p.s.i.)

SERVO CYLINDER
Make . . ... Ate
Designation ........ ... . . ... .. . .. . . Bromsgerät T 51

TIGHTENING TORQUES Kpm LbJt.

Attaching bo.Jts, front broke caliper 9-10 65-70
Atta'ching bolts, rea'r brake wliper . 6-7 45-50
Wheel nufs .. . .. . ... .. . .. . . . .. . ..... . . 10-14 70-100
Stop screw, master cylinder . . . . . . . ... .. . ... . ... .. . . . 0.5----0.8 3.6-5.8
Atta,Ghing nuts, master cylinder .. ... . .. ... . . . . . . . . .. . .. . 1.2-1 .5 8.7-10.8
Bleede r nipples ....... . .................. . .... .. ..... ... . .. . 0.4--0.6 3.0-4.0
Brake hoses ... . 1.6-2.0 12-15
W,a rning valve, switch 1.4-2.0 10-15
B~ake pipes . .... . 1.1-1.5 8-11
Plug, brake valve . . .. . 10-12 70-85
Lock nut, brake valve 2.5-3.5 18-25

FRONT END AND STEERING GEAR

. WHEEL ALlGNMENT (UNLOADED VEHICLE)
easter .... . o to +1°
Camber .............. . Q" 'to +0.5°
King pin inclinati'on ata camber of 0° .. . ......... . ........ . 7.5°
Toe-iln ................. . O to 4 mm (O to 0.16")
Turni,ng angles :
alt a 20° tum of the outer wheel the inner whee·1 should be
tumed 21.5° to 23.5°.
Shims, thickness .... . . . . . . . . . . . . . . . .. . .... . .... . . 0.15 mm (0.006")
0.50 mm (0.020")
1.0 mm (0.039")
3.0 mm (0.118")
6.0 mm (0.236")

MECHANICAL STEERING GEAR

Steering wheel diameter .. . . . .. ...... . ... . ......... . . . ..... . 423 mm (16.6")
Number of tums from stop to stop in vehide ... . .... . ...... . 4.8
Steering gelar :
Make . ......... . ... . .. . ... . . . ...... . . . . .. .. . .... . . Burman
Type .. ............. . ........... . ......... . . . . . .. ... . .. . . . Gam and ball nut
Redudion rati,o, centre position . ..... . . . .... . .. . ......... . 18.3: l
Clearance, steering shaft-bush, new part . ... . ...... . .... . . 0.025----0.063 mm (0.0010--0.0025")
wear limit ..... .. ... . .. . . . . 0.18 mm (0:007")
Balldi'a meter, bearings 7.14 mm (0.28")
ball nut 7.93 mm (0.31 ")

O: 13
 Shims ... . ... .. . .. .. . . . . .. . . ... . . ... . .. . . .... . . . . .. . . ... . .. . th = 0.05 mm (0.002" )
th= 0.127 mm (0.005")
th =0.254 mm (0.010")
Lubricant . ....... . ......... . .. . .. . .. . .... . .... . . . . . ... . . . .. . Typoid eil
Oil oa pacity .. . ....... . ....... . .... . .. . ... . ... . .. . .. . . 0.6 litre (1.1 Imp.pints = 1.3 US pints)

SERVO STEERING
Steering whee,1 diameter . . . .. . 423 mm (16.6")
Number of tums frem step te stop in vehicle .... . . . .. . . .. .. . 3.7
St'eering g'ear :
Make and type . . ...... . . . .. . . . .... .. ..... . . ... .. . . .. . . .. . ZF, ball and nut
Reductien ratie .... . . . . . . . . . .. .. . . .. . . .. .. . ... . . . . . . . . . .. . 15.7: l
Se'rv-o pump :
Make ond ty.pe . .. . . ... . . . . .. .. .. .. .... . . . .. . . . . ... .. .. . ZF, vane pump
Max. pressure ... .. ..... .. .. . .... . ... . . . . .. . . . . . . .. . . ... . 75±5 kg/cm 2 (1066±71 p.s.i.)
Theeretical capacity at 500 r.p.m . . .... . . .. ... . . ..... . .. . . . 6.65 11m (12 Imp.pints= 14 US pinrts/minute)
Min. capacity, 500 r.p.m., 50 kg/cm 2 (711 p.s.i.),80° C (176° F)
(176° F) .. . .. . ... ..... . . .. .... . .. . .. .. . . ... . 4.5 l/m (8 Imp ..pints = 9.5 US pints/minute)
Regul,a ted capacity .. . ... . ... ......... . .... . .. . . ...... . .. . . 5-8 l/m (9 Imp.pints = lO.5 US pints -14Imp.
pints = 17 US pints/minute)
Drive .. ... . . .... . ........ . . .. . . ... . .. . .. . ..... . .... .. . .. . . W ith belt
Ratio, engine-pump .... . . ... . .. . .... . . . . . .... .. . ... . . . . . . l :l
Oil type .. ........ ...... .. . ...... . .. . ....... . . ... ...... . Oil approved as "Automatic Transmission Fluid,
Type A"
Oil changing quantity .. . . . . Approx. 1.2litres (2.11 Imp.pints = 2.53 US pinfs)

TIGHTENING TORQUES Kpm Lb.tt.

Atta'ching holt for upper wishbene shaft ... . . ... . . 5.5-7.0 40-50
Nut for steering wheel . . ... . .. ...... . . ... . ......... . 3-4 20-30
Nut for .pitman arm ...... . ..... . ...... . . .. .... . . ... . .. . ... . 17.5-20 125-145
Locknut fer tie rod ..... . .... . . . ........... . .... . ..... . . . . . . 7.5-9 55-65
Meohanical steering g'ear:
Screw for steering bex screw cever . . .... . . ... .... . . 1.7-2.1 12-15
Screw for stop pl'ate ... . . ....... . . .... . ... . . . . .. . .. . 1.7-2.1 12-15

SUSPENSION, WHEELS
SPRINGS
FRONT SPRINGS
Type ... . . . .... . Helical spring
Wire diamet'e r ..... . . .. . . . .. . . . .. . .. . .. ... . . . . . .. . ... ... . . . . 15.3 mm 1{0.60")
Extemal di·ame,t er . . . 125.3 mm (4.93")
No.. of effective tums 6Y2
Test values:
Loading fer a cempression ef l cm (25/64") (measured within
a spring length of 185-205 mm= 79/22-81 /16) .. . ... . 61.9-65.9 kg (136- 145 Ib.)
Length, fully compressed . . .............. . max. 126 mm (5.0")
Length, when loaded with 600-630 ~g (1320-1386 Ib.) 195.5 mm (7.7")

REAR SPRINGS
Type . . . . . . Helical spring
Wir·e diameter . .. . 12.1 mm (0.48")
ExternaI di,ameter .... . 127.1 mm (5.0" )
No.. ef effective turns 8.9
Test va lues:
Loading (fer a cempression ef l cm= 25/64") ... . . ... . . .. . .. . 15.88-16.88 kg (35-37Ib.)
Length, fully cempressed .................. . . .... . . . max. 114.9 mm (4.52")
Load/spring length .. .. . .. . .. . .. . . ... . ... .. . . . ..... .... ... . 211-225 kp/297 mm (464-495 Ib ./11.?")

O: 14
 SH OCK ABSORBERS
Type . . ..... .... . Double-act.ing, hydraulic, telescopic
Tota,1 length:
front shock absorbers, compressed ... . .. .. . . ..... ... . . ... . approx. 223 mm (8.78")
unloaded . .. . . . . .. . . . .. . .... . ..... . approx. 340 mm (13.39")
front shock absorbers, compressed ..... . .. . ..... .. ... . . . . . approx. 279 mm (10.98")
unloaded ....... . .... . ......... .. . . approx. 443 mm (1 7.44")

WHEELS
WHEEL RIMS .
Designation . . . ... .. . .......... . .. . . . . .... . . . . . . 5.5 Jx15 L
Type .. .... ...... . .... . .... .. ... .. . . . . ....... . .. .. ..... . . .. . Dise
Radial throw .. . .. . . . .. .. . .. . .. . . . .. .. . ... . ..... . .. . ....... . max. '1.6 mm (0.063")
Warp .. .................... ... ... ......... . ....... . ... . ... . max. 1.6 mm (0.063")
Imbalance, complete wheel ....... . ........... . . . 900 gem (7.8 Ib.i n.)
Tightening torque for wheel nuts 10-14 kpm 1(72-101 IbJt.)

TYRES
Type ...... .... . . . ... ... . .... .. . . .. . .. . . .... . .. . . . . . .. .. . .. . Tubeless
Size ... . ... .. . . . . .. .. .. . . . . . . . . . ... . .. ....... .. . . ... . 165 SR 15

O: 15
 Part 1

SERVICI NG AN D MAI NTENANCE

 (ONTENTS
Instructions for oil level checking and changing ............. 1 : 1
Engine ... .... ............ . . . . . . . . . . . . . . . .. 1: 1
Gearbox (with out overdrive) ...... . ... .. .. . . . . .. .. .. ...... 1: 1
Gearbox (with overdrive) . . . . . . . . . . . . . . . . . .. 1: 2
Automatic transmission . . .. . ....... . . . . . . . . . . . . . .. 1: 2
Final drive ........................ . . .... . . . . . .... ... ..... 1: 3
Steering box, mechanical steering .. . . . . . . . . . . . . .. . . . . . . . . . . 1: 3
Servo steering ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1: 3
Checking the brake fluid level . . . . . . . . . . . . . . .. 1: 4
Instructions for lub ricating ........ .. . .. ... . . .... . . .. . ...... . 1: 4
Distributor ............... .... .. .. . . . . . ................... 1: 4
Ball joints . ........ . ..... . . . .. ... ... . . . .... . . ....... ..... . 1: 4
Body . .. ........ ......... . ..... . . . . ... . ... ..... 1 : 4
Checks when filling the tank . . . . . . . . . . . . . . . . . . . . . . .. 1: 6
Lubricating chart
 LUBRICATION
I NSTRU CT IO NS FO R 0 1L LEVEL CH ECK I NG
AN D CHANG IN G
ENGINE
The oil level should be checked with the help of the
dipstick, see Fig. 1-15.
With a new or recondition·e d engine, the oil should
be changed after the first 2500 km (1 500 miles).
Subsequent changing should normally take place
every 10000 km (6000 miles), howeve r, unde r the
following conditions:
The intervals for changing engine oil me dependent
to a very great 'e xtent on the oil used. For lubrication
of the engine, oil grade "For Service MS" should be
VOLVO
used. Conceming viscosity a multigrade oil is pri- 105005

marily recommended. This type of oil is befiter suited for Fig. 1-2. Checking the oil level in centre spindle

demanding operating conditions such as continuous

driving in city traffic interrupted by frequent start- low -20° C=-4° F) or when cold-starting difficul-
ing and stopping and with the engine idling for ties are anticipated, multigrade oil SAE 5 W-20 is
lengthy periods. For engine oil with viscosity SAE recommended.
10 W-30 (multigrade), 10 W-40, 10 W-SO or 20 W-SO, oH If multigrade oil is not used, .the viscosi.ty should be
changing takes place every 10000 km (6000 miles). If SAE 10 W below -10° C (14° F), SAE 20/20 between
an engine oil with viscosity SAE 10 W (singlegrade), -10° and +30° C {14 and 86° F) and SAE30 for
20/20 W or 30 is used, the oH should be changed temperatures above 30 C (86 F), all this presuming o
0 0

every S 000 km (3000 miles), however, at least twice stable air temperature.
a year. The quantity of oil changed is 5.2 litres (9.15 Imp.-
The oil should be drained off immediately after the ear pints = 10.97 US pints). The corresponding quanrtity
has been driven and while the engine is still warm. when the oil filter is included is 6.0 litres (10.56 Imp.-
For this, use the oil drain plug, see Fig . 1-1 . When all pints = 12.66 US pints).
the oil has run ou,t, check the washer and screw the
plug tightly into position aga in. Oil is added through
the rocker arm casing after 'removing the filler cap.
CARBURETTORS
As is shown above, an engin.e oil with grade "For
Eaeh time the engine oil is changed, the oil level in
Service MS" is used for subsequent topping-up. Con-
the centre spindle of the carburettors should be
cerning viscosi.ty, multigrade oil SAE 10 W-30 is pri-
cheeked to see that it reaches up to about 6 mm
marily recommended. At ve'ry low temperatures (be-
(1/4") from the edge of the spindie. If this is not the
ease, oil ATF should be used for filling up.

GEARBOX (WITH OUT OVERDRIVE)

To check the oil level, remove the filler plug (1, ,Fig.
1-3) and see whether the oil reaches up to the hole
for the plug.
In the ease of a new or reeondi,t ioned georbox, the
oil should be ehanged and the gearbox flushed out
after the first 2500 km (1 500 miles). The oil should
subsequently be ehanged after every 40000 km
(25000 miles).
VOLVO
The oil should be drained off immediately ofter the
103239
Fig. l-l. Drain plug on sump ear has been driven and while the oil is still warm .

1:1
 The oil should be dra ined off immedi a te ly after the
ear has been d rive n an dwhile t he o il is still w arm .
To do this remove the plugs marked l and 2 in Fig .
1-3 as weB as the cover for the oil strainer, see Fig.
1-4. Also clean the oil strainer as indicated in group
43 B.
Re-fit the drain plugs and bolt on the cover securely.
Fill with new oi!. Fill slowly to enable the o il to ru n
over into the overd rive. The oil should reach up to
the filler hole (l, Fig . 1-3). Screw tight the filler plug.
For a gearbox with overdrive, engine oi l with visco-
sit y SAE 30 is used all the year round. As an alterna-
Fig. 1·3. Gearbox tive, multigrade oil SAE 20 W-40 can be used . The oil
1. fi lIer pi ug 2. Drain plug
changing quantity is lA litres (2A6 Imp.pints-2.95
US pints).
When draining the oil, remove the plugs marked l
and 2 in Fig. 1-3.
Fill up with new oil after the drain plug (2) has been
AUTO M ATIC TRAN SMISSION
screwed tightly back into position. The oil should Normally oil changing only needs to be carried out
reach up to the filler hole (l). Screw the filler plug when the transmission is reeondi.tioned. The oil level,
tightly back into position. on the other hand, should be checked af~er every
Gear oil SAE 90 is used for the gearbox all the year 10000 km (6000 miles).
round. Where the air temperature is continuously The vehicle should stand leve!. Move the selector
below _10 C (14 F), SAE 80 should, however, be used.
0 0 lever to position "p" and I,e t the engine run a~ .idling
Alternatively engine oil with viscosity SAE 40 can be speed. Wipe off the dipstick with a nylon cloth, paper
used all the year round. or ehamois leather. Do not use waste or fluff y rags.
The oil changing quantity is 0.6 litre (1.1 Imp.pints= 1.3 Insertthe dipstiek, pull it up and cheå the oil leve!.
US pints). See Fig. l-S. N.B. There are different leve Is fO,r a warm
or cold transmission. For a wmm transmission, which
is the ease after driving 8-10 km (5--7 miles), the
GEARBOX WITH OVERDRIVE upper section applies (3 and 4, Fig. l-S). The lower
To check the oil I.e vel, remove the fill·e r plug (l, Fig. sedion (l and 2, Fig. l-S) applies to a eold transmis-
1-3) and then check to see that the oil reaches up to sion. The text on the dipstick wil l also remind you
the hole for the plug . of this.
111 the case of a new or reconditioned gearbox, ~he If necessary, fill up with oil until the level reaehes
oil should be changed after the first 2500 km (l 500 the "Max" mark. Do not fill above this mark, as this
miles). The oil should subsequently be changed after can cause the transmission to beeome overheated.
every 40000 km (25000 miles). The difference between the "Min and Max" marks

VOLVO
103243
Fig. 1-5. Checking the oil level
1. Max. oil level, cold fransmission
2. MilT. oil level , cold transmission
3. Max. oil level, warm transm,ission
Fig. 1·4. Overdrive 4. Min. oil level, warm transmission

1:2
 VOLVU
VOLVO 103244
105001 Fig . 1-7. Steering box filler plug
Fig. 1·6. Final drive
1. Filler plug 2. Drain plug

is about 0.5 litre (l pint). For topping-up, use oil ATF, intervals and in the same way as for a final drive
Type F, that is, a fluid meeting Ford specification without a differential lock.
H2C 33F.
If frequ,e nt fiHing up is found to be necessary, this
STEERING BOX, MECHANICAL STEERING
indicates leakage which must be put rightimmedia-
To check the oil le\rel, remove the filler plug (Fig. 1-7)
tely.
and then check to ,e nsure that ,the oil reaches up to
the hole for the plug .
FINAL DRIVE Normally i,t is not necessary to change the oil in the
To check the oil level, remove the filler plug (l, Fig. steering box except after reconditioning has been
1-6) and then check to ensure that the oil reaches up carried out. However, should the oil have to be
to the ha le for the plug . changed for any reason, the old oil can be sucked out
With a new or reconditioned final drive, the oil by using a suitable device, for example, an oil syringe,
should be changed after the first 2500 km (l 500 which is inserted through the filler hale, or the steer-
miles). Oil changing should therefore be carried out ing box can also be removed and emptied . Hypoid
only when overhauling is being done. oil SAE 80 is used for the steering box all the year
Oil changing should preferably be done immediately round.
after the vehicle has be,e n driven and while the oil is The oil capacity of the steering box is 0.6 litre 1.1
still warm. When draining the oil, remove the plugs Imp. pints=1 .3 US pints).
marked l and 2 in Fig. 1-6.
Clean the magnetic plug (2) weil. It is of great import-
SERVO STEERING
ance for the lifetime of the final drive that particles
CHECKING THE Oll lEVEl
and other impurities accumulated during the running-
in are removed. The oil level should be checked every 10000 km
After the drain plug or cover has been re-fitted, fill (6000 miles). First check the level with the engine
with new oil. The oil should reoch up to the filler standing to check possible oi l 1055. The oil level should
hole and the oil capacity is about 1.6 litres (2.82 Imp.
pints = 3.38 US pints). For changing the oil in ,t he final
drive oil which meets the requirements of the Ameri-
can MiJitary Standard MIL-L-2l0S B, SAE 90, is normally
used. Where the air temperature is con,t inuously below
-10 0 C (14 0 F), however, SAE 80 should be used.
A final drive fitted with a differential lock is filled
at the factory with a transmission oil which mee,ts the
requirements of the American Military Standard MIL-
L-2l0SB provided with an additive for final drives
with differential lock. For subsequent topping -up
and when changing, oil is according to MIL-L-2l0SB
having the above-mentioned additive. The oil level
VOLVO
103245
should be checked and the oil changed at the same Fig. 1·8. O il level

1:3
then lie about 5-10 mm (5/8" ) above th e level mark.
If the level is lower th a n t,his, fi ll with o il wi th t he
e ngine sta nd ing to e limi nate t he risk o,f a ir be in g
sucke d in. Start the engine and re-chec k the o il leve l,
whi·ch should now have falle n ,t o the level ma rk, see
Fig . 1-8. When the engine has stoppe d, the level sho uld
rise tö about 5-10 mm (5/8") above the mark.

Oll CHANGING

Normally the oil should be changed in connection

with repl'1l oement of the servo steering components,
see Part 6 of this Servi,c e Manual. On this occasion,
Fig. 1-9. Bra ke fluid contai ner
the filte r in the oil container should a lso be changed .

meets the requirem e nts acco rding to SAE 70 R 3. Bra ke

CHECKING THE BRAKE FLUID LEVEL fluid with the later designation SAE 70 R 3 (J70B) or
This check can be made without taking off the cap. SAE J1703 can also be used . Clean the brake fluid
(See Fig. 1-9.) If the check is car ried out in connection container cap before remova l and observe ma ximu m
with a vis it to a workshop, the level should be attended cleanliiness when filling w ith oil. Avoid spilling b rake
to if it is lowe r tha n the "Max" mork. Un de r no circum- fluid o n to th e pa intwork since thi s will damage it.
stances may the level be below the "Min " mark. Check to make sure that the vent-hole in the cap is not
If necessary, top up with first-class brake fluid which blocked .

I NSTRUCTIONS FOR LU BRICATI NG

BALL JOINTS
After every 10000 km (6000 miles) the distributor The upper and lower ball joints of the front end
should be lubricated. The distributor shaft should be together with the ball joints of the tie rod and steer-
lubricated by filling the o il cup (3, Fig. 1-10) with ing rod are plastic-lined. Therefore, the y do not re-
engine oil. After filling, close the cup. The surface (2) quire lubricating and thus have no grease nipples. As
of the cam disc is lubricated with a thin coating of the sealing is extremely important with regard to the
grease, Bosch Ft l v 4, or corresponding grease. The $ervice life of these ball joints, the rubber seals
ignitidn advance mechanism is lubricated by pouring should be checked every 10000 km (6000 miles) to
2-3 drops of light engine oil (SAE 10 W) on the wick ensure that they are not damaged. If cracked or
(l) in the distributor shaft. damaged, they should be replaced, see Part 6. When
being fitted, the rubber seals shoul be filled with
muHipurpose grease (un iversal grease).

BODY
To avoid squeaking and unnecessary wea r, the body
should be lubricated as described below. Nos. 2, 8, 10
and 11 of the lubricating scheme on the next page
should be lubricated approx. every 10000 km (6000
miles) and other parts of the body abou t once a
year. Moreover, during winter the door handle lugg-
age compartment lid locks should be lubricated with
V O LVO
103247
a suitable lock oil which would prevent them from
Fig . 1-10. Di.trib uto r
l. Lubricating wick 2. Cam disc 3, Oil cup f reez ing up.

1:4
 2 3 4 5 6 7 4 6 7 8 9

10 11 10 13 12 10 11 10

Fig. ]-11. Lubriceting poinls on the body

No. Lubricating point Lubricant No_ Lubricating point Lubricant

l Bonnet catch .. Paraffin wax 8 Luggage compartment lid hinges Oil

2 Bonnet hinges .. . .... . ... . . Oil 9 Luggage compartment lid lock Oil
3 Ventilation window catch and Keyholes ..................... . . Lock oil
hin ges .. . ..... . ....... . Oil 10 Door hinges . .. ... .... . .. .. . . .. . Grease
4 Striker plate See Fig . 1-13 11 Door stops ... . . . Paraffin wax
5 Roof opening wind defledor Oil 12 Window winclers . . . . ......... Oil and grease
6 Door hand le lock buttons . . Paraffin wax Locks ............. Silicon grease
Keyholes .... Lock oil (Accessible after the door uphols-
7 Ovter sliding su.rface of door tery panels have been removed.)
lock .. Paraffin wax 13 Front seat slide rails and catches Paraffin wax
and oil

VOLVO
105002 VOLVO
101827

Fi9. ]·]2. Hinges Fig. ]-]3. Striker plete Fig . ]-14. Deor lock with guide plete
1. Hinges, grease Inner sliding surfaces, spring and pin are Apply paraffin wax
2. Doar stop, paraffin wax lubricated with mo lybdenum disulphide grease
3. Hinges, grease

1:5
CHECKS WHEN FILLlNG THE TANK
The following should be carried out when filling the
tank
l. Check to make sure 1hat the oil level in the
engine is between the "Max" and "Min" marks on
the dipstick (see F1ig.1-15).
2. Without removing the cap, check that the level in
the brake fluid container is above the "Min" mark
(see Fig. 1-16).
3. Check that the coolant level is between the "Max"
and "Min" marks on the expansion tank (see Fig.
1.-17). VOLVO
104314
4. Check that the fluid con1ainer for the windscreen
Fig. 1·15. Oil dipstick
washer is filled (see Fig. 1-18).

VOLVO
VOLVO 104315
104300
Fig. 1-16. Drake fluid container Fig. 1-17. Expansion tank Fig. 1-18. Fluid container

The following should be carried out every other week

l . Check that the eleotrolyte level in the battery is
about 5 mm (3/16") above the plates (Fig. 1-19).
If necessary fill with distilled water. Also check
that the batte.ry and battery terminals are secure.
2. Check to make sure tha·t the pressure in the tyres
correspond to the foHowing values:

Cold tyres, kp/cm 2 (p.s.i.)

P·e-rsons Front Rear

165S15 165SR151c5S15 165SR15
6.85-15 6.85-15

1-2 1.6 (23) 1.7 (24)11.7 (24) 1.8 (26)

Max.load 11.7 (24) 1.8 (26) 2.1 (30) 2.1 (30)
VOLVO
104302
For prolonged drivin~ at speeds over 140 km.p.h. (90 m.p.h.)
Fi9. 1-19. Battery
the pressure should 'be increased by 0.3 kp/cm 2 (4.5 p.s.i.).
Maximum tyre pressure for the 165 S 15 type tyre must not,
however, exceed 2.1 kp/cm 2 (30 p.s.i.).
For the 165 S 15 (or 6.85-15) type, the speed should not ex-
ceed 175 km.p.h. (11 O m.p .h.).

1 :6
 Part 2
ENGI N E
 (ONTENTS
Tools 2: l
·. Group 20. General
Description ..... . 2:3
Repa'ir In s,t rudions .. 2:4
Remov ing the engine 2:4
Instailling the engine .. 2:5
Oil sump 2:5

Group 21. Engine

Des,c ription 2:7
Repair Instruotions ...... ... . . 2:9
DismanHing ,t he engine 2 :9
As·s embl'ing the engine .. . . .. ... . ...... . .. . . 2:9
Valve grinding and decarbonizing ... . . . . . . . . . . . . 2 : 10
Cy'linder head and valves ........... .. . . . . . . . .. . 2: 11
Cylinder block ..... 2 : 12
Pistons, piston rings and gudgeon pins 2 : 13
Connecting rads ........ . 2 : 14
Crank's haft ..... ............... . . . . . . .... . . . . 2 : 14
Replacing orankshaft rear oil seal ..... . . .. . . . . .. . . . . . . 2: 15
Replacing oil sea I, timing gea,r casing . . .. . . . . . 2 : 16
Rep,l aoing the timing gears ..... 2 : 17
Posi~ive crankcase vent·ilation 2 : 18

Group 22. Lubricating System

Desoeription ........ . 2 : 19
Repa i·r InSltructi·ons ..... . 2 : 20

Group 23. Fuel System

Description ............ . ....... . . . .. . . .. . . .. ..... . . ... . 2: 23
Repair Instructions .. . . .. . . . . . . . . . . . . . . . . . .. . . . . . . .... . 2 : 31
Periodical check ... ...... . . .. .. .. . . .... . . ..... .... . ... . . 2 : 31
Setting the carburettor . . . . ...... . ....... .. . 2: 31
Faulty carburettor function . .... .. . . ......... . . . . 2 : 34
Flap housing, constant air temp. device .......... . . . . 2: 38
Air cleaner . . . . .................... .. . . 2 : 38
Fuel pump .... . . .. . .. . . . . . .. . ... . . . . . . . . . . . 2: 38
Venting filter 2 : 39

Group 25. Cooling system

Description ... . . . 2: 40
Repair Instructions 2 : 42
 TOOLS

1426 1867 2250 2408 2424 2435 2814 2815

1&
28 16
JIL 281 7
,
28 18
I
2819 2822 282 3 4 090

2903

VO LVO
105234

Fig. 2-1. Tools for eng ine

SYO 1426 Drift for fitting pilot bearing in flywheel (crankshaft)

SYO 1867 Drift for removing and fitting bush in rocker arm and
connecting rod
SYO 2250 Puller for camshaft gear
SYO 2408 Press too l for fitting camshaft gear
SYO 2424 Grip tool for remo ving and fitting val ve tappets
SYO 2435 . Dowel pin (2) for fitting cylinder head
SYO 2814 Puller for polygon hub
SYO 2815 Press tool for fitting cranksha'f t drive and po lygon hub
SYO 2816 Drift for fitting crankshaft oi l sealon engine front end
SYO 2817 Dr ift for fitting crankshaft oil sealon engine rear end
SYO 2818 Drift for removing valve guide
SYO 2819 Drift for fitting valve gu ide
SYO 2822 Pull e r for crankshaft drive
SYO 2823 Ring for fitting standard piston
SYO 2903 Spanner for removing oil cleaner
SYO 4090 Puller for crankshaft pilot bearing

2: 1
 272 7

a,
l 2811 2813

2821

VOLV O
103357
Fig . 2-2 . Tools for removing engine
SVO 2727 Tool for lifting engine front or rear e nd to remove oil SVO 2812 Li fting arm for attaching lifting beam 2810 in rear end
sump and gearbox resp. of engine
Used tagether with tools SVO 2811 and SVO 2812. SVO 2813 Support for lifting arm SVO 2811 for liftin g engine
SVO 2810 Beam for lifting out and installing engine. with cylind e r head removed
Used taget her with tools SVO 281 1 and SVO 2812. SVO 2821 Support for lifting tool SVO 2727 f~r lifting end af
SVO 2811 Li ft ing lug for altaching lifting beam 2810 or 2727 in engine
engine front end

Fig . 2-3. Engine sland

SVO 2520 Stand. Used tagether w ith 1001 SVO 2820
SVO 2820 Fixture for mounting e ngine on stand 2520

2:2
 GROUP 20

GENERAL
DESCRIPTION
The B 30 A engine (Figs. 2-4 and 2-5) is an in-I.ine, six- fan is of the slip-coupling type. The seven -bea ring
cylinder, wate'r-coo,led overhead-volve unit. H is pro- crankshaH has a flywheel damper moun,t ed on its
vided with two horizonta,1 carburel\ltors as we'" as an front end.
exhaust ,emission con,trol system which produces clea- The output ~i'gures for the engine ore given In the
ner eX ha u'st gases. The engine is also fi>lted with an "Specifications".
air preheater and positive crankcose ventila~ion. The

Fig. 2-4. Engine B 30 A viewed from left Fig. 2·5. Engine B 30 A viewed from right

H'
se,
15O,---,--,----,---,-----r-----,

1<0+--+--+-+--+-/-+--1
SAEL
130+--+0- I-N-j--t---t-I/--///f-
"0t---+--j--t---jL'
.Il
100+--+--+---/-/-/':/_'!--_!----I

/
'+--+---/---/1/--+--1--1

:: ___ __ _&-+/I-_-_-t-_-_-_+_-_-_-1 ::m::::

6O~br:,fl~~~~ : : ;
50 +------+------Il-/--------+-----+-----~-'\'-t\~j.----\-----_+:: ~:~
,/
If
2000 3000 4000 5000 6000 .pm

VO LVO
103273

Fig. 2-6. Output and torque curves B 30 A Fig. 2-7. Engine compartment

2:3
 REPAIR INSTRUCTIONS

VO LVO
VO LVO 1033;<, I

Fig. 2-8. Lifting out the engine with lifting too I SYO 281036c Fig. 2-9. Lilting lug SYO 2811 on engine Iron I en d

REMOVING THE ENGINE 11. Remeve the lewe'r nuts frem the engine frent
meuntings. Fit the engine lifting unit with lifting
l . Remeve the gear ,l ever.
beam SYO 2810 and meve the bleck runner te
2. Discenned the pesitive lea,d from the battery.
the rea'r end ef the lifting beam, see Fig. 2-8. (Use
Empty the ceelant.
a nut puHer for tliis adjustment.)
3. Remeve the bennet (heod) frem the hinges.
12. Remeve the propeller shaft from the gearbex.
4. Discenneot the hese fer the expansien tank as
Discennect the earth (greund) cable frem the en-
weil as the lewer radiater hese frem the radiator.
gine and the electriccables frem the gearbex and
Remev'e the upper radioter he's e frem the engine
eve,rdrive. Remeve the speedomeler hese.
and finalily the 'radiaterand fan casing .
13. R,e meve the exhalJst pipe clamp from ,t he bracke,t.
5. Remeve the distributor cap and the ignitien leads
Remeve the gearbex member and the rubber
f.rom ~he spark plug's. Remove the electric cable
bleck and bracket frem the g,ea,rbex.
frem the ,&,tributer. Remeve theignitien ceil and
14. Remeve the el ukh wi,re pin frem the lever and
place i,t te the side.
the elukh wire sleeve frem the dutch casing.
6. Discenned the fue,1 hese from the pump and
plug the ,hese. Remeve the eleotric cables frem
the starter moter.
7. Remeve the a'i,r de'aner cever and lift ,it forwards
tegether with ,t he ottached heses. Remeve the
e,lectr,i'c cables frem the altemator and alse the
temper,a ture and oil pressure teM-tale units.
8. Remeve the preheating plate and the atfaching
nuts for the ,e xhaust manifold flange.
9. Remeve the throttle centre I shaW fmm the pedal
shaft, ,Iink reds and br'acket. Remeve the cheke
wire frem the carburetter and the vacuum hose
for the brake se,rve frem the manifeid . Dis-
cenned the water hoses fer the heoter element
from rthe eng'ine.
10. Fit lifting lug SYO 2811 te the frent end ef the
engine as shewn in Fig. 2-9 and 'I'ifting arm SYO
2812 ,en ,t he engine reor end as ,s hewn in Fig. 2-10.
VO LVO
Prep up the vehicle with feur blecks. Fig. 2-10. Lilling arm SYO 2812 on rear end 01 engin~03 362

2:4
 VOLVO
\033t-1
Fig . 2·11. Fitting support SVD 2813 with cylinder head removed

VOLVO
103 131
Fig. 2-12. Lifting tool SVD 2727
15. Heist the eng·ine with the lifting unit, lowering at
the same time the ,e ngine rear end by adjusting
the block unli,t on <the li#ing heam . PUII,I the engine
forwards a'cross The front member mising i,t af the 11 . liit the igniti-on coi,I, the distnibutor cap and the
same time. Level ou,t ,t he engine ·a nd g·e orbox and igni,tion ,Ie'ads os we'U as the .e:!'e'otri,c cable.
pull the entire unit forwards . 12. Fit the radi,a tor and conne'at the r-adi·a tor ho,s es
and hese for the expansion tank. f'i,I,1 with coolant
INSTAlLlNG THE ENGINE and check theeng'ine 'o it
13. Fit the bonnet (hood) and connect the hattery
l. Fit lifting lug SYO 2811 and arm SYO 2812. Install
lead. Fit the gear ,lever. Cheok the fundion and
the engine in position with the help of lifting beam
for leakage.
SYO 2810.
Attn. Make sure that the exhaust manifold does
not come into contact with the oil filter.
2. Firt the bmcket 'a nd rubber block on the gearbox. Oll SUMP
(Do nort tighten the bol,ts finolly. This is dene at Since for certain types of work on the engine much
point 7 below.) Fit the gearbox memher. time can be spared by being able to remove the oil
3. liit the ealnth (ground) cable as weil as the eledric sump without lifting out the engine, the following
cables for the overdrive and ·g earbox. Install the working method has been evolved.
spee,d ometer hose as we,lIas the propeller shaft.
4. Remove the lifiting beam and Illi~ting "'ugs from the
engine. Fi,t the nuts for rthe engine front mountings.
5. Sewre the exhaust manifol,d <togethe'r with gasket REMOVING
and fit the preheating plafe. l. Pilace support SYO 2821 on ,t he side-members as
6. liit the clukh wi,r e sl,e'eve and conneot the wire shownin Fig. 2-12. The pins should (:tolint forwards
to the ,I,e ver. Adju,srt the dutch a,o condingto Part 4 and ,lie ag,a,imt the front plo.tes. The support plate's
(41 ). shou,ld face upwards. Fit I,jfting ,Iug SYO 2811, see
7. Fit the damp for the exhaust man'ifold. T,ighten Figs. 2-12 and 2-9. Place I'ifting tOQlI SYO 2727 on
the bolrts for the engine rear mounting's. Lowe:r the suppo.rt and secure the hookin the lifting lug.
the v,e hide. Ra'ise the front end of the engine to off-Ioad the
8. Conneot the water hoses for the hea,t er unit. In- engine mOlmtings. Remove theo.ill dipstick.
staiII the ell'edric cahles to the t·e mperature and oil 2. Jack up the v,e hicle under the front ja'ck attach-
pressure ,te"'-1talle un,its as welil as the alltemaror. ments. Drain off the engine oi!. Rama,v e the lower
9. Connect the va,cuum hose. Firt the throttle cont,nol nuts for rI1he engine mountings.
shafit, the choke wire as weil as the air de,aner 3. Place a workshop ja,ak undelr the front axle
CO'sing. Conned ,t he hoses to the ai'r intake and member. R,e move the rear bollts of the front axl'e
preheoting pola,t e respectiy,ely. member and insteod fit two a'uxi,l'i ary bolts (UNC
10. Wi're the electni,c cables to the st,a rter motor and 1/2-13 X 114). Remove the front bolts for the fl'ont
connect the fuel hose. axle member. Lower and rem ove the ja'ck so that

2:5
 the front axle membe-r hangs in the two auxiliary 2. Place the r,e,inforcing brocket ,in position and
holts. lIighten 01,1 the bolts manuaHy. Then tighten
4. Remove the reinforcing brocket (at the flywheel securely first the bolts for the flywheel casing and
oasing). Unsorew the bolts for the oil sump and then those for the cylinder block.
I'i,f,t down the sump. 3. Ra,i'se the front mde member and tighten securely
5. Remove the o ld g<aske-t and dean the contact the front boHs. Remove the auxiliary bolts, fit and
svrf.aoes of the cyl1inder block and oil sump. l1ighten the rear bo-I,ts.
4. Fit the nu.ts for the engine mountings.
FITTING 5. Lower the vehicle. Remove tlle I,ifting toois.
l. Place the oil sump and gasket ·in posirtion and 6. Fill with o,il 'a nd ,insert the oi,1 dipsl1iok.
re-~it the bolts. T'igMen securelly the dmin plug. 7. Start the eng1ine and check for any ,Ieakage.

2:6
 GROUP 21

ENGINE
DESCRI PTION
CYLIN DER BLOCK CAMSHAFT AND VALVE TAPPETS
The cyl,i nder block (43, Illustration 2 A) is made of The camshaft (61) ,is made of special-alloy cast iron
speciO'I ca st -iron and is ca st in ,a single unit. The and has case-hardenedwms. It ,is ,driv'e n from the
cylinder bores, which are surrounded by coo,ling crankshaH through a g,e'a r train which has a ratio of
jackets, are machined directly in ,the block. The oil- l : 2. The camshalit is carried in feur be-arings, all ef
ways in the block are a.rranged so that the oil filter, which have the same diameter. Camshaft axial loco-
which is of t-he full-How type, ,is di~ectly attached to tionis maintained by me'ans of a bronze axial washer
the ,right-hand side of the block. located at the front end of ,t he camshaft. Axia,1 play
is determine,d by a spacer ring behind the camshaft
CYLINDER HEAD AND VALVES gear. The valve tappets (41) are aciu,ated directly by
The cylinder head (37) is secu'red to the block by the camshaft. They are locat,e d in hOIles in the block
means of bolts. MI -t he combus~ion chambers are above ,t he camshaft and transfer mov,ement te the
machined throughO'utand have separa.te inl,et and valves by means of push rods and rocker arms. There
exhaust ports, one for each va,lve. are no inspection covers for the valve tappe,ts since
The valves (6 and 9, IHustra~ion 2 A) which are fift.ed they me accessible af,t er the cylinder head has been
suspended in the cyl,inder head, are made of special removed.
ste-e,1 and are ca~ried in replaceable guides. The va,lve
stems are chromed. CONNECTING RODS,
The valve collet is provided with three lands and the PISTONS AND PISTON RINGS
va,lve with corresponding grooves, whrich hold the The conneding rods (55) are made of drop-forged
valve but also make sui,~able rolation possible. steel and are provided with a precision-machined
(Compare with Fig . 2-22.) The valves are provided bush whi'ch aots as a bearing for the gudgeon pin.
with volve gvide rubber sea-Is, which are mounte,d on The big-end bea-ring she'Ms are precis-i on-manufaotured
the guides. and O're replaceahle.
Viewed in order from the front, the va,lves are placed: The pistons (62) are made of light-alloy and have two
intake, ,exhaust, j,n take, exhO'ust, and so on. compression rings and one oH scraper -ring . The upper
The cooling jackets are designed so tha,t the air compression ring is chromed in order to reduce cy-
around the spa,rk plugs is also coolied. Water distri- I'inder wear.
bution is by means of a pipe, the wat-e r being directed The gu,dgeon pin (59) has a f.loating f'itin both the
towa'rds the w(ll~mest parts of the engine. piston and connecting red. The a~ial movement of
the gudgeon pin is Ilimi,ted hy circlips in the gudgeon
CRANKSHAFT AND BEARINGS pin hole.
The crankshaTIt is made of stee,land has ground, case-
hardened be'aring journalis. Itis carnied in seven mOlin
FLYWHEEL DAMPER
bearings, the re-air flange hearing of wh'ich also The flywheel damp er (76) is of therubbe,r type. The
functions as a p-ilot be,a 'ring axiO'My. There are drilled hub is jeinte1d to the crankshaH by means of a poly-
oilways in the crankshaoTIt for the ,Iubniwting oil. gon joint. The flywheel mass is j-oumalMed on the hub
A gear mounted on the front of the crankshaft drives through -a rubber 'Suspension. The gmduartion for the
the t,iming gears through a splined joint. The crank- igni,tion setting i,s ma,rked on the flywheel damper.
shaft end projeding from ,the gea'r wheel has a
pOllygon profi,l,e. Mounted on this pin is the polygon INTAKE AND EXHAUST MANIFOLDS
hub for the flywhe'e,1 damper. The intake and exhaust manifoids, the mate-rial of
Both the ma-in-beaning and the big-end be,aning shelIs, whi-ch ,is of nodvlor i'ron, are cast on to a bmnch pipe.
which are re'P'laceable, consist of a stee,1 backing with They have been designed with a view to the exhaust
indium-plate lead-bronze bearing metal. Both front emission controi system, with prehea,ting chamber
and rear crankshaf'r oil seals are rubber-lip type sea Is wherein the temperature of t.he fuel-air mixture is
with metal fra me. mise1d by the heat from the exhaust ports.

2:7
A spring-Ieade,d thretHe (secendary threttle, 10) is te The partiai vacuum which arises in the intake manifeld
be feund in e,ach of the intakes. when the engine is driven, brings abe ut apartiol
The ,intake manifol,d has ~he foMewing vacuum eutlets : vacuum in the crankcase threugh the hese (3).
l . Te the vawum geverner fer the negative vacuum Freshair is supplied te the recker arm casing threugh
setting the air cleaner via the hese (2). A plate in the recker
2. Brake serve arm casing (see Figure) ensures that the fresh air circu-
3. Positive crankcase ven,ti latien lates sufficiently in erder te mix with the crankease
gases.
As the fresh air supply passes threugh the carburetter
air cleaner, impurities are prevented from getting inte
POSITIVE CRANKCASE VENTILATION the engine. Where ~here is ,a high er medium degree
This an·angement prevents crankcase gases f.rem be- ef partiai vacuum in the crankcase (intake manife,ld),
ing releas'ed in,te the atmesphere. They are instead whi ch happens du'ringidling and when eperating
sucked inte the engine threugh the intake manife,ld under a Hght load, the system functiens as described
and take pa,rt in the combus~ien precess. The re'sidue abeve. When the partiol vacuum in the cr,ankca'se is
is blewn eut threughthe exhaust pipe tegether with less than that in the ai'r cleaner, which eccurs at fu'"
the ether cembusien .resi,dues. lead and/er with large flew qu,anti,ties, nO' fresh air is
Between the eil trap (6, 2-13) and the intake mani- supplied. Insteod the Hew in the cennection between
feld there is a hese (3). It is cennected te the intake the recker arm casing and air cle,a ner reverses and
manifeld by means ef a calibrated nipple (l). (This the crankcase g,a'ses ge beth ways, pa'rtly threugh the
nipple sheuld be cleaned every 40000 km = 25000 hese (3) and partly threugh the air deaner and car-
miles.) Between the recker arm casing and air cleaner bvrettor te the intake manifeid. In this way, the crank-
the re is a hese (2) cennected fer the fresh-air supply. oase ventilatien system can deal with relative,ly large
At the cennectien te the recker arm casing there is a quanMies ef crankease gases witheut any escaping
fla me arrester (4), which censists ef a metal filter. inte the a,t mesphere.

VO LVO
105135
Fig. 2-13. Positive crankease ventilation
1. Nipple 4. Flame arresler
2. Hose for fresh air supply 5. Plole
3. Hose for crankease gases 6. Oil trap

2:8
 REPAIR INSTRUCTIONS

VOLVO
103359
Fig . 2-14. Engine on sland

DISMANTLING THE ENGINE VO LVO

24838

After the engine has been lifted out of the vehicle, Fig. 2-15. Removing valve lappet

dismantling is car6ed out as follows. (Instruotions for

the indivi'd ual parts are given under the sepa<rate
heO'dings concerned.) spirit. Pistons and bearing she'lrls must never be washed
l . Place the engine on stand SYO 2520 with fixtu're in causti'c soda. Rinse the parts with warm water and
SYO 2820. See Fig . 2-14. Check tha<t the oil has blow them dry with compressed air after wash-ing .
been drained off. Clean the oilways with particulor thoroughness. All
2. Remove the starter motor and reinforcing plote on seal'ing p'lugs at the oi,lway openings in the cylinder
the lower front edge of the f1ywheel housing. block must be removed during the c1eaning process.
Remove the flywheel housing together with the
georbox. Then l'emove the c1utch and f1ywheel. ASSEMBLlNG THE ENGINE
3. Remove the aHernator, water pump, distributor, When assembl'ing the en~ ine, follow the instructions
rocker o,rm casing, rocker arms and oil filter. for the parts concerned. Check the marking of the
Remove the mon,ifolds with carburettors. Toke off bearing's according to Fig. 2-16. The main bear,ingsare
the cylinder head . Rtemove the valve tappets with marked 1-7, and the big-end bearings 1-6, counting
tool SYO 2424, see Fig. 2-25. from the front.
4. Remove the timing gear CCIsing and 1he timing
ge·ars. Goncerning the tool·s for this purpose, see
under the heading "Replacing The Timing Gears".
Remove rt he camshaft and then the oil nozzle.
5. Decarbonize the top of the cylinders. Remove the
oil sump, re·ar seaJ.ing flange, oil pump and con-
necting rods with pistons. Repl·a'ce the caps cor-
rectly on the respective connecting rods.
6. Invert ·and turn the engine . Remove the orankshaft.
Place the caps correctly in their respective posi-
tions.

CLEANING
After di~mantling, wash the parts rthoroughly. Parts
made of steel or cast iron can he washed in a de-
VOLVO
greasing tank with a caustic soda solution. Light-alloy 103351
Fig. 2-16. Marking main and bi g-end bearings
parts can, however, be damaged by caustic soda so
1. Main bearing No. l 2. Big-end bearing No .
that they should preferably be c1eaned with white 3. Main bearing No. 2

2:9
 12 8 4 5 9 13

Fig. 2-17. Tighte~ing sequence for cylinder head bolts

To be tighlened in two stages
151 51age, 2.5-3.0 kpm (18--22 Ib.fl.)
2nd stage, 8.5-9.5 kpm (61~9 Ib.fl. )

Check that aH parts are clean and I·ubrica,te ~Iiding

surface·s wi,th oil before assembling . Always use new F}g. 2-19. Rear end of engine

gaskets, split 'Pins and lock washers. No adhesive 1. Dowe l pin 6. Sea Ii ng ri ng
2. Care plug 7. Crankshaft
shoulld be U'se1d on the g,aske~s . Se1arling at the ends 3. Sealing flange B. Plug
of both the oil pump del,ivery pipe and the water 4. Circlip 9. Dowe l pin
5. Pilot bearing
pump pipes is provided by rubber rings. These rings,
which seal ra·d ia·lly, are made of spe'c ia,1 rubber with
very close tolerances. Only genuine Volvo parts
shou-Id be used. fiitting is facilita,t ed by coating the
ring's with soapy water. Slip the rings on the pipes
and then pre'ss them ,into their 'c orrect positions be-
cert-ain sequence, see Fiig. 2-17, to avoi·d unnecessary
fore finalHy tightening the a,t taching screws. The oil
stresses. The bolts should be tight ened in two stages.
pump flonge shou.ld lie flush against the cylinder
Check that the oi,1 hole (Fig. 2-18) for lubricating the
block berore tightening . Crankshaft sea'ls at the front
rO'c ker arms is open .
and rear ends Irespeotively ·are insta,Med accord'ing to
The pilot beoring (5, Fig . 2-19) should be lubricated
the instrudions gli ven on page 2 : 15.
be.fore foitting wi,th heat-resista.nt boM bearing grea·s e.
When reconditioning, replace the connecting rod, bolts
The be,aring and protecting washer ore·· held in posi-
and nuts with new ones.
tion :by a cirdip (4).
The reinforcing bracket at the flywheel casing is fitted
The most important bolts and nuts should be tightened
occording to Point 2 "Fitting" on page 2 : 6.
with a torque wrench, see "Tightening Torques" in
The cylinder head is firt ted with the help of guide
"Spe'c ifications".
dowe·ls SVO 2435. The bolts must be tightened in a

VALVE GRINDING AND DECARBONIZING

Removing the cylinder head
l. Drain off the coolant from the radiator and cylin-
der block.
2. Remove the choke wi're and al,1 the hoses from
the intake manifoid, carburettors and air cleaner
casing. Remove the throtHe controi shaft from
the pedalshaft, the 'Iink rods and brocket.
4. Remove the heat con tro I valve hose from the en-
gine. Remove the upper radiotor hose.
5. Take off the ignition leads from the spa'rk plugs
and the electric cable from the .temperature tell-
tale.
6. Unscrew the preheating plate ·from the exhaust
manifO'ld as weH as the nuts for the exhaust mani-
fo ld flange .
VOLVO
7. Remove the tensioning iron of the oHernator from
103364
Fig. 2-18. Öi l hole in cylinder head the cylinder hea·d.

2: 10
8. Remove the rocker arm casing and the rocker
a rm shaft. Wt out the push rods. Unscrew the
bolts for the cyl,inder head and lift oH the head.
R'emove the manifold from the cyl,i'nde'r head.
9. Recondi,tion the volve system a'ccording to the
description given under the he,ading "Cylinder
Head And Yalves".

Fitting the cylinder head

l . Check to make sure that the cyl'inder hea,d and
block as we il as the pistons and cylinder liners
are dean.
Fig. 2-20. Va lve seat width A=2 mm (0.08")
. Check that the oilway (Fig. 2-18) for the rocker
arm mechanism is clean on the tappe1 side. In
the cylinder head the oil goes up through the bolt
hole, between the boH and the waH cavity and guide. The clearance with a new va,lve must not
~hen through an oblique drill,ing to the attaching exceed 0.15 mm (0.006"). Also check thC't the valves
boH for the rocker arm shaft and final ly up the are not excessively worn. See "Speoifiications"
shaft. under the headings "Yalve System" and "Wear
Mount the manifold on to the cylinder head. Place Tolerances".
the cylinder head gasket and cylinder he'ad in
posi,tion . (Dowel pins SYO 2435 can be sui1ably Cleaning
used for this purpose.) Fit the bolts and tighten With rotating brushes dean the valves, the combustion
them according to the tightening sequence given chambers and the oillways from cmbon and combus-
in Fig. 2-17. tion deposits.
N.B. The bolts should be tightened in two stages.
2. Fi,t the push rods in position and mount the rocker Grinding the valves and valve seats
arm mechanism. Adjust the valve dearance, 0.50-
l . Grind the volves in a machine a~ter they have
0.55 mm (0.020-0.022") for both the exhaust and
been cleaned. Fiit new vCllves if the old ones are
intake valves.
excess,ive,ly worn .
3. Fit the rocke'r arm casing. Fit the ol,t ernator ten-
2. Grind the va,lve seats. Use an el'ectricaHy driven
sioning iron to the cyl,inder head.
glrinder or a hand miHing cutter. A pilot spindle
4. Fit the 'nuts for the exhaust manifold Hange and
must be wrefully fi#ed before work is sta'rted and
aIso the preheating plate.
any worn gu,ides must be repl'aced with new ones.
5. Fit the throttle controi and choke wire, also con-
The sea,t should be ground until a good sea,ling
nectall hoses to the intake manifold and car-
surface is obtoined. The angle is 45 0 and the
bureHors. Fi,t the air deaner cover with hoses.
width of the sealing surface is approx. 2 mm
6. Connect the ignition leads and e,ledric cable for
(0.08" ), see "A" Fig . 2-20. If the sealing surface is
the temperature teH-tale.
too wide after g'rinding, it can be 'r educed by
7. F,it the hose for the heater contro~ valve and the
U'sing a 70 0 grinding stone from the inside and a
upper radiator hose. Fill with coolant.
20 0 grinding ston e from the outside.
8. Check the function and also for leakage. Fill if
3. Coat the va,lve sealing surfa'ce's with a ,thin layer
necessary with coolont. Adjust the valve dearance
of fine grindin,g paste and lap in the valves
if required. The cylinder head bolts need not be
against their seats.
subsequenrt-Iy tightened.
Then clean the valves and seats and check that
good sealing i's obtained.
CYLINDER HEAD AND VALVES
Dismantling Replacing the valve guides
l . Remove the va,lve spnings by first compressing 1. Press out the old guides wirth ~ool SYO 2818.
them with valve pliers and removing the valve 2. Press in the new gui,d es using drift SYO 2819,
collets, after which the pliers are released. Place which gives the correct pressing-in depth. See
the valves in order in a valve rack. Remove the Fig. 2-21.
va lve guide seais. 3. Check that the guides are free from burr and that
2. Measure the dearance between the stem and the valves move easily in them.

2 : 11
 SV02818

SVO 2819

VOLVO
103269

VOLVO
103 271 Fig. 2-22. Valve calle! and valve guide sea I
Fig. 2·21. Replacing valve guides
1. Metal ring 3. Washer
A= 17.5 mm (0.689") 2. Rubber seal 4. Valve coli et

Assembling
l. Check that the parts are in good condition and
clean. Test 1'he springs to ensure that they main- CYLINDER BLOCK
talin the values given in the "Specifications".
Measuring cylinder bores
2. Place the valves in position. Fit the valve guide
The cylinder bores are measured with a special dial
seal, spring, washer and collet.
indicator. Measuring should be carried ovt just below
the top edge of the bore on,ly ·in the transV'erse direc-
Replacing the rocker arm bus hes and tion of the engine .
grinding the rocker arms A letter is slamped on each cylinder bore indicating
l. If wear amounts to 0.1 mm (0.004"), replace the the classifiwtion of the bore and piston (only on
rocker arm bush. Use tool SVO 1867 for pressing standa·rd modeois).
the bush out and in, se'e Fig. 2-23. Then ream the
bush with a suitable reamer until an accurate fit
on the shaft is obtained. The hol e in the bush
shoul·d coinoide with the hole in the rocker arm .
2. If necessa-ry, grind the pressure pad of the rocker
arm in a special machine .

Adjusting the valve clearance

The va'lve clearance can be adjusted satisfactorily
with the eng,ine stationary, irrespective of whether the
eng,ine is cold or warm. The cle,a rance is the same
for both the inlet and exhaust valve. When adjusting,
use two feeler gauges, one "Go" 0.50 mm (0.020") thick
and the other "No-Go" 0.55 mm (0.022) thick. The
clea'rance is adjusted so that the thinnest gauge Gan
be inserted ea·sily while the thicker one must not enter.
When the piston in No. l cyl,inder is at top dead
centre (the compression stroke), valve Nos. 1, 2, 3, 6,
7 cind 10 (counted from the front) are adjusted, and
with ,t he piston in No. 6 cylinder ·a t top dead centre,
valV'es Nos. 4, 5, 8, 9, 11 and 12. Fig. 2-23. Replacing bush in rocker arm

2: 12
 VOLVO
103270
Fig. 2-24. Marking on pistons and cylinder block

PISTONS, PISTON RINGS

AND GUDGEON PINS
Measuring the pistons
The pistons are measured with a micrometer at right
angles to the gudgeon pin hole 2.5 mm (0.098") from
the lower edge on the piston marked 71/4 on the
Fig. 2-25. Fitting the piston
crown face. On late prod. pistons marked 71/9 the l. Fitting ring SYO 2823
corresponding measurement is 12 mm (0.47").

Fit of pistons in cylinders

The fit of the pistons in their respective cylinders is clearance at a few points. See "Specifications" for
tested without ,the piston rings being fitted. The clear- the proper measurements.
ance at right ongles to the gudge.on pin hole is
measured with a feeler gauge 1/2" wide and 0.05 mm IN A WORN CYLINDER BORE
(0.0020") thick attached to a spring balance. The force When checki'ng the fit in a worn cylinder bore, the
applied should be 1 kp (2.2 Ib.). This gives the aver- rings must be checked at the boMom dead centre
age value for piston clearance. When the above- position where the diameter of the bore is smallest.
men~ioned force is opplied, the pis·t on clearance ob-
ta'ined is equal to the thi'ckness of the feeler gauge Assembling and fitting the piston
used. Feeler gauges which are 0.04 mm (0.0016") or and connecting rod
0.06 mm (0.0024") thick can, therefore, also be used. When assembling, make sure that the piston is turned
The test is carried out at several different depths.
correctly so that the slo1 on top of the piston faces
Standard bore cyl,inders have a letter stamped on forwards as shown in Fig. 2-24. If the piston is turned
which shows the dimen·sions, and the pistons concern- the wrong way, this will cause a ·loud noise. The
ed shou,ld be marked with the same letter. number marking on the connecting rod should be
turned to face away from the camshaft side. The
Piston ring fit gudgeon pin is then fitted, the cirdip placed in posi-
IN A NEW OR RE-BORED CYLINDER tion and the piston rings fitted.
1. Push down the piston rings one after another in Use piston ring g,rips when fitting the rings. The
the cylinder bore. Use a reversed piston to ensure compression rings are marked "TOP" and the upper
tha·t .the rings come into the correct position. ring on each piston is chromed. Place the bearing
2. Measure the ring gap with a feeler gauge. The shelIs in position.
gap should be 0.40-0.55 mm (0.016-0.022"). If Turn the rings so tha.t the g,aps do not come directly
necessary, the gap can be increased with the help under one another. Then lubricate the piston and
of a special file. bearing surfaces.
3. Check the piston rings in their respective grooves Use fitting ring SYO 2832, see Fig. 2-25, when fitting
by rolling them in the groove. Also measure the the piston in the cylinder bore. Tighten the connecting

2: 13
 Fig. 2·26. Replacing bush in connecting rod
1. Drift SYO 1867

rad bolrl's with a to·rque wrench, see "Specifications"

VOLVO
for the correct tightening torque. 22902
Fig. 2-27. Bearing journal

Gudgeon pins
The gudgeon pins are available in oversize 0.05 mm
shou'l,d be carried out at several points round the
(0.002") larger than the standard diameter 22.00 mm
cireumference and along the longitudinal axis of eaeh
(0.866"). If the gudgeon pin hole in the piston is worn
journal. Out-of-roundness on the main bearing journal
50 much that 'an ave·rsize is necessary, the hole should
should not exceed 0.05 mm (0.002"), and 0.07 mm
first be reamed out to the eorreet measurement. Use
(0.003") on the big-end bearing journals. Taper should
a ·reamer fitted with a pilot guide andonly take small
not exceed. 0.05 mm (0.002" ) on any of the journals.
cuts at a t ime.
If the values obtained are close to or exceed the wear
The fit is correct when the gudgeon pin can be pushed
limit mentioned abave, the crankshaft should be
thmugh the hale by hand with light resistance.
ground to undersize. Suit,able bearing sheiis are avail-
able in five undersizes. The mea5U'rements eoncerned
CONNECTING RODS are to be found in the "Spec ifiwtions".
Replacing the bus hes Check that the crankshaft is straight to within 0.05 mm
If the old bush in a eonnecNng 'r ad is worn, press il (0.002") by using a dial gauge. The crankshaft is placed
out by using drift SVO 1867 and press in a new bush on two V-blocks and a dial gauge placed against the
with the same ,tool, see Fig . 2-26. Make sure that the centre bearing journal after whieh the crankshaft 15
lubricating holes index with the hol,e s in the eonnect- rotated. If necessary, straighten the orankshaft in a
ing rod. Then rea m the bush to the eorrect fit. The press.
gudgeon pin shou'id slide through the hole under light
thumb pressure but without any noticeable looseness.
Grinding the crankshaft
Before the orankshaft is ground, a check should be
Straightening
made to ensure that it is straight, this being don e as
Before being fitted, the eonneeting rod should be
described previously. Grinding is carri.ed out in a
che'Cked for stmightness, twist and any S-distortion.
special machine whereby the main hearing journals
Straighten them if necessary. Nuts and boltsshould
and the big-end bearing journals are gro und to iden-
be rep'laced wirth new ones when recondi·t ioning is
tical measurements. These measuremen ts, which are
being earrried out.
given in "Specifiications", must be carefulrly followed
in order to ensure correot c1earan'ce with ready-
CRANKSHAFT machined bea'ring she,lls.
After the erankshaft has been c1eaned, its journals On no account must the bearing sheiis be shaved or
must be measured with a micrometer. Measuring the bea.ring caps fi'led.

2: 14
The fillets at the ends of the journals should have
a radius of 2.0-2.5 mm (0.080---D.l00" ) on alll journals,
see Fig. 2-27. The width measurement (A) for the
pilot bearing depends on the size of the journal and
should be ground in order 10 ob1ain the correcl
meaSUirement.
After grind ing has been COImpleted, all the burr should
be carefully removed from the oilway openings and
all the journals lapped with a fine grinding paste to
t he finest poss ible surface finish. The crankshaft should
the n be washed. All the oilways shouId be cleaned
w i,th particula'r tholroughness in order to remove any
metal chippings and grinding residue .
VO LVO
103366
Fig . 2·29. Fitting sea li ng flange

Bearing sheHs
In addition to standard sizes, bearing shelIs are avail- Pilot bearing for clutch shaft
able in undersizes of 0.010" and 0.020". The rear main
The pilot bearing circlip and protecting was her are
bearing shelIs are provided with flanges and have a
removed, and the pilot bearing pulled out with tool
larger width relative to the ir size. If the orankshaft
SYO 4090 and checked after having bee n washed in
has been ground to the correct measu re ment, the right
white spirit. If the bearing is worn, it should be re-
bea,ring clearance is automaticallly obtained when the
placed with a new one. Before fitting, pack the bear-
bearing shell 'c oncerned is fitte,d . The bearing shens
ing with heat-resistant ball bearing grease . The bearing
mu,s t not be shavedand the caps must never be filed
is fitted with drift SYO 1426, afte r w hich the protecting
in order to obtain a closer bearing fit.
washer and circlip are fitted .
The bolts should be tightened with a torque wrench,
see "Specifications" for the t ightening torque.

REPlACING THE CRANKSHAFT REAR

Oll SEAl
Grinding the flywheel
l . After having removed the gearbox, clutch and
If the wear surface of the flywheel is uneven or burnt,
flywheel from the engine, rem ove the two bolts
the surface can be ground in a saddle-mounted grind-
for the oil sump in the sealing flange. Slacken
ing machine. Not more than 0.75 mm (0.03") of the
one of the two bolts on each side so that oil
origlinai thickness must be ground off.
surap pressure on the sealing flange will not be so
great. Remove the sealing flange.
2. Press out the seal w ith the help of the drift for
tool SYO 2817. Use a suitable cushion for the
sealing flange to prevent it from being damaged.
3. Press in the sealing ring w ith tool SYO 2817, see
Fig 2-28.
N .B. First inspect the wear surface of the crank-
shaft.
The sealing ring can be fitted in three positions
with tool SYO 2817, see Fig . 2-32. Wi,th a new
crankshaH or a crankshaft with approved wear
surface, fit the seal in its outer position (fu lly
screwed in center bolt). With the wear mark on
the crankshaft, fit the crankshaft with the center
boH screwed out a couple of turns or completely.
4. Fit the sealing flange, its sealing surface being weil
cleaned, and a new gasket. (Oil first the sealing
ring .) The sealing flange should be mounted on
the crankshaft carefu,lIy, see Fig. 2-29. Use your
Fig . 2·28. Fitting oil seal finger to fit on the sealing lip.

2 : 15
 Fig . 2-32. Center spindle position on SYO 2816

be fi,Hed in its outer position (position l ). With

VOLVO

Fig. 2·30. Removing polygon hub

103279 a wear mark on ,the polygon hub, fit the seal
in position 2 (114 turns of center bolt screwed out).
With two wear marks on the hub, fit the sealing
in position 3 (center bolt screwed out ful/y). With
three wear marks, the polygon hub shovld be
REPlACING THE Oll SEAl IN TIMING
replaced with a new one.
GEAR CASING
5. Fit the polygon hub with tool SYO 2815, see Fig.
l. Empty the coolont from the system and remove 2-33. Before fittiRg, the sliding surfaces of the
the radiator and radiator gril/e. polygon hub should be greased. Note the mark-
2. Re'lease the fan belt. Unscrew the bolts for the ing, that is, the center punch marks on the crank-
pul/ey and the flywheel damper and remove the shaft end and polygon hub. Fit the center bolt
bolts. and tighten it to a torque of 7-8 kpm (50-57
3. Remove the center bolt and take off the polygon Ib.ft.).
hub with pvl/er SYO 2814, see Fig. 4-30. (Firstcheck 6. Fit .the flywheel damper and pul/ey. Since the
to see whether it is po's sible to pu,1/ off the poly- bolt holes are not locoted symmetrical/y, fitting
gon huh by hand.) can only be done in one ,pos-ition.
4. Remove the oil sea!. Lubricote the sealing lip on 7. Fit the fan bel:t. The pul/ey belt should be so ten-
the new seal and fit the sea I with drift SYO 2816, sioned that it can be deflected 10 mm (3/8") with a
see Fig. 2-31. force of 11 .5-14 kp (25-31 Ib.) applied to the belt
N.B. Fi,rst inspect the wear surface of the polygon between the water pump pul/ey and alternator
hub. The oi,1 seal can be fitted in three positions pulley.
with tool SYO 2816. With a new polygon hub, Fit the radiator.
the center bolt of the tool should be screwed in
f ul/y, see Fig. 2-32. In this position, the seal will

VOLVO
10327B
Fig . 2-31. Fitting oil seal Fig . 2-33. Fitting polygon hub

2: 16
 VOLVO
103276
Fig . 2-34. Removing camshaft gear vOLVO
103277
Fig. 2-36. Fitting crankshaft gear

REPLACING THE TIMING GEARS

l . Empty the coolan,t from the system and rem ove the
radiator and radiator grille. Remove the fan belt
and fan.
2. Carry out operations 2-3 from the previous sec-
tion.
3. Remove the timing gear casing. Slacken a couple
of bO'lts extra for the oil sump ond observe due
calre that ,the sump gasket is not damaged.
4. Remove the camshaft nut and pull off the cam-
shaft gear with pu,IIer SYO 2250, see Fig. 2-34.
5. Pull off the crankshaft gear with puller SYO 2822,
see Fig. 2-35.
Screw out the oil nozzle, blow it dean and re-fit
it, see Fig. 2-38. The gears are lubricated from
this nozzle. VOLVO
103260
6. Re-fit the crankshaft with tool SYO 2815, see Fig. Fig . 2-37. Fitting camshaft gear
2-36.

SyO 2822

I
VOLVO
103275
Fig. 2-38. Markings on timing gears
Fig. 2-35. Removing crankshaft geor 1. Oi l nozzle 2. Markings 3. Dowel pin

2 : 17
 7. Re-fit the camshaft gear with tool SVO 2408, see 8. Re-fit the timing gear casing with gasket. The
Fig. 2·37. Both gea,r wneels should take up the t,iming geor casing is I'ocated in position by means
correct posi,tion relative to each other, see Fig . of the dowel pin. Carry out operations 5-7 from
2-38. When the timing gear drive markings are the previous seotion.
opposite each other, then the piston fo'r No. 6
cylinder is at top dead center, firing position . Do
not press the camshaH backwards so that the sea 1-
ing washe,r at the rear end loosens. Fit the nut and
tighten it to a torque of 13-15 kgm (94-108
POSITIVE CRANKCASE VENTILATION
Ib.ft.). OVERHAUL
The measuring values for the tooth flank c1earance At intervals of 40000 km (25000 miles), the nipple
and the camshaft aXile c1earance, which is deter- (1, Fig . 2-13) should be screwed out and c1eaned. At
mined by the spacing ring behind the camshaft the same time check the hoses and replace those in
gear, are given in the "Specifica:tions". pO'Or condition.

2 : 18
 GROUP 22

LUBRICATING SYSTEM
DESCRI PTION
The engine hals <l force -feed lubriwting system, see vari,o us lubricatin g poinrts. All the oil supplied ~o the
Fig. 2-39. Ppessure is ,provided by ,a gear pump d riven lubriw~ing points, therefore, first passes through .the
from the camshaft and fi1:ted under the crankshaft in oil filter.
the sump. The gear pump forces the oil past t he The engine is fi tted with an o il coole r for certain
rel,ief valve, whichis 0150 fitted on the pump, through markets.
the o il f,ilter and ,t hen <through oi'lways out to the

Fig. 2·39. Lubrication system

l. Oil pump
2. Sump
3. Nozzle
4. Oil filter

O ll PUMP, RELIEF VAlVE O ll FilTER

The oil pump, see Fig. 2-40, is ·o f the gear type and The o,i,1 f Mer (see Fig. 2-41), which is manufactulred as
is driven through a geQr train from the camshaft. a single unit complete with element, is of the full-
The delivery pipe from the pump to ~he cylinder How typ e ,and is screwed directlyinto the cylinder
hl,ock does not have screw unions and is, therefore, block. The oil which is fed out to the various lubricat-
automati'ca"'y tightened in posi,tion when :the aift,a·ch- ing points in the engine first passes through the oil
ing bol,ts for the pump are tightened. At each end filter element which is made of special paper. In the
of the pipe thereare sealing~i'ngs ma,d e of special oil filter there is a by-pass valve whichallows the
rubber. The relief valve ,is fitt.ed directly on the pump o,il TO by-pa'ss the element if resistance to flow should
and cons;~s of a spring-Ioaded ball. The ba:!1 has a become excessive. When ,replacing the filter, the old
cyHndricol guide with a stop at the end position and, one is discarded completely and a new one fitted .
therefiore, operates flexibly. Even at idling spe,e a
there ,is a ,c ertain amount of overflow, so thart the oil
pressure is then re'latively low.

2 : 19
10

9
2 3 4 5 6
VOLVO
103310
Fig. 2-41 Oil filter
8
1. Overflow valve 4. Nipple
2. Element 5. Gasket
3. Body 6. Cylinder block

7 6
VOLVO
1032i ..!

Fig. 2-40. Oil pump

1. Drive shalt 6. Strainer
2. Pump body 7. Retainer clip
3. Bushes 8. Driven gear
4. Driving gear 9. Spr ing for relief valve
5. Cover lO·. Va lve ball

REPAIR INSTRUCTIONS
REPLACING THE OIL FILTER fitting. Start the engine and check that there is no
leakage at the joint. Fill up with oil if necessary.
Together with the element and relief valve, the oil
filter (see Fig . 2-41) is screwed as a complete unit on
to a nipple fitfted in the cylinder block.
The filter should be replaced every 10000 km (6000
miles), when the old fiHer is discorcled.
1. Remove the old filter with the help of chain tongs,
see Fig . 2-43.
2. Coo,t the rubber g05ket (l, Fig. 2-42) of the new
filt-e r with oi,1 and make sure that the cont-a ct
surface for the oi,1 filter is free · from dirt. By
sme'o,ring it with oil, the gasket slklesinto better
contoct with the sealing wrface. Screw on the
filter by hand unhl it just touche's t he cylinder
VOLVO
block. 26493

3. Continue to screw on the oil filter a further half Fig . 2-42. Oil filter ready for fitting
turn by hand. Chain tongs must not be used when 1. Gasket (oiled) 2. Filter

2: 20
 Oll PUMP AND RELIEF VAlVE
Af ter the pump has been di's mantled and cleaned,
check that all the parts are ,in good cQnditiQn. Test
the re,lief va,lve spring (2, Fig . 2-44), see "Specifica-
tions" for the valu'es concerned.
Check that the tQQth flank clearance is 0.15-0.35 mm
(0.006-0.014" ), see Fig. 2-45.
Measure the end fIOlat, 0.02-0.10 mm (0.0008-0.0040"),
with a feeler gauge and a new CQver Qr the old Qne
if nQt nQticeably WQrn . If the bushes Qr sh af t are
worn, replace them with new Qnes. NQte that the
driving shaft with g'ear .is rep laced as a single unit.
The new bushes shQu,ld be 'reamed after pressing in
with areamer prQvided with a pilQt guide.
Fig. 2·43. Removing t he oil filter The sealing rings at the ends Qf the del,iv,e ry pipe
are made Qf special rubber and are manufactured
tQ very clQse tQlerances, see Fig. 2-47. Use Qnly
genuine VolvQ spare parts. The delivery pipe must
be clamped in its CQrrect PQsitiQn firs,t in the Qil
pump and then the Qil pump and pipe tQgether
clamped aga'inst the block. The pump cQnnecting
flange 'shQuld ,I·ie flushagainst the blQck befQre being
tightened. BefQre fitting the rubber rings Qn the pipe,
apply SQapy water since this enables the pipe tQ take
up its PQsitiQn mQre eosily. Top lightly Qn the pipe
with a SQft mollet if necessary.

VOLVO
Fig. 2·44. Oil pump 24747

1. Pump body 3. Gear

2. Spring for relief 4. Valve ball
valve 5. Hale for oil pipe Fig. 2·45. Measuring tooth flank clearance

2: 21
 u

VOLVO
2~65S

Fig. 2·46. Distributor drive position

A=opprox. 35°
Fig. 2·47. Delivery pipe sealing rings

OllWAYS FITTING THE Oll PUMP

Before hei'ng fitted, aM the oilways must be c1eaned When No. 1 cylinder is at ,t op dead centre, fit the
vefY thoroughly to a\'oid damage to the bearings, oil pump drive and dis~ributor. T,he sma ll part at the
beoring journa,lsand other components. groove is turned obliquely upwards-backwards and
To clean the cylinder block oilways, rem ove the the g'rOove set at an angle of 35 0 to the longitudinal
se,aling plug's. After aleaning and drying with com· ax is of the .en~ine, see Fig. 2-46 (A). Make sure that
pressed air, fi,t new plugs. the shaft goes ,down into its groove in the pump
shaft.
(N .B. When the ,timing gear marks are opposite each
othe,r, then the piston for No. 6 cy,linder is in the top
dead centre position, firing position.)

2: 22
 GROUP 23

FUEL SYSTEM
DESCRI PTION

,
Fig. 2-48. CarbureHors, B 30 A engine
1. Cold air hose 13. Hose for fuel fumes to 22. Throttle stop screw
2. Constant temperature device flap carbureHors 23. Air hose for crankease gases
3. Warm air hose 14. Venting filter 24. Hose for crankease gases
4. Temperature compensator 15. Air valve 25. Idle trimming screw
5. Front carbureHor 16. Vocuum hose for vacuum for air 26. ThroHle controi
6. Clasp for air c1eaner cover valve and dislributor 27. Bracket
7. Air c1eaner 17. Hose between fuel tank and 28. Th rotll e stop screw
8. Fuel hoses venting filter 29. Manifold with preheating
9. Temperature compensator 18. Vacuum hose for distributor chamber
10. Rear carbureHor (negative yacuum seHing) 30. Vacuum connec1ion
11. Hot start valve 19. Vacuum hose for brake servo 31. Idle trim ming screw
12. Hose between hot start valve 20. Choke wire 32. Throtlle by.pass va lve
and ve nting filler 21. Secondary throH le

The B 30 A engine is fitte,d with two horizontal ear- The carburettor consists of ,three mam parts of light-
burettors ,of type Swomberg 175 CD-2SE (Fig. 2-48), the aHoy, the middle pa1rt of whieh eomprises the carbu-
eonlskuction of whieh is shown in Fig's. 2-49, 2-50, 2-52 rettolr hou'sing. The lower section i,s made up of a
and 2-53. This type of carburettor has been designed floatchambe r, whieh encloses the jet and the float.
with a view to the exhaust emission eon~röl system. It is The upper 's ection consists of a suetion chamber eover,
provided with a fixed jet, pressed into the carburettor whieh fo'rms a suetion chamber together with a
housing, the fuel flow orifiee area of whieh is varied diaphragm fixe d in the air valve. The suction eham-
by means of a movable tarpered needle. The position be'r Iregulates the air va'lve lift and thereby the loea-
of the needle is determined by the carburettor hous- tion of the needle in the jet.
ing vaeulIm ope~arJ1ing an air valve in whieh the needle By means of c hanneIs in the valve, the suetion ehClm-
is fitted in a spring-Ioaded suspension. The spring force ber i,s I'inked to the spa,ee between the carburettor
always presses the nee,d le against the same side of throttle and valve.
the jet, and this ensures an aecurately oontrolled fuel Both earburettors are fi.tted with a temperature eom-
flow through the jet. pensator (8, Fig. 2-50 and 2, Fig. 2-53). This is eon-

2: 23
 1

3 1----~

10 2
4 8

5
4 7

6
6

.::;:7'----'- 8
7

VOLVO
103389
Fig. 2·49. Carburettor, front, from the left Fig. 2-50. Carburettor, front, from the right
1. Suction chamber 1. Venting channel from floatchamber
2. Throttle stop screw 2. Drilling for air supp ly under diaphragm
3. Lever 3. Sea led plug
4. Primary throttle 4. Drilling for air supply to temp. camp. and idle trimming screw
5. Drilling to vacuum side of by-pass valve 5. Stop screW for by-pass valve
6. Drilling for fuel-air mixture from by-pass valve 6. By-pass valve
7. Throttle spindle cam (for regulating secondary throllle) 7. Idl e trimming screw
8. Floatchamber plug 8. Temperature compensator
9. Floatchamber 9. Hydraulic damper
10. Fuel inlet

structed as an air valve reglJla,t ed by the carburetter level rises, the f loat lifts and, by maans ef the fleat
temperature and maintains the fuel-air mixture cens- arm (2) and tag, cleses the needle en its seating when
tantinespective ef the fuel temperature. the correct leve l has been attained .
The frent carburetter is previded wi,th a threttle by- The fuel gees threugh f.eur heles in the fleatchamber
pass valve (6, Fig. 2-50 and Fig . 2-58), the purpese ef plug and te the inside ef the jet, where the I,evel is
which is te direct aregulated flew ef fuel-air mix- the same as in the fleatchamber. Sealing between
ture past the carbure~ter thr·e ttle when th is is clesed fleatchamber plug and chamber is provided by an
at high speeds. O-ring.
This ,reduces pewedul·ly the V'elume ef nexieus exhaust
gasas preduced.
The throttle spindle's are previded wi,th s·e als te reduce
the wear on the spindies and bushes and alse te
elimina,t e air leakage.
The het-start valve (12 Fig. 2-48) is described en page
2: 28.
I't---+--S
The pesitive vacuum cennectien fer the ignitien distribu-
ter i·s leeated en the rea'r carburetter. 4

FLOAT SYSTEM
Fuel flows inte the flealchamber via the f1eat valve
(4, Fig. 2-51). The f1eat (l), wh ich is made up ef twin Fig. 2-51. Float system

expandedrubber Heats, is carried en a bridge on the l. Float 4. Float valve

2. Float arm 5. Venting channel from float-
lower side of the carburetter heusing. As the fuel 3. Float shaft chamber to air cleaner

2: 24
 13

12

11
10
.9
3

4
8

----7
VOLVO
103391
Fig. 2-53. Carburettor, rear, Irom the right

VO LVO
1. Sea led plug
104481 2. Temperature compensator
Fig. 2-52. Carburettor, rear, Irom the lelt
3. Fuel inl et
1. Attaching sleeve for choke controi 4. Idle tr im ming screw
2. Throttle stop screw 5. Lever
3. Throttle spindle cam 6. Primary throttle
4. Fast idle stop screw 7. Connect ion for vacuum hose
5. Connect ion lor choke contra I 8. Hydraulic damper
6. Cam disc lor fast idle
7. Floatchamber
8. Dri lling lor air supp ly to temp. camp. and idle trimming screw
9. Cold start device
10. Drilling lor air supply under diaphragm
11. Venting channel from Iloatchamber
12. Hot start va lve controi
13. Suct ion chamber

COLD START DEVICE AND FAST IDLE

To facilitate starting during cold weather, the rear
carbvrettor is fitted with a cold sta.rt device (Figs. 2-52
2-54 and 2-55).
The col:d sta rt ·devi'Ge Gonsists of a valve disc (3, Fig.
2-54) which is provided with four ·c alihrated holes and
an e.longatedopening as weil as a disc (4) mounted
on a spindle whichis operated by the .choke controI.
On the same spindie, ou.tside the ·o over (5), there is
a cam disc (6, Fig. 2-52) with oonnedion for the choke
controi pull wire. When the cold start device is
engaged, the valve disc tu-rnsand this links up the
channel (l , Fig. 2-54) from the floatchamber via one
or several of the calibrated holes to the channel be-
hind the valve disc and then the opening to the
channel (2), whi·ch tenminates in the venturi between VOLVO
103393
the vawum plunger and choke flap . Through this Fig. 2-54. Cold start device

lin k-up, rthe engine receives extra fuel (a richer mix- A. Co ld start device, disengaged B. Cald start device, engaged
1. From Iloatchamber
ture), to facilitate co ld starting. At the same time, 2. To ve nturi
less air is supplied by means of the choke device. 3. Choke lever
4. "Channei Disc"
When the choke controi is pushed in, the valve disc 5. Housing

2: 25
 VOLVO
103347
V OLVO
Fig. 2·55. Col d storti ng, principle 103 34 8

l. By·pass valve Fig. 2-56. Id ling , warm e ng ine

2. Id le trimming screw
3. Valve for temperature compensator
4. Bi·metal spring for tempe rature compensator
5. Suction ch omber
6. Spring
7. Damper piston
8. Diaphragm
9. Drill ing for air supply under diaphragm
10. Air va lve
11. Metering needle suspension
12. Dri ll ing for air supply to temp. comp. and id le trimming screw
13. Fuel jet
14. Carburettor housing (middle section)
15. Metering needle
16. Floatchamber
17. Rubber ring
18. Flootchamber plug
19. Drilling for cold sta rt fuel (Iocated in corb. opposite wall)
20. Dri ll ing for extra air through temperature compensator
21. Dril ling for extra air through idle trimming screw
22. In let chan nel for fuel mixing through by-pass va lve
23. Outlet channel for fuel mixing through by-pass valve
24. Secondary throttle
25. Primary th rottle
26 . Vacu um outl et for igni tion d istri b utor

VOLVO
103 349

Fig. 2-fi1. Normal running, with open secondery throllle

2 : 26
 nels in the plunger to the sudion chambe'r whieh is
2----i'-ll!;:;:.Ii seale,d from the main body of thecarburettor by the
diaphragm . The pressure difference between the un-
derside of the air valve, where theTe is pressure in
the carburettor inlet port, and the upper side of the
volve, where there is vacuum, causes the valve to
I,ift from the bridge. This also lifts the tapered me-
tering needle (15, Fig. 2-55), which is attached to the
plunger, out of the jet. The effective ehoke area widens
9 and inereases the fueI flow. See Fig. 2-57.
10 As the vacuum in the engine induction manifold is
dependent upon the engine speed and load, a cor-
11
rect fuel flow is obtained under 0011 operating condi-
VOLVO
103636
tions.
Fig. 258. By-pass valve
Be'cOouse of the variable choke area between the
1. Adiusting screw 7. Diaphragm
bridge and the valve, the air velocity and pressure
2. Rubber ring 8. Outlet channel for
3. Cover fuel/air mixing drap aaross the jet orifice will always remain approx-
4. Nut 9. Valve
imately constant, thus ensuring good fuel atomization
5. Spring 10. Inlet channel far
6. Drilling to underside fuel/air mixing at all speeds.
of diaphragm 11. Primary lhrol1le

turns and closes the inlet to the channel. At the same ACCELERATION
time as the mm disc is operoted, the throttle flap To prov ide at any point in the throHle range a tem-
opening is also influenced in sucha way that turning porarily riche r mixture at the moment the throttle is
the cam disc opens the throttle through the fast idle suddenly opened, a hydrau,lic damperis arranged
stop screw (4, Fig. 2-52) and the lever, before any of inside the va,lve rod. The hydrau,lic damper consists
the cal,ibrated holes open the connection to the fuel of a plunger mounted on a ,rod. The plunger ope'rates
drilling. With this arrangement, the idling speed can in oil. When the throttle is suddenly opened, the
if necessary be raised by the driver of the vehicle vacuum in the suction chamber ,i ncreases rapid ly.
during the wmming-up period of the engine. When the air valve (10, Fig. 2-55) lifts, the damper
piston (7) is forced against its seat and oil is pre-
vented fr,om flowing past from the upper side the
IDLlNG lower side of the damper plunger, this retarding the
When the engine is idling, the vacuum in the car- movement of the valve (10). This temporarily results
burettor suction chamber i,s low and ,t he column bet- in a more powerful vacuum above the jet so that the
ween the air valve and the bridge will be small (see fuel-air mixture becomes for the moment richer.
Fig. 2-56). At this stage, the thicker section of the The downward stroke of the air valve is assisted by
the spring (6). The rod in the volve should be filled
metering needle is in the jet and thus on ly a small
quantity .of fuel, corresponding to idling ,requirements, to approximately with in a 1/4" from <the upper edge
with oil whieh is approved as "Automatic Transmission
is sucked into the engine. The tempe'rature compen-
Fluid, Type A".
sator (Fig. 2-55) is regula1ed by 'a bi-metal spring (4)
which influences a valves (3). When the engine is hot
and the temperaturein thecarbure,ttor 'rises, the valve
opens and air is supplied to the earburettor venturi EXHAUST EMISSION CONTROL SYSTEM
to compens·ate for the increase in the fuel flow, whieh The engine is equipped with an exhaust emission
is ob~ained .ciue to the aolteration in ,the fuel's visoosity, controi system in accordan,ce with the principle of a
see Fig. 2-56. fine adjustmept of the engine idling more complete eombustion which reduces the eontents
speed can be carried out wi h the id le trimming screw of carbon monoxide and hydrocarbons in the exhaust
(2, Fig. 2-55). gases to an acceptable level. This is achieved mainly
by a modified induation system that enables a more
exact and leaner mixture ratio between fuel and air
NORMAL RUNNING to be used.
With the opening of the throttle fia p, engine induc- How the system works is il,lustrated in Fig. 2-59.
tion manifold depression is transferred via the ehan- The intake manifold is fitted with a secondary throttle

2: 27
 Fig. 2·59. Exha ust em issio n contra I
syste m, principle of o pera tion
1. Intake manifold
2. Exhaust manifold
3, Secondary throttle
5. Carburettor
4. Primary throttle
6. Preheati ng chamber

· ,
Light load (preheating) Heavy load (direet inlet)

(3) at each carburettor. For normal driving (with low throttle facing the induction manifoid, see Fig. 2-60.
power output the throttJ,es (3) are dosed thus forcing The vacuum in the induction manifold depends on
the mixture of fuel and air from the carbure.ttors to a lhe engine load and speed.
cen~ral preheating chamber (6) where the intake At high vacuum, the vacuum valve is kept c10sed
charge is heated and thoroughly mixed, whereby a (Fig . 2-60). When the vacuum drops the valve opens
completely evaporated and homogenous mixture is and air is drawn through the venting filter and vacuum
ohtained. valve to the carburettor venturi . Fuel fumes stored in
When higher output is required, that is the primary
throtHes (4) are opened wide'r, the seconda1ry throttle's
(3) also open up and the mixture of fuel and air pas-
ses from the carburettors directly to the cylinders
without going through the preheating chamber.
No particularly accurate synchron izing of the ear·
burettors is required since they are lin ked to each
other through the intake man ifoid.

EVAPORATlVE CONTROL SYSTEM

AND HOT 'START VALVE
Vehides for the USA market are fitted with an eva-
porative controi system which prevents fuel fumes from Fig. 2-60. Evoporative controi system with controi rod (7) at id le
being released out into the atmosphere. Its function is 1. Fuel tank 7. Controi rod
2. Expans ion ta nk (co nn eeted to thrott le)
outlined in Fig. 2-60.
3. Yenting filter 8. Air eleaner
Fuel fumes formed in the fuel ,t ank, especially during 4. Air valve 9. CarbureHor
5. Diaphragm 10. Floatchamber
warm weather, are led to the expansion tank (2) and
6. Yalve (hot starl valve) 11. I ntake manifo ld
from there to the venting filter (3) where they are
absorbed by active carbon . The expansion tank is
located behind the protective wallboard in the lugg-
age compartment, se Fig. 2-64.
The venting filter (Fig. 2-62) is located in the engine
compartment on the right-hand side, see Fig. 2-67.
Fuel fumes from the f10atchamber (10, Fig 2-60) are led
via the valve (6) to the venting filter when the engine
has been switch ed on or during idling . Throttling shuts
off the connection between the venting filter and the
Hoat chamber so that the fumes trave I via the valve to
the air c1eaner (Fig . 2-61).
The air valve (.fig. 2-63) controls the connection
between the venting filter and the carburettor venturi.
The space above the diaphragm (l) is connected by a
line to the carburettor venturi on the side of the Fig . 2-61. Evaporative controi system with controi rad at running

2: 28
 VOLVO
104 388
Fig . 2-62. Venling filler
1. Foam plastic filter 7. Hose connection from
(replace every 40 000 km hot starl valve
=25000 mi les) 8. Conneclion lo Air valve
2. Plate (perforated) 9. Wire net stocking
3. W ire net (gauze) 10. Perforated pipe VOL VO
104464
4. Felt 11. Cannisler
5. Active carbon Fig. 2-65. Hoista ri valve, functi on, id li ng
6. Hose connection from 1. Throlt le lever 10. Air cleaner housing
expansion container 2. Valve controi 11. Valve housing
3. Screw for valve controi 12. Oullet to atmosphere
4. Locknut or venti ng fi Iter
5. Controi rad 13. Rubber rings
6. Hol start valve 14. Piston
7. Outlet to air cleaner 15. Thrust spring
8. Hose lo floatchamber 16. Controi rod
9. Rivet 17. Rubber seal

the venting filter follow the air into the engine and
take part in the combustion (Fig. 2-61).
The valve (6), which is known as the hot start valiv e,
is to be found on all veh icles with twin carburettors.
The difference between a valve used on a vehicle
with or without an evaporative controi unit is that
Fig. 2-63. Air valve
in the latter case there is no hose connected to the
1. Diaphragm
2. Connection for hose lo rear carb urettor
3. Connection for hose lo front carburettor
4. Va lve rad
5. Thrust spring
6. Connection for venl ing filler
7. Rubber sleeve
8. Valve
9. Va lve sea I
10. Housing

V OLVO
104445
Fig. 2-64. Expansion lank
VOLVO
104465
1. Fuel filling ·pipe 3. Expansion lank
2. Hoses lo fuel tank 4. Hose to venti ng fi Iter Fig. 2-66. Hoi slori valve, function, dri ving

2 : 29
 Cl Cold air
D Warm air
[(]] Temp. air
Fig. 2.67. Venting filter and hoses
Fig . 2·70. Constant air temp. device
1. Hose to fuel lank 7. Vacuum hose for dislributor
2. Hose to hot starl va lve and air va lve 1. Air eleaner 5. Flop housing
3. Brocket 8. Hose for fuel fumes to 2. Thermostat 6. Cold·air intake
4. Venling filter carburettor 3. Flap controi 7. Warmair inlake
5. Air valve 4. Flop 8. Heater plate
6. Vacuum hose to air
valve
outlet (12, Fig. 2·65), and the fumes are led directly out
into the atmospere when the engine is switch ed off or
idling .
The function of the hot start valve is as follows:
During warm weather and when the engine is warm,
a great deal of fuel fumes develop in the floatchamber.
These are vented through a channel, to the air cleaner
and resulting the engine obtaining a somewhat rich- II

ter" fuel mixture. This makes it difficult to start the

engine. To counteract this, the hot start valve is fitted
to the connection between the floatchamber and air
cleaner by means of hoses.
When the throttle is at idling position, the lever (1),
Fig. 2-65, presses against the valve controi (2). The
Fig. 2.68. Hose conneefians
piston (14) is thereby lifted to its upper position by the
1. Hose lo hot slarl valve
controi rod(16). The connection between the float-
2. Oullello air eleaner chamber and air cleaner is closed and fuel fumes are
3. Hose lo carburetIor floaIchomber
led direcfi,y out into the atmosphere through the outlet
(12). (On vehicles fitted with an anti-fume device, the
fumes are led from the outlet (12) to the venting filter.)
When the accelerator pedal is depressed (See Fig.
2-66), the lever (1) releases the valve controi (2) and
the piston (14) is pressed by the spring (15) against its
lower position. The outlet (12) is shut off, the fuel fumes
are led into the air cleaner, and when the engine starts
running, further through the carburettor and into the
engine combustion chambers.
If it is to function proper/y, it is important that the
hot start valve is accurately adjusted so that it has
proper contact with the carburettor lever.

Al R CLEANiER
VOLVO
105229
The air cleaner (Fig. 2-69) functions both as a cleaner
Fig . 2·69. Air cJeaner for the intake air and as an intake silencer. It is fitted
1. Air eleaner housing, upper seclion with a replaceable paper insert. This insert must not
2. Air eleaner housing, lower section
3. Cleaner be washed or moistened. At the recommended inter-

2: 30
val, 40000 km (25000 miles), it should be discarded 9
a nd replaced by a new none. o
The engine is fitted with a constant air temp. device, 11
see Fig . 2-70. (Not, howeve r, on vehicles with right- 12

hand drive.) This device consists of a flap housing (5),

a hose (6) for cold air and a heat-resistant hose (7)
for warm air as weil as aheater plate (8), which
is secured to the exhaust pipe. The thermostat (2),
13
fitted in the flap housing, is inserted in the air cleaner 14
housing and regulates the flap (4) by means of the ~T7't-----15
Hap controi (3). The warm air taken at the exhaust 16
pipe and the cold air taken at the front of the ve- 11
hicle are regulated by the flap, mixed. The tempera-
ture of the mixture then influences the thermostat. In
this way, the air supplied to the carburettors is main-
tained at a constant temperature (30±5° C=87±42° F).
This arrangement el im inates the occurrence of ice form- Fig . 2·71. Fuel pump

ing in the carburettors. Thanks to this system in con- 1. Lower pump housing 10. Strainer
2. Pin 11. Inlet pipe
junction with the temperature compensator, the vehicle 3. Circlip 12. Plug
can be driven more or less irrespective of the tempera- 4. Return spring 13. Inlet valve
5. Lever 14. Diaphragm
ture of the atmosphere. 6. Outlet pipe 15. Diaphragm spring
7. Outlet va lve 16. Guide
8. Diaphragm 17. Rubber sea I
FUEL PUMP 9. Cap
The fuel pump is of the diaphragm type and is driven
by a cam on the camshaft. When the rocker arm in
the pump is p ressed upwards by the cam, the dia- side of the diaphragm exceeds the spring pressure
phragm is pulled downwards and fuel is drawn up and pumping action ceases. A diaphragm (8) is fitted
to the pump. When the rocker arm returns, the dia- in the upper section of the housing and its purpose
phragm is pressed upwards by a spring (15, Fig. 2-71) is to obtain a more even flow of fuel to the float-
and fuel is fed to the floatchamber in the carburettor. chamber. The diaphragm compresses the air in the
When the level in the floatchamber is sufficienHy cap (9). When the diaphragm (14) sucks fuel, the com-
high, the float valve closes and the pressure in the pressed air above the diaphragm (8) maintains the
delivery line rises until the pressure on the upper pressure in the line to the floatchamber.

REPAI R I NSTRUCTIONS
The carburettors are specially set by the manufacturer Also check that there is no air leakage on the intake
and fine-adjusted with a CO-meter at the factory. side and that the air cleaner is not blocked. To be
In order not do disturb the setting of the carburettors, on the safe side, check also the flap function of the
it is absolute l1Y essentiai that the following repair in- constant air temperature device. {See page 2:38.)
structions are accurately followed when any work is The function of the throttle controi and throttles
to be done on the carburettors. should be checked as weil. It should be noted here
that the engine drops its idling speed, alter the engine
PERIomCAL CHBCK speed has been raised, somewhat more slowly than
Every 10000 km (6000 miles) check that there is o il with a carbu rettor without a by-pass valve.
in the damper cylinders (see, Fig. 2-73).
The spindle in the piston should be filled to about a SETTING THE CARBURETTOR
1/4" from the upper edge with oil approved as "Auto- The best setting of the carburettor is obtained by
matic Transmission Fluid, Type A". using a CO-meter.
Before any adjustment or repair to the carburettor is However, the setting can be checked without the use
carried out, the following sh ou Id be checked and, if of this meter, but if the checking with either of these
necessary, remedied: methods results in unsatisfactory running of the engine
Valve clearance, spark pliUgS, compression, contact and it has been established that the fault is due to an
breaker (dwe ll ang le) and ignition setting. "ove rrich " carburettor or "too lean" fuel mixture, the

2: 31
 6z--g
---in
tttAlfi'
~L
r
r ==== 6 7 ----~

0--:
Or---9
6--" 3-0
~
·rl-- - - -·11 2
©'------s
4 9

,----i ~ l 1l
~
1,- - - - -

I 1 1 .l .

VOLVO VOLVO
103401 103400

Fig. 2-72. Upper section dismantled Fig . 2-74. Floalchamber dismantled

1. Spring 7. Screw for diaphragm 1. Screw for floatchamber 6. Float
2. Suction chamber cover 8. Washer 2. Floatchamber 7. Float pin
3. Sealing plug 9. Diaphragm 3. Gasket 8. Washer
4. Screw 10. Air va lve 4. Rubber ring 9, Float valve
5. Hydraulic damper 11. Metering needle 5. Floatchamber plug
6. Washer

carburettor nozzle should be adjusted with a special eoalant thermostat has opened. (One way of find-
tool in accordance with Workshop Bulletin P-08-13. ing th is out is by feeling the upper radiator hose
a~ the ra1diator which should start to get warm.)
SETTING WITH OUT CO-METER 3. Adjust the engine spe,e d to aOOr.p.m. with the
1. Check that there is oil in the damper cylinders. throttle stop sorews (2, Fig . 2-49). The speed should
See under "Periodical Check". be adjusted to 700 r.p.m. for a vehicle wi,th auto-
2. ~un the engine warm. The adjustment shou,ld be matic transmission. (If the engine does not reduce
carried out wi~hin about lOminutes after the i,ts idling speed, see under the heading "By-pass
valve".)

____ l

VO LVO
103637

Fig. 2-73. Checking the damper ail

Fig. 2-75. Setting the controi
1. Damper piston
2. Oil approved as "Aulomalic Transmission Fluid, Type A" A=O.l mm (0.004")

2: 32
- -- - - - - -- - - - -

Fig. 2-76. Throttle controi

l. Bush 7. Ball ioin! VOLVO

103732
2. Link rad for pedal 8. Lever Fig. 2-77. Funnel for exhaust evacuation
3. Controi shaft 9. Lock wire
4. Lever 10. Stop for lever
5. Link rad 11 . Bracket
6. Locknu!

N.B. Screw equaHy for both carburettors. Check

to make sure that both carburettors have the When mea'suring with a CO-meter, it -is important that
same air valve I-ift. This is checked easily by simp ly the carburettor temperature is the correat one. When
making sure that the distance visu-ally between the the engine is idling, the floatchambe-ris exposed to
bridge of the carburettor housing and the air va,lve he-at radiation from the exhaust man ifold whi-Ie the
is the same for both carbureHors. A more accurate How of cald fu-el through the floatchamber is small.
synchron iza,tion is not reqvired . The resultant rise in temperoture -c avses an increase in
4. Adjust wi th -t he idle trimming screws 7, Fig. 2-50 the fuel flow through the jet due to the alteration in
from the basic setting, which is 2 screwed-ou·t turns the visoosity and the increase in the CO-value. Ra-cing
of the screw so that the best idling speed is the engine speed cools ,t he carburettor to a certain
obtained. Screw equdly for both carburettors. extent due to the step up -in the fuel How. The tempe-
5. Adjust the ,Iink rods. With the controi against its rafure can be checked to make sure that it is not
stop on ,t he manifold braeket, rthe link rods should excessive by fee ling the floatchamber with the hand.
be adjusted so that there is a dearance of about It should "feel cald", that is, it moreor -less should not
0.1 mm (0.004") between the lever and the primary exceed room temperature.
throttle spindle flange. See Fig. 2-75. Before reading off the CO-meter, briefly revy up the
6. Adjust so that the valve controi of the hot start engine so that the air valve is in the proper position.
va-Ive is aga'inst the carburetrtor lever with the In order to be cerIa·in -t hat the measu-red CO-valu'e is
valve piston in the upper position and the throttle wrred, measuring should be carried out within lhe
controi at idle. (See Figs. 2-65 and 2-66.) time period mentioned above.
Lubricate the contact surfaae with Molykof.e and There are a number of different types of CO-mete-rs
check that the engine returns to idling speed after availab le w hich function with acceptab le accuracy.
briefly revving-up several times. The instructions on their use accompany each meter.
7. Setting ,the fost idle: PlJlI out the choke controi Note thait when connecting the hose for evacuating
23-25 mm (arlmost l ") so thatt the mark on the the €xhaust gases, the hose must not be placed so
rapid idle cam comes opposite the centerline of that the exhcwst gases are completely evacuated from
the rapid idle screw. the CO-meter connection to the exhau'st manifoid .
Then adjust the rapid idle screw to give an engine A funnel, see Fig. 2-77 could suitably be used here.
speed of 1100-1300 r.p.m . With the funnel installed, the suction at the connec-
tion would not be so g'reat as to upsert the measuring
SETTING WITH CO-METER bUlt sufficient -t o suck up the exhaust gases so that
The setting should be made at a temperature of 60- they clo not fill the workshop.
80° F and must be made within 8 minutes after the When doing any measuring with the CO-meter, it is
coolant thermostat has opened. Warming-up should important that the exhaust pipe and silencer are in
be done with a completely cold engine. good condition, that is, they do not leak.

2 : 33
 11 10 9 8

VOLVO
103402 VOLVO
\0373\
Fig. 2-78. Cold-slarl device
Fig. 2-79. Temperalure compensalar
1. Rubber seal 7. Screw for cover
2. Rubber seal 8. Cross-slofled screw
3. Valve 9. Adjusfing nuf
4. Bi-melal spring 10. Housing
5. Cover 11. Marking
6. Screws for femperafure
l. Check thai there is oil in the damper cylinders. compensator
See under "Periodical Check".
2_ Connect a tachometer and run the engine warm
at 1500 r.p.m. until the coolant thermosta~ opens. check that the engine returns to idling speed after
(One way of finding this out is by feeling the upper briefly revving-up several times.
radiator hose at the radiator which should start to 7. Setting the fast idle: Pull out the choke controi
get warm.) 23-25 mm (almost l") sothat the mark on the
3. Adju'st the engine speed to 800 r.p.m. with the rapid idle cam comes opposite the centerline of
throftle stop screws (2, Fig. 2-49). The speed should the rapid id le screw.
be adjusted to 700 r.p.m. for a vehide with auto- Then adjust the rapid 'idle screw to give an en-
matic transmission. (If the engine does not reduce gine speed of 1100-1300 r.p.m .
its idling speed, see under "By-pass valve".)
N.B_ Screw equally for oo,th carbureftors. Check
tha,t bothcarburettors have the same air valve FAULTY CARBURETTOR FUNCTION
lift. This is easily checke,d by measuring with the l. Check to make sure that the reason for the fault
eye the distance between the carbureftor house in the function is notf due to wrong damper oil or
bridge and tfhe ai'r valve. The distance should be oi'l ,level, impurities in the floatchamber or a faulty
the same for both carburertors. More accurate float va,lve and floalt. See the ,respective headings.
synchronization is not required. 2. Remove the air cleaner and cheå that the suction
4. Conned a CO"meter and check that the CO-con- valve('s) ope'rate eO'sily and without jamming. (The
tent is within the limits 1.5-3.5 %. With the hel p damper piston{s) removed.) If this is not the case,
of the idle trimming screws (7, Fig. 2-50) the CO- rem ove the suction chamber cover and dean the
content can be adjusted within small deviations. pistans. At the same time, check to make sure
(If the CO-content is too high, che'ck ~irstf the tem- the diaphragm is in good condition. Plug-seal
perafure compensator, see under "Temperature after fitting.
Compensator".) N.B. If the met,e ring needle mu'st be released or
5. Adjust ,t he link rods. With the controi against its moved, it shoul,d be adjusted, see under the head-
stop on the mani.fold bracket, the link rods should ing "Replacing the metering needle"_ A CO-meter
be adjusted so that there is a clea,rance of about is recommended for this purpose.
0.1 mm (0.004") between the leve,r and the flange
of the primary throttle spindl'3. See Fig. 2-75.
6. Adjust so that the valve contral ,of the hot-start Temperature compensator
valve ,is against the ca-~burettor lever with the 3. Should there be a powerful drop in the idling
valve pistonin the upper position and the throttle speed during idling for a lengthy pe'riod, especi-
controi at idle. (See Figs. 2-65 and 2-66)_ ally when the weather is warm, check the function
Lubricate the contad surface with Mo'l ykote and of the temperatu're compensator by removing the

2: 34
 Check th e funotio n by r unn~n g the engine briefly
up to about 2 000 ,r.p.m . The eng,ine sho uld then
return to idling speed . (Note that the eng ine will
return to ,idle somewhat slower than is the ca se
with a carburettor wi,thou,t a by-pO'ss val",e.) When
correct fu'nction ,is obtained (that is, even the
function according to B), turn the screw a further
1/2 turn to ~ he ,Ieft.
B The valve does not ope n:

Ti r 11 10 9
Normally the air valve of the front carburettor
should go down to the bridge a li ttle after that
of ~he rear ca,rburetto r on racing the engine speed.
Turn the adjusting screw to the right until normal
VOLVO function is obtaine,d. If this not possible, replace
103635

Fig. 2-80. By-pass va lve the hy-pass valve complete, see under "Replacing
l. Gasket 7. Screw for cover the by-pass valve".
2. Housing 8. Cover N.B. When ad justing, do not press the adjusting
3. Gasket 9. Rubber ring
4. Diaphragm 10. Adiustin g screw screw inwards since the rubbe r ring (9, Fig. 2-80)
5. Gasket 11. Spring sealing between the screw and cover can drop out
6. Screws for by· pass va Ive
of posi,tion . Check for air Ilwkage by e.g . placing
a finger over the rubber ,ring hol'e.

plas,tic cover and pressing ,in the valve [3, Fig .

2-79). This should move under very light pressure
REMOVING THE CARBURETTORS
and return to its position without sticking. This
Remove the valve controi for the hot-start valve and
appl'ies at a temperature above 80 0 F. The valve
the air c1eaner. Remove ~he lin k .red ball joints from
starts opening at 70 0 -77 0 F.
~he carburettors. Tak,e .off the fuel hoses, vacuum hose
Pressing the valve inwnrds deteriorates the qUClltty
and ,c hoke wire.
of t he idle. If ~he valve has a tendency to be stiff
Remove ,t he nufs for the carburettors and take off the
in operation er if the compensafor is incorrectly
carburettors. Remove the proteation plates and
adjusted, the lartter should be replaced complete.
gaskets. Mask over tl1e intake holes with tape.
See under "Replacing the temperature compen-
sator".
For adjusting siaeken one of the cross-slotted
screws (8), for the bi-metClI spring and center the FITTING THE CARBURETTORS
valve so that i,ts function wil l be as above. If Cle an thegasket surface. Fit the protection plates,
necessary adjust as follows : new goskets and then the carbure#O'rs. Connect ~he
At 70-77° F the valve should just start to open. In boll joints, fuel hoses, vacuum hose and choke wire.
other words, the valve should be loose in its seat Make sure that the choke controi on thedashboard
at th is tempe'rature. is pushed in. Then secure the pull wire in the clamping
When checking the setting, remove the tempera- screw of the rapi,d id l,e cam. A~erthis dip on the
ture compensator from the carbvrettor and stere outer sleeve of the pull wire.
it a~ a temperature of 70-77 0 F until it has reached Fit the ai'r c1eaner and connect the hose for the
this tempera~u're . Adjust with the nut (9) for the crankcase ventil a,fi.on . Fit the valve controi for the
bi-metal spring. hotstart va lve. Adjust the carburettors, see under
"Setting the carburettors".

By-pass valve (front carburettor)

4. With faulty function of the by. pass va,lve, or if ,the Checkin g the secondary throttles
engine does not reduce speed at ·i'dle (Hrst check Che'ck to moke SlJre ~hat the secondary throttles are
that ,t he throttle controi is correctly adjusted) or centered and can be turned without jamming. Check
if ~he valve does not open, then adjust as follows: the locotion ["A", Fig. 2-81 ) of the levers. When the se-
A Engine does not reduce speed at idle: condary throttle i,s dosed, the distance "A" between
Turn the adjusting screw (5, Fig . 2-50) to the left the leve r pin and the 'i ntake man ifold flange should
until the engine reduces idling speed. be 2.7- 4.3 mm (0.11-O.17").

2: 35
 Fig. 2·81. Throttle position
Throttle position Fully open throttle
at law output
1. Secondary thrattle 2. Primary fhrottle
··A"=2.7-4.3 mm (O.l1-O .17")

Fig. 2·83. Dia phragm in a ir valve

CLEANING THE FLOATCHAMBER

The floatchamber is removed by unscrewing the f1oat-
chamber plug (5, Fig. 2-74 and the screws (l). Clean
REPLACING THE DIAPHRAGM
the gasket surfqae and fi,t a new rubber ring (4). Fit
l. Screw out the damper piston . Make line-up marks
the floa1chamber wi·th a new gasket.
on the suction chamber cover and carbu1rettor
N.B. Fit the f10atchamber plug before tightening the
housing. Remove the seal plug, release th e screws
floatchamber screws.
and 1ake off the suction chamber aover. Remove
the spring.
2. Pull up the air va.Jve with diaphragm . Remove the
FLOAT LEVEL
diaphragm by unscrewing the four sarews. Clean
Before che'cking the float level, remove the carbu,ret-
the air valve.
tor, invert tt and take out the floatchamber.
N.B. Observe due care that the metering "needle
The float is removed by wrefully breaking the f10at
is not bent or moved from its position.
sp,irndle from the bridge. The float is fitted with the
3. Fit the new diaphragm, see Fig. 2-83. The rubbe r
sloping side facing away from the carbu~ettor hous-
reg'i's ter shoul,d ht into the valve groove.
mg.
4. Move the air valve down and fit in the rubher
M the corred Hoatievei, . the top poin[ on the float
register as shown in Fig. 2-84. Fit the cover and
should lie 15-17 mm {0.59-O.67") and the rear edge
fill with damper oi!.
9-13 mm (0.35-0.51/1) above the sealing surface (see
5. Plug-seal the suction chamber cover.
Fig. 2-82). If the level is incorrect, adjust by bending
the tag at the float valve.
N.B. Do not ben d the arm between the float and the
pin .

VOLVO
103341

Fig . 2·82. Float level

A= 9-13 mm (O.3S---{) .Sl/1)
B = 15--17 mm (O.S9-O.67") Fig. 2·84. Diaphragm in carburettor housing

2 : 36
REPLACING THE BY-PASS VALVE
The by-pass valve is replaced complete. The valve is
removed from <the ca,rburettor by screwing out the
th ree screws (6, Fig. 2-80). Clean the gasket surface
and fit the new valve with gas~et (l). Carry out a
funet ion test. Note that the by-pass va'lve is marked
y on the cover.

REPLAC;; ING THE TEMPERATURE COMPENSATOR

The . tempemture compensator is replace d complete.
It is remove,d from the carburerltor by unsorewing the
screws (6, Fig. 2-79). Take out the old seal (l ) from the
carburettor and fit a new one. Pla'oe a new seal (2) on \&~~ö'
Fig. 2-85. Fitting the metering needle
the tempemtlJrecompensator an,d "'it the compensotor.
The temperaturecompensator is marked "60" (see 11,
Fig. 2-79).

W'ith any fault in the dampe'r plunger change i<t com-

plete.
If the damper deviceis to funetion correctly, then the
REPLACING THE METERING NEEDLE level of the damper oil must be correct (see Fig . 2-73).
After replacing the metering needle, the following The interval prescribed for the periodical check is
check with a CO-meter is recommended. 10000 km (6000 miles).
l. Remove the air valve from thecarbuirettor and
c1ean it.
2. Remove the needle by unscrewing ,t he lock screw
and pull the needle out with the spring suspen- ADJUSTING THE ACCELERATOR PEDAL
slon. The length of the long, vertical 'Iink ~or the pedal is
3. Before fitting the new needle, check that the adapted so that there is a deorance of l mm (0.039")
3. needle designation is Bl BE. between the throttle lev'er lug and ,the fuH throttle
The designa~ion is punched on the needle and can stop on <the oarburettors, when the a!ccelera<tor pedal
be read by pulling the needle out of the spring is fuHy depressed. With a fuliy depressed peda!I, the
suspension far enough to reveal the designation. force of if'he dri"er',s foet is taken up by ~he toe-plate
4. Fjt ,t he needle with the spring suspension so that withoutimposing unnecessary loading on the throttle
the ~Iat surface faces the lock sorew. The n,e edle controI.
should indine from the hol,es in the air valve, i.e.
in towards the air cleaner flange.
The needle should be inserted so far that the
plastic washer lies flush with the valve, se'e Fig.
2-83. Tighten the .lock sorew.
5. Fit the air valve in the carbvrettor. Plug-seal <the
suction chamber cover.

DAMPER DEVICE
If the engine does not reaet properly during accelerat-
ion, the reas on may be a faul.ty c1earance on the
damper plunger, the alCia'l clearanoe of which (see A,
Fig. 2-86) should be 1.1-1.9 mm (0.04"-0.07") early
prod. 0.05-1.1 (0.02"-0.04" ). The diameter on the VOLVO
103818
plunger should be 9.32-9.35 mm 1(0.36-0.37"). Fig. 8-86. Damper plunger clearance

2: 37
 2 3 456 7
VOLVO
10381 7
Fig. 2.87. ConslonI air lemperalure deviee flop
1. Thermostat 5. Flap
2. Lock 6. Hot air intake
3. Air cleaner connection 7. Cold air inlake
4. Flap contra I
Fig. 2·88. Cheeking Ihe flop fu nelion
1. Cold air inlake
2. Flap spindle
3. Tab
FLAP HOUSING FOR CONSTANT AIR 4. Flop
5. Stop for marking flop position at temp. below 58--77' F
TEMPERATURE DEVICE 6. Stop for markring flop position at temp . above 95-104' F
If the flap (S, Fig. 2-87) does not open, there will be 7. Hol air inlake

too high atemperoture for the intake air and this

will have a negative effect on the engine.
The flap shou 1d be closed for cold air a,t a tempera-
1 No c1eaning of any type should be carried out bet-
ture of 70-77° F and for warm air at 95-10So F. If ween the replacements. The insert must on no condi-
correot function is not obtctined, replace the flap tion be moistened or oiled.
housing with the thermo's tat complete. Increased fuel consumption is a sign of a blocked air
The flap ·I ocation can be checked wi:th the fia p hous- cleaner.
ing fitted in position. A small tab on the flap spindle
proje-ots from both sides of the housing (see 3, Fig.
2-88). The longitudinal pin for these tabs coincides FUEL PUMP
with thaI of the spindle and tums pamllel with the
Cleaning the strainer
spindie. In other words, the location of the flap can
When cleaning the fu'el strainer, unscrew the plug
be seen at different t·e mperatures by compa,ring the
(12, Fig. 2-71).
angle of a tabin 'relation to the stops outside the
housing.
The thermostat can he checked ,in ,Iukewarm water.
The flap should be closed for col,d air at 70-80 0 F
Checking condition of fuel pump
and closed for hot air at 9S-10So F. If correct func- Before </'emoving the fuel pump, check ,its condition
·tion is not obtained,change Ithe flap housing with w~th a fuel pressure gauge. Connect a pressure gauge
the1rmo'Stotcomplete. and run ,t he engine until the pressu.re no longer rises.
When fitting the flap housing, observe thai the ther- Stop the engine, check the presslJre and oompare with
mostatisloca.ted in the centre of the air flow and the the values given in "Specifications". Check also the
tightening screw for the hose clamp is on the upper pressure drop ofter the engine has stopped. If the
side of the flap housi·ng. pressure drops, this is a sign that the valves leak.

Removing
AIR CLEANER Disconnecl the connections for the fuel lines and screw
The insert shoul,d be :replaced wi·t h a new one every off the pump.
40 000 km (2S 000 miles), if the vehicle is driven in
areas with moderate air pollution . With driving in
ve,ry dust y areas, repla,c ement may have to be done Dismantling
more often . 1. Screw out the plug 1{3, Fig. 2-89) with strainer.

2: 38
 , 'Y-17
4 ------~f
-, .~ . y"~

:--)( ~
~
~~~-----16

:===============~~;~: ~~::
~13 Fig. 2-90. Loco!ion of inle! valve
YSSYI'
10-----------'l1ii'1iiliiI'
B-----·12
11-------~

VÖLVQ
103375
Assembling
Fig. 2.89. Fuel pump, dismantled
l. Fit th~ inlet valve, see Fig. 2-90, and the stop arm.
1. Upper pump housing 10. Rubber seal Tighten the screw, but on ly sufficiently so that the
2. Sealing washer 11. Lower pump housing
3. Plug with strainer 12. Lever pin spring lies weil against the pump body.
4. Inlet val'le 13. Circlip
2. Fit the spring (8) and guide (9), see Fig. 2-89. lever
5. Stop arm 14. Lever
6. Screw 15. Spring retainer on the rubber seal {lO with the flange facing 10-
7. Diaphragm 16. Return spring
wards towards the guide.
8. Spring 17. Screw
9. Spring guide 3. Fit the diaphragm unit in the upper section of
the pump. Press downwards so that the rubber
seal comes into its corred position.
2. Make line-up marks on the upper section and 4. Press down the diaphragm, move in the lever (14)
lower section. Screw loose the upper pa~t from make sure ttlOt it locates correctly in re,lation to
the lower part. the diaphragm rad. Fit the pin (12), circlip (13),
3. Remove a circl ip (13) fmm the lever pin 12). Press spring retainer (15) and spring (16).
out the pin, Pull out the lever (14) and the spring 5. Fit the upper seotion observing the line-up marks
(16). and secure it.
4. Remove the diaphragm with spr,ing (8), guide (9) 6. Fi,t the strainer and plug.
and rubber seal (10). lever the rubber sealover Test the pump. When installing, make sure that the
the nylon washer and then remov·e the spring. lever lo-catescorrectly above its cam.
5. Sorew loose the undersi,de from the upper section,
remove the stop a~m and the inl,e t valv·e (4). The
outlet valve cannot be re moved.
VENTING FILTER
The foam plastic filter (l, Fig . 2-62) should be changed
Inspecting every 40000 km (25000 miles). This is done by slacken-
Check the dtaphwgm and gasket for leakageand ing the bracket screws, lifting up the venting filter
the moving pants for wear. Replace damaged or worn and drawing Ollt the foam plastic filter. Fitting is in
parts. reverse order.

2: 39
 GROUP 26

COOLING SYSTEM
DESCRI PTION

Fig. 2-90. Sealed cooling system

GENERAL
The engine is water-'cooled and the cooling system is
of the sea led type, see Fig. 2-91. A fan cover mounted
on ,t he radia,t'o r improves the cooling function of the
fan. The fan is speed-regulated, a so-oaHed sl'ip-
coupling type (see Fig. 2-92), the function of which
is to ensu,re thalt the fan hlades do not exceed a
certain speed even if 1he engine speed is exceeded .
See Fig. 2-98. The five fan blades are mounted asym-
metrically to keep down the no,ise leve!. The fan
coupling consists of the casing (11, Fig. 2-92) in which
the fan blades (1) are secured with the bolt (2). The
casing (11) has two halves which, however, cannot
be separated for repairs, the fan coupling then
hei,ng reploaed .c omplete. The hub (8) ha's a light fit on
the water pump flong,e (6) and is loaked by means
of the center bolt (7). The hub is provided with o slip
dis'c of friation material (9) surrounrded by oi!. During
Fig. 2-92. Fan coupling
idling and at l-ow spe,e ds, the slipping i's insignificant,
9. Friction material
so that the fan provides an air current for satis-
1. Fan blade 5. Washer
2. Balt 6. Flange, water pump 10. Rubber ring fadory cooiing. When the ingoing speed (that of the
3. 0il 7. Center bolt 11. Casing
8. Hub
water pump) exceeds about 3500 r.p.m., the slipping
4. Seals

2: 40
 . ~.

Fig. 2-93. Water pump

l. Housing 5. Lock spring
2. Impeller 6. Shaft w ith ball bearings
3. Seal ring (integra l unit)
4. flange 7. Wear ring

increases (see Fig. 2-98). With this arrangement, the

fan speed should never exceed about 2500 r.p.m.
The fan noise output would then be .Iow compared
with a fan which runs at the same high speeds as the
water pump . Compared with this latter type of fan,
Fig. 2-94. Coolant flow, thermostat cJosed
the output loss Wfl-l be less for theslip-coupling type
l. Ta radiator 5. Di·s tributi ng pi pe
fan. 2. Thermostat 6. Water pump
A centrifugal pump, Fig. 2-93, takes care of the 3, Cy linde,' head 7. From radiator
4, By-pass pipe
aoolan,t cilrwlation and a twin operating thermostat
provides rapid warning up of the engine and con-
tributes to the engine maintaining the most suitable
t,emperature under alloperating con'ditions.
In order to achieve the desired effect with the sea led
cooling system, it must be welol filledand nort leak. the inner circuit (the by-pass). This circuit aovers the
As coolant, a mixture consisting of 50 % ethyl,e ne eng'in,e and ear heater. The thermostat is closed, that
glycol and 50 % wateris used all yea,r round. This is, the outlet to the radiator is shut off. The coolant
mixture provides protection against frost down to passes throughthe thermostat by-pass to the distribut-
minus 35 0 C (minus 32 0 F) and should be changed ing pipe (S, Fig. 2-94) in the cylinder head. This results
every other year, on which occasion the engine, radia- in a uniform cooling of the warmest parts in the
tor and expansion tank shou,ld be f.lushed with clean cylinder head . Even the pa,rts around the spa-rking
water. plugs me also cold and thereby maintained at a
If Volvo anti-frost for cars is used (it is red in colour), con'srfant temperature. The coolant surrounding the cy-
it should not be mixed with orthe,r types of anti-frost. linde'r waHs is circulated by means of thermo-syphon
action.

COOLlNG SYSTEM INNER CIRCUIT

(BY-PASS) COOLANT SYSTEM OUTER CIRCUIT
The oooling systel41 consists of two circuits, an inner When the coolant in the i'nner circuit reaches a suit-
and an outer one. When >the engine is warming up able temperature for the engine, the thermostat be-
aJ11d in very cold wemher when large quantities of gins to open during which time the by-pass between
heat are required for warming up the in,s ide of the the the nmostat housing and the pump is gradual'ly
ca'r, the coolant drculotes almost exclusively through dosed, see Fig. 2-95.

2: 41
 Coolant flows from the engine into the upper part
of ,t he radiator, is cooled and then sucked by the
pump out from the lower P01rt of the radiator from
where i<t is conveyed into the engine through the
distributing pipe.
An a,ir cu'shion forms in the upper part of the ex-
pansion tank and permits thecoolant to expand
w ithout involving any loss of coolant so that fhere is
alirsuotion at ~educed tempelm ture and v0'lume. This
arrangemenrt ensures that the coo,ling system is al-
ways filled with 'o oolant, thus minimiz:ing the risk of
confO'sion . When theco0'ling system is being topped
up, ,it will probably be diWculrt to preventair from
entering this syst'em . The air, howeve'r, is ,s ubsequently
separated and forced out into the expansion tank
where it is replaced by coolant from this tank. It is,
therefone, imp0'rt,a'nt to check the co0'lantlevel after
the system has been empti,e d and f illed with new
coolant.
The expansion tank cap is ' provided with a va lve
wnich open when the pressu're in the sysrtem goes up
to 0.7 atmospheric gauge. There is also a valve whi::h
opens when there is apartiai vacuum in the system
and admits air into the expansion tank.

VOLVO
103309

Fig. 2-95. Coola n! flow, !hermos!a! open

Concerning numbers abo ve, see previous figure

REPAI R I NSTRUCTIONS
TOPPING UP WITH COOLANT FILLlNG EMPTY SYSTEM WITH COOLANT
Topping up wi,th c0'olant, consisting of 50 % glycol Before fi,lling, flush the cool.ing sysrtem with elean
and 50 % water (al,1 year round) ,is done in the ex- water. When filling wi,th coolanrt, through the filler
pansion tank, when the I·e v,el has faHen to the "Min" opening on top of the r01diator, the heater oontrol
malrk. should be set at max. heat. Fil! the radiator to the
N .B. Never top up with water only. top and fit the cap. fill,1 O1lso tne expansion tank to
the "Max" mark or to max. 30 mm (1/8") above this
DRAINING THE COOLlNG SYSTEM mark. Run the eng·in e for several minu.tesat different
To drain the ooolling system, open a cock on the en- speeds. If necessary, top up with more coolant and
gine and rem ove the ,I0'wer radiotor hose. The expan- then fit the expansilon ,t ank cap. Alter driving for a
sion tank is ,e mptied by fint taking 'it off its mounting short .time, check the coolontievei and top up with
and holding it at a sufficient height tha,t the coolant more coolant since it takes some time before the
ru ns into the radia,tor. Another way to empty the system is complete,ly devo'i,d of air.
tank is by rturning it upside down.

2: 42
 VOLVO
103 672
Fig. 2-97. Fan bell le nsion
F= 11.5-14 kg (25-31 Ib.) A= 10 mm (apprax. 3/8")

VOLVO
)03386

Fig. 2·96. Expansion lank 6. Fill with coelant, see under "Filling empty system
with coelant". Start the eng.ine and check fer
leakage.
COOLlNG SYSTEM LEAKAGE CHECK
The cooling system is checked for leakage as fol-
lows : Remove the radiator cap and make sure that
the filling hole and sealing surface are clean . Con- REPLACING THE WATER PUMP
nect a cooling system pressure tester to the filling Remove the radiO't~r .. accerding to the instructiens
hole . given under "Replacing the radiator" and screw eff
Make a connection for the tester by drilling a hole the water pump. Clean the sealing surfaces ond re-fit
in a radiator cap, soldering a pipe to the cap and the pump with new gasket. Make wre when fi~ing
connecting a hoze between the tester and cap. that the sealing rings on the upper side ef the pump
Carefully pump the pressure up to almost 0.7 kg/cm 2 locate cenectly. Alse press the pump upwards against
(10 p.s.i.). Observe the pressure tester gauge. The the cyl·inder head exrtension unde'r the bo/lting, so that
pressure must not drop noticeably during 30 seconds. the sealing between the pump and cylinder head will
If it does, examine and remedy the leakage. be satisfactery. Make sure that the seal·ing rings of
the water pipes are not doma'g ed ond press in the
pipes thoreughly when aNaching.

THERMOSTAT
After being removed,the thermos~at can be tested In
a vessel con~aining hea·ted water. The thermostat
TENSIONING THE PULLEY BELT
shoul-d open and dos,e according to the values given
The pulley belt is tensioned se that it can be deflected
in "Specifiwtions". A faulty thermostat shovld be
10 mm (3/8") with a ferce ef 11.5-14 kg (25--31 Ib)
disca-rded. Usea new gasket when fitting the ther-
appolied toO the belt between the water pump pul:ley and
mostat.
alternator pulley. Fig. 2-97.
The amount of force appl,i,e d wil'l depend en the
lecation of the bolt in the oblong slet in the ten-
REPLACING THE RADIATOR siener. With the belt al the end of the slert (long
l . Remove the radiator cap and drain the system belt), the ferce opplied sheuld be 11 .5 kg (25 Ib) ond
of coolant by disconnecting the lower radiator with the bplt art the beginning ef the s'l ot (short bel·t),
hose. a ferce of 14 kg (31 Ib) sheuld be applied. If the
2. Remov.e rthe expansi,on tank with hose and empty bolt is located anywhere betwe,e n theseextremes, the
ou.t the Goolant. Remove the upper radiotor hose. ferce applied sheuld be proportienaHy within the two
3. Remove the bolts for the radiator and fan casing. limits given.
L'ift off the ra d,i a·t or. N.B. The aHemater must no.l be ohl,i quely loaded.
4. Place the radiator in position and tighten the bolts If an imn lever is used fer adjusting, it should be
for the radia·tor and fan casing. placed between the engine and the front alternator
5. Fit the radiator hoses os we,1I os the expansion end.
tank with hese. Note that if the lower alternator belt is not s,lockened

2: 43
when adjusting, there will be heavy stresses on the Fan speed, r.p.m .

drive end bearing shie'l,d. 400

On fitting a newbelt, final tensioning shou,ld be

ca'rried out a,Fter dr iving for about 10 minu,tes. This
will ensure a longer lifertime for the pulley bel~. 300

FAN COUPLlNG 200 o

v V -t--
t-- r-
V
The fon coupling fundion can be checke,d with a /'
stroboscope with variable blinking fr,equen'cy. Make
a mark on the fan and one the water pump puHey. 100 J/
1000 2000 3000 4000 5000 6000
Find out the speed rel,a tion'ship between fan and pulley VOLVO
105134

by me'a ns of 1he strobo'Scope. The fan speed should

Inpul speed, r,p.m. (waler pump)
follow the spee'd of the water pump according to the Fig . 2-98. Curve for fan coupling slip
curve given in Fig. 2-98.

2: 44
---------------~- ---

Part 3

ELECTRICAL SYSTEM
AND
INSTRUMENTS
 (ONTENTS
Group 30 General Repair Instructions
General ... 3:l Headlights . . .. 3: 26
Replacing the headlight insert ." 3: 26
Group 31 Battery
Replacing the bulb .... .... . . . ...... . 3: 27
Checking and adjusting the headlights . ' . 3: 28
Description ...... . . 3:l
Foglights ... . .. . 3: 28
Repair Instructions .. 3:l
Parking and flasher lights .' 3 : 29
Rear lights .' 3 : 29
Group 32 Alternator
License plate light . . 3: 29
Description ....... . ...... . . . .. . . .. .. . ... . . . 3:2 Side marker lights . . 3 : 30
Repair Instrllctions
Special instructionsfor work on alternator G roup 36 O ther Elecfricol Standard Equipment
equipnient .... . .... . .... . . . ... . 3:3 Description
Removing the alternator . ..... . . .. . . . 3:3 Directional indicator system ...... . . . ..... . 3: 31
Dismantling the alternator ...... . 3:3 Ignition switch .. . 3 : 31
Checking the dismantled alternator . . 3:4 Horn .. . ...... . 3 : 32
Replacing the rectifier diodes .. ... . 3:5 Windshield wipers 3: 32
Replacing the bearings .. .. ........ . 3:6 Windshield washer .... 3: 32
Replacing slip ring end shield O-ring 3:6
Switches ......... . 3: 32
Assembling the alternator .,. 3:7 Interior lighting .. ... . . 3: 32
Fitting the alternator .......... . . 3:7
Controi relays ...... . 3 : 33
Luggage/engine compartment I,ighting .' 3 : 33
Voltage Regulator
Fuses .. 3 : 33
Description Brake light switch .. . .. . . . . .. . . . . . .... . . . 3 : 33
Function . ... . . . . 3:8 Repai r I nstructions
Replacing the dir. indicator lever switch 3: 34
Testing the Alternator and Voltage Regulator Replacing the ignition switch ........ . 3: 34
General ......... .. . . .. . 3:9 Removing and adjusting the horn ring 3 : 34
Checking the alternator circuit . .. . . . .. .. . . 3:9 Windshield wipers ... 3: 34
Testing the battery . .. ... . . .. ... .. . . 3:9 Removing the switches .... . . . 3: 35
Checking the voltage drop .... . 3:9 Replacing the inte rior light bulb .,. 3: 36
Checking the alternator ..... . . . 3:9 Replacing luggage or engine compartment
Checking the voltage regulator .. . 3:9 light bulb . ................. . ... . 3: 36
Fault Tracing . .... . 3: 11 Replacing the brake light switch . . . . .. . . . . . . 3: 36

Group 33 Starter Motor Group 38 Instruments

Toois ................. . ...... . ... . 3 : 12 Tools ...... . 3: 37
Description . . .. . 3 : 12 Description
Repair Instructions Instrumentation .,. 3: 37
Removing ...... . ...... . . . 3 : 13 Speedometer . . . .. . 3: 38
Dismantling the starter motor . . . 3 : 14 Temperature gauge .,. 3: 38
Inspecting . . ... . ....... . .. ... . . .. . .. . 3 : 15 Fuel gauge ........ . 3 : 38
Checking the controi solenoid ... ... . 3 : 16 Voltage stabilizer ... . . . .. .... . . . . . . . . .. . . 3: 33
Replacing the brushes ............ . 3 : 16 Warning lamps ..... . . . . . 3: 38
Fitting t he self-Iubricating bushes .... . 3: 17 Repair Instructions
Replacing the field windings ... . 3: 17 Removing the combined instrument ....... . 3: 40
Assembling ..... . . . . .. . . .. .. . 3 : 18 Replacing warning lamps and instrument
Fitting ....... . ... . .. ... .... . .. . .... . . . 3 : 18 lighting lamps ... . .. . ................. . 3: 40
Remove the instrument base plate ........ . 3: 40
Group 34 Ignition System Removing the fixing plate for speedometer
Description and mileometer/trip meter ........ . ...... . 3: 40
Ignition coil . . ...... . .. . 3 : 19 Checking the speedometer cable .. . ...... . 3: 40
Distributor ..... . . 3 : 19 Removing and checking the temperature
Repair Instructions gauge ............... .. ................. . 3: 41
Distributor . .. . .. .... ... .. . .. . . . ... .. ... . . 3: 21 Removing and check in g the fuel gauge ... . 3: 41
Ignition setting . . .. . . 3 : 25 Checking the voltage stabi lizer . ....... . . . 3: 42

Group 35 Lighting Wiring diagram

Description ............ . . ... . . .. . . ..... . 3: 26
- - - - - - - - - - -- - - -

GROUP 30

GENERAL
The electrical system is designed for a voltage of regulator, starter motor, ignition system, lighting, re-
12 V. The equipment can be divided up into ,the fol- mai,ning electrical standard equipment and instruments.
Jowing main parts : Battery, alternator and voltage

GROUP 31

BATTERY
DESCRI PTION
The battery, Fig . 3-1, is placed on a shelf to the rig ht with a capacity of 60 Ah and with the negative pol e
of the radiator. The battery is a 12 V lead battery stud grounded.

REPAIR INSTRUCTIONS
REMOVING the plates. If the level is too low, fill up with distilied
water as necessary. Ensure also that the battery is
l. Remove the cable terminals from the battery ter-
thoroughly secure and the cable terminals firmly In
minal studs. Use a puller if the cable terminals are
position .
stuck to the terminal studs.
The cable terminal studs should be coated with a
2. Remove the securing bar and lift up the battery.
thin layer of vaseline to prevent oxidation.
3. Clean the battery with a brush and rinse it with
clean 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 termina l studs
with vaseline.

SERVICING
Ir. order for the battery to function satisfactorily, the
acid must be maintained at the prescribed leve!. VOLVO
J05433
Make sure that t he level is about 5 mm (3/16') above Fig. 3-1. Battery

3:l
 GROUP 32

ALTERNA~OR
DESCRI PTION

Fig. 3-2. Exploded view of alternatar

l. Brush holder 5. Stator
2. Isolation diades with holder 6. Rotor
3. Slip ring end shield 7. Drive end shield
4. Redilier (silicon diades) 8. Fan

The alternator is a three-phase, star-connected alter- The alternator has a rotating field (rotor) and statio-
nator unit which is located on the right-hand side of nary generating windings (stator).
the engine and is driven by a v-belt from a pulley on The rotor is of the c1aw-pole type with the field wind-
the crankshaft. ings fed over ~he slip rings. The construdion of the
rotor has made it possible for the alternator to have
The alternator has a rectifier built into the slip ·ring a max. speed of 15000 r.p.m.
end shield. This rectifier consists of six silicon diodes. The isolation diodes (2, Fig. 3-2), which are placed on
the outside of the alter.nator, have <two functions: They
prevent the battery fromdischarging through the regu-
lator and alternator field, and they provide a simple
means of operating the charging warning lamp.
B+ D- DF_. _ _ _~ The alternator is self-limiting (max. 55 amps.) and for
this reason a simple voltage regu lator can be used
with only voltage controI.

5
I
14 VOLT
....-- I---
+ /
I 50
/
40 /
. 4 I. /
30
/
I I 20 /
L. ___ ._._.~ 4
VOLVO
104374
10 I
/

Fig . 3-3. Alternatar inner circuit o

o 1000 2000 3000 4000 5000 6000 7000 8000 RPM
l. Stator 4. Redilier diades VOLVO
2. Rotor (field winding) 5. Isolation diades 10437:';

3. Slip ring and brush holder Fig. 3-4_ Alternatar output curve

3:2
- - - - - - - -- -

REPAI R I NSTRUCTIONS
SPECIAL INSTRUCTIONS FOR DISMANTLING THE ALTERNATOR
WORK ON ALTERNATOR l . Release ~he two screws holding the brush holder
EQUIPMENT and re move the isolation plate. Pull out the brush
l. When teplacing or fi,tting the battery, make sure holder.
that the new battery is connected with the correct 2. Remove the nut and washer. Lift off the pulley,
polarity. fan, key and spacer washer.
2. Never run the alterna,t.or with the main circuit 3. Remove the nuts and washers on terminal 61 and
broken . The battery and/or alternator and regu- the corresponding on the other side of the isolation
lator leads mustnever be disconnected while the diode. Lift off the isolation diode holder, Sl'le
engine "is .runn ing. Fig. 3-6.
3. No attempt should be made to polarize. the alter- 4. Mark the drive end shield, stator and' slip ring
nator since this is not necessary. end shield to avoid confusion when assembl ing.
4. When charging the battery while installed in Remove the four attaching screws.
the vehide, the negOi~ive battery lead should be 5. Remove ,the stator and slip ring end ' shield with
disconnected . the hel p of two screwdrivers, which are inserted
5. A rapid charger should n,o t be used a's a help in in two of the sockets between the stator and drive
starting . end shield, see Fig. 3-7.
6. When using an extra battery as an aid in starting, N.B. The screwdrivers may not be inserted
always conneot it in paralIeI. deeper than 2 mm (just over 1/16"), otherwise
7. When carrying out any electric welding on the the stator may be damaged.
vehide disconn,e ct the neg1ative battery lead as 6. Release the three screws holding the support plate
weil as all the altemator leads. The welding unit of the drive end bearing. Release the bearing
should always be conneoted as nem as possible by knocking the end of the sh art against a piece
to where the welding is to be ca~ried out. of wood, see Fig. 3-8.
7. Remove the nuts and washers for the diode-
holders.
8. Remove the stator and diode holders for the
REMOVING THE ALTERNATOR slip ring end shield .

l. Disconnect ~he negative lead to the battery.

2. Disconnect the leads to the alternator.
3. Remove the bolt for the adjusting bar.
4. Remove the bolt holding the alternator to the
engine block.
5. Remove the fan belt and lift the alternator for -
wards.

VOLVO VOLVO
104 469 104470
Fig . 3-5. Alternatar filled Fig. 3-6. Removing the isolation diades

3:3
 VOLVO
1044 i'l
Fig . 3-7. Disma ntling the a lter na ta r
VOLVO
103011
Fig . 3-9. Ch eckin g th e stator

CHECKING THE DISMANTLED diode holde r (with three diodes) must be replaced.
ALTERNATOR If any of the isolation di odes is faulty, replace the
STATOR holder, complete with isolation diodes.
Check the sta·t o r fo r any short-ci rcuiting. If one or If a diode tester is not available, the diodes should
be soldered loose (see page 3-6) and tested with an
several of the coils are burnt, there must be a short-
ohmmeter. The di odes should have high resistance in
ci rcuit in the stator. Con ned a test lamp (12 V. 2- 5 W)
reverse direction and low resistance in the flow direc-
between the stator plates and a terminal on the stator,
tion.
see Fig. 3-9.
If the lamp lights, the isolation between the stator
winding and the sta·t o r plates must he burnt out, in ROTOR
which case the stato r should be replaced . Check to make sure that the slip rings are not dirty
N.B. Only a 12 V, 2-5 W test lamp may be use d; or burnt.
110 or 220 V, D.C. or A.C. lamps may NOT be used. Check the winding for breakage or damaged isolation.
This a.p plies to a ll the alternator components. Measure the resistance between the slip rings, see
Check the diodes with a diode tester, see Fig. 3-10. Fig. 3-12. At 25° C (77° F) the resistance should be
If any of the redifier diodes is ~aulty, the entire 3.7 ohms.

VO LVO VOLVO
104472 103 0 12
Fig . 3-8. Remaving t he d rive end shield Fig. 3-1.0. Checking the diades

3: 4
 VOLVO
103015
Fig. 3·13. Checking the brush hold er

Fig. 3·11 . Cecking the isolation diades frame "_" brush. The lamp should g,ive a steady light
even if ~he brush or the terminal I,e ad i's moved.
If the brush holder does not meet the above require-
If the slip rings are dirty, clean them carefully with a ments or if the brush length is less ,than 5 mm (approx.
cloth. moistened in trichlorethy.lene. The slip rings 3/16"), then replace the brush holder.
can also be polish ed with fine sand paper. The brush length is measur.e d between the brush con-
If .the winding is faulty, the entire rotor must be re- tact surface and holder, with the brush resting against
placed. the spring, see Fig. 3-14.
Check the bearings. (The bearings should a lways be
replaced when the alternator has been dismantled.)

REPLACING THE RECTIFIER DIODES

BRUSH HOlOER l. Mark the leads connecting the stator to the di odes
Solder leose the leads.
Connect a test lamp between the brushes. The lamp
2. Place the new diode holder in exactly ,t he same
must not light.
position occupied by the old one. Ho ld the out-
Connect the test lamp between the DF-terminal and
going diode lead with a pair of flat pliers. (This
"+" brush. The lamp should give a steady light even
is to conduct the heat from the soldering point so
if the brush or the terminalcable is moved see Fig.
as not to damage the newdiode.)
3-13. Conned the .f.e'st lam p between the brush holder
3. Solder on the diodes, see Fig. 3-15.
N.B. The complete "+" or "-" diode holder must
be replaced even if only one diode is faulty.

VOLVO
VOLVO 103940
103014
Fig. 3·12. Check·measuring the rotor Fig. 3-14. Measuring the brush length

3:5
 Fig. 3·15. Soldering on the diodes

Use a well-heated soldering iron, minimum 100 W for

the soldering.
VOLVO
103017
Never change pla,c es for the two diode holders. The Fig . 3-16. Removing the bearing
positive diode holder i·s isolated from ~he frame by
means of isolation washers and sleeves and its diodes
a,re ma rked in red.
The negative diode holder is not ,i's olated and ils
REPLACING SLIP RING END
diades are marked in black.
SHIELD O-RING
l . Remove the O-ring with a steel blade with rounded
edges (for example, a feel·e r gauge), see Fig. 3-18.

REPLACING THE BEARINGS 2. Wash the groove clean .

Check that the hole in ~he bearing shield is not
DRIVE END SHIELD BEARING
blocked.
Removing
1. Place the rotor in a vice with soft jaws.
2. Pull the bearing off with a claw puller, see Fig.
3-16.

FiHing
l . Place the support plate on the rotor shaft with
the three el~vations facing the rotor winding.
2. Press the b~aring in with the help of a tubular
sleeve wni'oh presses on the bearing inner ring,
see Fig. 3-17.

SLIP RING END BEARING

Removing
l . Place the rotor in a vice with soft jaws.
2. Pull the bearing off with a claw puller.

Fitting
l. Press the bearing on with a tuhular sleeve which
presses on the bearing inn·e r ring. Fig. 3-17. Fitting the bearing

3:6
- -- --- -- -- - -- --

Fig. 3-19. Checking the alternator

VO LVO
103019
Fig. 3-18. Removing the O-ring

3. Fit a new O-ring. Fit the isolation diode, put on the nuts and
Lubricate the O-ring and the hole with mine'ral washers. Fit the brush holder.
oil or similar. 6. Fit the spacer washer, key, fan, pulley, washer
The O-ring should be replaced each time the alter- and nut. Tightening torque 4 kpm (29.0 IbJt.).
nator has been dismantled. 7. Connect a test lamp between B+ and the alter-
nator fra me. Swikh the termi,nals. The lamp should
light only in one direction, se,e Fig_ 3-19. Afte'r any
ASSEMBLlNG THE ALTERNATOR repairs, the altemotor should be test-run in a test
1. Fi~ the stator and the diode holders In the slip
bench.
ring end shield. (Do not forget the isolation
washers for the positive diode holder). Fit the
nuts and washers on the negative diode holder FITTING THE ALTERNATOR
screws. 1. Place the aHernator in position while fitting on the
2. P·ress the rotor into the drive end shield. Fit the fan belt at the same time.
three screws for the drive bearing support plate. 2. Fit the attaching bolts and tensioning iron with out
3. Fit together the rotor and stator sections. tightening up the bol,ts. Adjust the belt tension (see
4. Fit the attaching screws. Tightening torque 0.28- Part 2, Engine, Group 25) and secure the alternator.
0.30 kpm (2.0-2.2 IbJt.) N.B. Force may only be appli,ed ,,"o the ~ront end
5. Fit the plastic tub e and isolation washers on the of the alternaitor when adjusting the beH ten,sion.
sorews on which the isolation diode is to be moun- Fit the I'e ads to the alternator.
ted. 4. Fiit the balt tery I'e ad.

3:7
 VOLTAGE REGU LATO'R
DESCRI PTION
~_--o .(61)

~--1-+---O EXC (OF)

-(O -)
VOLVO
VOLVO 104376
103297
Fig . 3·20. Vollage regulator fitled Fig. 3.21. Inner wiring of regulator
SI Voltage wi nding
S2 Acceleration wi nding
R1 Regulator resistances (2)
la Q ± 10 %
The regulator, Fig . 3-20, is a twin contact regulator R2 Oomping resistance
30Q ± 10 %
with a fixed upper contact, a movable contact and a R3 Compensation
fixed lower one. The movable contact is attached to an resistance (adapted to
RT during manufactl're)
armature which is actuated byavoltage coil. The RT Compensatian
regulator also houses four res istors and one thermistor. thermistor approx,
4 Q af 25° C (17" F)'

FUNCTION When the reguloting voltage has been reached the

When theignition key is switched on, current flows arma,t ure is a#racfed by the cail. This ·o ause's the con-
through the charging warning lamp to +(61) on the taets to open and the fi,e'ld current must pass the re'si-
regulator. It is then conducted via the regulator sfances R1, Fiig. 3-21.
through the field winding to earth. If in spite of ~his, the voltage rises, the armature is
When the alternator starts rotafi.ng, alternating cur- drawn further down and the movable contact meets
rent is formed in the stator. This alternating current is the lower contact so that the field winding is eaMhed
rectified by the sil,ioon diodes and the di,r eet current at both ends, this causi ng the voltage to drop rapidly.
produced is re-fed via the regulator to the field wind- The cycle is repeated continuously so that the voltage
ing until the regu lating voHage has been reached. is maintained constant.

3:8
 TESTING THE
ALTERNATOR AND VOLTAGE REGULATOR
GENERAL CHECKING liHE AlTERNATOR
Fixed clamps should be used for all testing of the (In a test bench or in the vehicle)
alternator equipment. So-called crocodile damps Con ned up the alternato r as shown in Fig. 3-22. Check
should not be used as they have a certain ~endency to that the current through the field winding (ammeter C)
loosen . A loose lead can result in thealternator and is 3-3.5 amps. (If the current is not the corred one,
regula-tor being damaged. When about to con ned up then check the brush holde r and fiel d wind.ing .) Run
instruments, disconned the battery first. the alterna't or to a speed of 3000 r.p.m. (Engine speed
1500 r.p.m.).
The alternait or should then produce at least 48 amps
CHECKING THE AlTERNATOR CIRCUIT at 14 volts. (A furthe r load may be connected up in
Before carrying out any tests on the alternato r or order to maintain the voltage at 14 volts.) This applies
regulator in the vehicle check the battery and vehicle to a warm alternato r and an am bient temperature of
wiring system for damaged leads or insulation, loose 25 0 C (77 0 F).
or conroded lead te,rminals and poor eadhing. Check Measure the voltage at B+ and 61 when the alternator
the fan belt l( seePart 2, Engine, Group 25). Any of the charges.
above faults must be remedied before the eledrical The voltage should be 0.8-0.9 volt more than at ter-
checks can be started. minal 61, otherwise the isolation diodes is faulty
and should be replaced.

TESTING THE BATTERY

Test the battery with a hydrometer and battery tester. CHECKING THE VOLTAGE REGUlATOR
If the battery is not fully charged, remove it from the (Ir: a test bench or in the vehicle)
car and charge it or replace it with a new one if ne- Con ned up the alternator and regulator as shown in
cessary. A fully charged batt.ery which is otherwise in Fig . 3-23. Run the alternator at about a speed of 5000
good condition should always be used when testing . r.p.m. (engine speed 25000 r. p.m.) for 15 seconds. Then
read oH the voltage on the voltmeter. With no load
on the alterna10r, the voltmeter should read 13.1-14.4
volts with the r,egulator ambient temperature at 25 0 C
CHECKING THE VOLTAGE DROP
This test is made to check the leads between the alter-
(77 0 Fl·
nator and the batt.ery and also the battery earth lead.
The test should be carried out with a fully charged
battery in good condition. The batt,e ry terminals should
be weil cleaned and tightened. Load ,the alt,e rnator
with about 10 amps. Suitable load: Mainbeam lights
switch ed on. With the engine running and the alter-
+
nator supplying 10 amps., meawre with a suitable
voltmeter the voltage between the positive pole of
the battery and B+ on the a litern ator. If the voltage
at this test exceeds 0.3 volt, there is a fault in the
lead or contact, which must be remedied immedia- A
tely. After repairing the leads or contads, measure C
once again. With the same load as above, measure
the voltage drop betweenthe negative pole of the
batte'ry and the alt,e rnator terminal D-. Here the
voltage drop must not exceed 0.2 volt. If the voltage
drop exceeds 0.2 volt, check the battery earth lead, VOLVO
103054

the alt'e rnator contact with the engine and ,the engine Fig. 3-22. Wiring diagram for testing alternator

contact with the chassis. Aft·e r making ,the necessary A Alternatar DAmmeter 0--50 amps .
B Battery 60 Ah E Voltmeter 0--20 volts
repairs measure aga in. C Ammeter 0--10 amps.

3: 9
•
 16

+ 15
~"'"
~t ,t" ~,:,:,:::: ~

tt t,~ :":,:,,
B
-
::,:;:: ,:::;::: ~

14 """ "::'"
",:,: ",:, :::::: :;::::::;;,
~} ",:}: ?:::: ~,:f, ,;:::"

- "",;
"':::: }:,:
:},:
,:,:::,:,: :::::"'::::
A ;;;;:", ,,::, :":::: ,:,::::
{::, ,:::: :{
.... ,::" ,::::::: ,,:::::
13
-
:,:::':'
~

12
-20 o +40 -lo 60 +80
VOLVO
103040

VOLVO
Fig . 3-24. Voltage-temperature diagram for eold voltage regulator
103039

Fig. 3-23. Wiring diagram for testing voltage regulator

A Allernatar DAmmeter 0-50 amps.
B Baltery 60 Ah Voltage regulator nator. The engine should be turning over at about
C Voltmeter 0-20 amps . Warning lamp 12 volts. 1500 Lp.m. (3000 alternator r.p.m.) when the measur-
2 watts
ing i's being carried out. When the regulator ambient
temperature is about 25 0 C (77 0 F). the voltage should
be 13.85-14.25 volts. For other am bient temperatures,
see fig. 3-25.
Load the alternator with 10-15 amps, for example,
full-beam headlights, and read off the voltage. The
volt,a ge should also lie on this occasion between 11:'
13.1-14.4 volts. For ambient temperatures other than
25 0 C (77 0 F), see the diagram in Fig. 3-24.
If the voltage is outside the tolerance limits, the regu- 15·
lartor should be repla,ced.
If t,he voltage regulator is to be tested more accura-
tely, instaH it in the vehicle which should then be 14-
IIId ~

'.
"

~~
-~: "
driven for about 45 minutes at a speed above 50
km.p.h. (30 m.p.h.).
1'3 ~
The reason for the driving is to enable the regulator
to obtain the correct working temperature.
N.B. The vehicle must be driven. It is not sufficient
just to have the engine idling. 1'2
-20 o +20 +40 +50 +BO
Immediately after, or preferobly during driving, mea- ~gLoW
sure the voltage between B+ and D- on the alter- Fig. 3-25. Voltage-temperature diagram for warm voltage regulator

3: 10
- -- - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- -- - -----

FAULT TRACING
FAULT REASON

Alternator does . not charge. Worn or insuffidenllly ,tensioned fan belt.

Breakage in charging circuit.
Worn brus hes.
Breakage in rotor winding.
Breakage in isolation diodes.
Faulty regulator.

Charging weak or irregular. Worn or insuffi,oi,enl1ly tensioned fan belt.

IntermiHent breakage in charging circuit.
Worn brushes.
Breakage or short-cipcuiting in one or several rectifier
diodes.
(Breakage in a diode reduces the cha,rging current
about 5 amps. Short-circuiting in a d iode limi~s the
alternator charging current to 7-8 amps and causes
a 'rumbl,ing ~ound in the alrt,e rnator.)
Pa'fti a I short-circuiting in the rotor.
Breakage or short-circuiting in the stator.
Faulty r,egulator.

Too high charging. Faulty regulator.

Faulty terminals on regulator or alternator.
Short-circuiting in isolation diades.

Noise in alternator. Worn fan belt.

Loose pulley.
Worn bearings.
Short-circuiting in one or several rectifier diodes.
Alternator pulley incorredly aligned in relation to
the crankshaft pulley.

Charging warning lamp g lows. Voltage drop in fusebox.

3 : 11
 GROUP 33

STARTER MOTOR
TOOLS

EF 2722 EFAL3 EF 264J{ EF2649

VO LVO
103299
Fig. 3-26 Bosch special tools
EF 2722 Sleeve and drift for fitting circlip
EFAL3 Smoothing drift
EF2649/1 Smoothing drift
EF 2649 Drift for fitting bush

DESCRI PTION
The starter motor, Fig. 3-27, is fitted on the flywheel An extra confact is built into the solenoid for by-pass
housing on the left-hand side of the engine. It con- connecting of the pre-coupling resistor on the ignition
sists of a 4-pole series-wound motor. The pinion on coil.
the starter motor rotor shaft moves axially to engage
with the flywheel ring gear. The pinion is controlled
by a solenoid.

3: 12
 -

VOLVO
'21527

Fig. 3-28. Starter motor, general arrangement

DISMANTLING THE STARTER MOTOR 6. Unscrew the nut which holds the field terminal
connection to the controi solenoid.
l . Remove the small cover on the front end of the
7. Unscrew the attaching screws for the controi
shaft.
solenoid. Remove the solenoid.
2. Lift off the lock washer and adjusting washers
8. Remove the drive end frame and armature from
as shown in Figs. 3-31 and 3-32.
3. Remove the two bo l,ts holding the commutator the stator.
9. Remove the rubber washer and metal washer,
bearing end and remove the frame.
4. Lift up the brushes and holders. see Fig. 3-36.
5. Remove the bridge from the armature shaft. N.B.
The washers are as shown in Fig. 3-34.
When the bridge is 'r emoved, the H _ H brushes
foll ow a lso, but H + H brushes will remain in the
field winding.

~--------------- l

VOLVO
103301

Fig. 3-30. Starter motor terminals

VOLVO
103300 l. From battery 3. To fie ld winding
Fig. 3-29. Starter motor installed 2. From ignition switch 4. To ignition coil

3: 14
 VOLVO
101088
Fig. 3·31. Removing the lock washer
VOLVO
103302
Fig. 3·33. Starter motor with bearing frame rem ove d

10. Remove the screw on which the shift lever is car-

ried.
11. Lift the armature with pinion and arm out of the
drive end fra me.
The commutator should be checked with a micrometer
12. Knock back the stop washer and remove the snap
after turning. A radial throw of 0.08 mm (0.003") can
ring on the armature shaft.
be considered permissible. The insulation between the
13. Remove the stop washe'r and pu'I,1 off the starter laminations sh ou Id be milled down to 0.4 mm (0.016")
pinion.
below the surface of the laminations, see Figs. 3-38
and 3-39. This work is carried out in a special ap-
paratus, or if such i·s not available, with a ground-
Examine the armature for mechanical damage such as off hacksaw blade.
a bent or worn shaft, scored commutator and dam- Examine the armature for shorting by placing it in a
aged windings. growler machine. Switch on and hold a hacksaw
If the armature shaft is bent or worn, the armature blade a few mm from the armature, see ~ig. 3-40. If
should be replaced. the blade vibrates in any position when the armature
If the commutator is scored or unevenly worn, it is rotated, one of the following faults can be the
should be turned. The commuta,t or diameter must not reason : Shorting through the armature frame, shorting
be less than 33 mm (1.3"). in the commutator or between the windings.

VOLVO
103303
VOLVO Fig. 3·34. Starter motor with brush bridge removed
101 P87
Fig. 3-32. Removing adjusting washers l. Sleel wosher 2. Fiber wosher

3: 15
 Fig. 3-37. Armature with pinion
VOLVO
1m 304

Fig. 3.35. Controi solenoid

•
motor. If, on the other hand, it engages satisfactorily,
exarnine the starter switch and leads.
Check the stator wi,th 40 V A.c., see Fig. 3-41 . Exa-
When the controi solenoid has been removed, it
mine the drive end frame with brush holders. If any of
should be wiped dean. Then press the plunger in
these parts a're damag·e d or e~cessively worn, they
several times and test again by connecting it to a
must be replaced . Abearing dearance of up to
battery. If the controi solenoid does not function
0.12 mm (0.005") may be considered permissible.
after the above measures, replace it with a new one.
Inspect the other parts and replace any that are
damaged or worn. The snap ring should always be re-
REPLACING THE BRUSHES
placed with a new one, since when being removed it
may have been damaged or lost its tension. When replacing the brushes the starter motor is re-
moved and dismantled. The brushes are soldered
loose from their attachments in the brush holder and
CHECKING THE CONTROL SOLENOlD
field winding respectively. The new brushes should
If the controi solenoid does not function, first check
be soldered on quickly and with sufficient heat.
that the battery is in good condition. If there is no
Solder must not be allowed to run down into the
fault in the baUery, connect a lead between the
brush leads as this will prevent the movemenf of the
battery positive terminal and the controi solenoid
brushes in the brush holders and may reduce the
contact screw for the controi lead. If the controi
brush spring pressure. Brushes which have worn down
solenoid still does not en gage the starter pinion and
shorter than 14 mm (9/16") should be replaced with
main current, it should be removed from the starter
new ones.

VOLVO
10:1354

Fig. 3-36. Removing the sealing was her Fig. 3-38. Milling the commutator

3 : 16
 VOLVO
'l1547
Fig. 3-39.
Fig. 3-41 . Checking the stator
A. Incorrect milling B. Correct milling

FITTING THE SELF-LUBRICATING BUSHES REPLACING THE FIELD WINDINGS

The s'elf-Iubricating bushes are on ly worninsignific- l. If the starter motor has not been dismanHed,
antly during operation if ~hey are lubricated in the this must be done. Follow the insfructions under
correct manner. If lubrication is negl,ected, the bushes the heading "Dismantling".
dry out, with the result that they are worn quickly. 2. Mark the pol e shoes and pole housing in a suit-
For feplacement purpose, bushes are supplied ready- able manne'r so that they come in the same po-
machined to suitable dimensions. When being fitted, sition whenassembling.
the bushes should not be machined internally or ex- 3. Then place the stator in the rotary c1amping block
ternally since the pores can then be partially blocked as shown in Fig. 3-42 (Bosch EFAW 9) or similar
up, resu lting in r,educed lubricating capacity. and unscrew the pole screws.
l . Drive out the worn bushes with the help of a
suitable too I.
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, i,t
should lie in light oil for at least l hour.

Fig. 3-40. Testing the armature Fig. 3-42. Rotary clamping block for removing field windings

3: 17
 2

VOLVO
102 '168

Fig. 3·45. Lubricating scheme for starter motor

Use Bosch lubricant (or equivalent) in accordance
with the following directions,
1. Fl 2 V 3. Place a thin layer of grease on the insulation
washers, the shalt end, the adjusting washers and
lock washer .
YöWf/il 1 V 13. Place the bush in oi l for 1 hour before fitting.
2.01
Fig. 3·43. Stator with soldered brushes Apply plenty of grease in the rotor thread and the
3. Ft 2V 3.
engaging lever groove.
4. Ft 2V 3. Place a thin layer of grease on the armature shaft.
5.01 1 V 13. Place the bushes in oil for 1 hour before fitting .
6. Ft 2 V 3. Lubricate the engaging lever joints and the iron
core of the solenoid with a thin layer of grease.

4. Before fitting new field coils, these should be

heated slightly. Then place the po le shoes in
position in the field coils and slide ,them into the
2. Fit the starter pinion on the armature shaft, and
stator. Tighten the pol e screws slightly. Press in a
the wear washe r as weil as the snap ring . Secure
suitable drift. Set up the stator in the rotary clamp-
the wear washer in position .
ing block and tighten the pole shoes.
3. Fit the shift lever on the pinion. Fit the armature
5. Press out the drift with a press. Check the fi eld
in the drive end frame .
windings fitted for breakage and shorting.
4. Fit the screw for the shift lever.
5. Fit the metal washer and rubber washer in the
drive end frame.
ASSEMBLlNG
6. Fit the stator on the armature and the end shield.
l . Lubricat,e the parts of the starter motor according 7. Secure the solenoid in the shift lever. Screw tight
to Fig. 3-45. the solenoid.
8. Fit the washers on the armature shaft as known in
Fig . 3-34.
9. Place the brush bridge in position . Fit the brus hes.
10. Fit the commutator bearing frame. Screw the
starter motor together with the two through bolts.
n. Fit the adjusting washers and the snap ring on the
shaft end. Check the axial clearance of the arma-
ture. If necessary, adjust with the washers until
the play agrees with the values in the "Specifica-
tions".
I--~~- L·2 ~------I
12. Screw on securely the small casing over the shaft
1 .-.-----.--- ... ---- end.

~r----- .- . -.-. I--

J ---- ------. -.. - ........ /5. FITTING

--12+2 MM
I

l. Place the starter motor in position and secure il.

VOLVO
101065
2. Connect the electric cables.
Fig. 3·44. Press drift for fitting fi eld windings 3. Fit the lead terminal on the negatlive pol'e stud of
. D=66.04-66.09 mm (2.599-2.602") L=85 mm (3.346") the battery.

3: 18
 GROUP 34

I G N ITI O N SYSTEM
DESC RI PTION
The ignition sys'tem is of the battery ignition type. It
consists of the fol,lowing ma·in parts:
Ignition coil with advance engaging resistor, d istri-
butor, ignition leads and spark plugs.

IGNITI ON eOll
The ignition coil and advance engaging resistor are
fitted on the bulkhead, see Fig . 3-46. In order to make
sure that a completely satisfactory spark is obtained
at high speeds, an ignition coil is fitted which is
designed for a voltage lower than 12 volts. An ad-
vance engaging resistor is connected in series with the 2
ignition coil for the purpose of lowering the voltage
to the right value.
In orde'r to raise :the ignition voltage at t,he moment
starting takes place, the advance engaging resistor
is by-passed when the starter motor is engaged. The VOLVO
1033 13
ignition mi l is activa,t ed directly by the battery volt- Fig . 3-47. Distributor
age via a contact on the starter motor (se,e wiring 1. Primary connection w ith capacitor
diagram). The advance engaging resistance has a 2. Lubricator
3. Atlaching bo lt
resistance of 0.9 ohm. 4. Vac uum regulator

constructed 50 that during engine braking Of idling if

lo wers the firing during the basic adjustment. When
engine brak,ing or idling ,t akes place, the throttles
in the carburettors are closed so that there is no
vacuum in the connection from the carburettors (5, Fig.
3-49) so that the return spring (6) presses back the
primary diaphragm (7) against the stop (8). The pull rod
(2) which is secured to the primary diaphragm (7) frans-
VOLVO'
103312 mits the movements in the diaphragm to the breaker
Fig. 3-46. Ignition coil and advance engaging resistar
plate. If the vacuum in the connection from the intake
manifold (3) is sufficiently large, pull the secondary
diaphragm (4) from the stop (8) and this lowers the
DISTRIBUTOR firing during the basic adjustment.
The distributor is mounted on the left-hand side of During throttling, diaphragm (7) is influenced by the
the engine, see Fig . 3-47, and is driven from the vacuum in the carburettors and takes over the re-
camshaft. The setting of the distributor in relation to gulating function irrespective of the vacuum in the
engine speed is regu la,t ed by a centrifugal governor intake manifoid.
fitted under the break,e r plate. Adjustment in relation The positive part of the vacuum regulator is not used
to loading is controlled by a vacuvm regulator mount- in vehicles intended for the U.SA market. Only the
ed outside ,t he distributor (4, Fig. 3-47). negative part, which lowers the firing during idling,
The vacuum regulator has two d iaph ragms and is is used .

3: 19
 -----1

.. ~--------------2

~--3

~~--4

24
~~--5

23 -----
.-----6

21 ~---

20----
~-7
19 ----------,<~
8
18
17----

16~ -----9
....----10
15----
~--11
1w- - -
-------12
13- - -_ __
VOLVO
103369

Fig. 3·48. Distributor

7. Distributor housi ng 13. Spring ring 19. Centrifugal governor spring

l. Distributor cap
8. Cap damp 14. Flange 20. 8reaker cam
2. Distributor arm
9 Rubber seal 15. lubricator 21. Washer
3. Contact breaker
10: Fiber was her 16. Primary connection 22. Snap ring
4. lock screw for breaker
11 . Steel washer 17. Distributor shaft 23. Breaker plate
contacls
12. lock pin 18. Centrifugal weight 24 . Rod brush (carbon)
5. lubricating felt
6. Vacuum regulator

3: 20
 REPAIR INSTRU CTIONS

Fig. 3·50. Removing the vacuum regulator

VO LVO
103314
Fig. 3·49. Vacuum regulator
1. Eccentric for adjusting firing drop
2. Pull rod
3. Connection from intake manifold
4. Secondary diaphragm
5. Connection from the carburettors
6. Return spring from primary diaphragm Disconnect the lead from the breaker contacts
7. Primar}' diaphragm
and remove the primaryconnection, Fig. 3-51 .
8. Register
9. Return spring for secondary diaphragm Lift up the breaker plate.
3. Disconnect the springs for the centrifugal governor
and mark up how the breaker cam is located in
re lation to the distributor shaft. Secure the break-
er cam in a vice with soft jaws. Carefully knock
on the distributor housing with a plastic mallet
(Fig. 3-52) until the snap ring (22, Fig. 3-48) has
released.
DISTRIBUTOR
REMOVING
l. Release the lock clamps for the distributor cap
and lift of the cap.
2. Remove the prima,ry lead from the primary con·
nection (l , Fig. 3-47).
Remove the vacuum hoses from the vacuum re -
gulator. (When removing the hose from the bake-
lite connection, observe great care not to break
the connection.)
3. SIaeken 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 regu lator.
Remove ,t he vacuum regulator according to Fig.
3-50.
2. Mark up how the clamps for the cap are located
and remove them.
Fig. 3·51. Removing the primary connection

3: 21
 VOLVO
102979
Fig. 3·52. Removing the s nap ring
VOLVO
103317
Fi9. 3·53. Removing the driving collar

4. Remove the resilient ring (13, Fig. 3-48) and mark Distributor housing
up how the driving collar (14, Fig . 3-48) ·is located 1. The play between the distributor housing and the
in relation to the distributor shaft. shaft should not exceed 0.2 mm (0.008"). If the play
Tap out the pin (Fig. 3-53), lift off the driving is excessive, replace the bushes and, if thi s is
coll:Jr and pull up the distributor shaft. insufficient, also the shaft.
Check tha,t no washers haY'e been los,t.
5. Removethe lock springs for the centrifugal
weights and lift up the weights. ASSEMBLlNG
l . Lubricate the di stributor parts according to the
instruetions given in Fig. 3-55.
INSPECTING 2. Fit the centrifugal we ights and a lso the lock
Disfribufor plafe springs on to the weights. Fit the breaker carn-
l. The surface of the contact breaker points shou ld shaft on to the distributor shaft. Hook on the
be flat and smooth. The colour of the contaets
should he grey. Oxidized or hurnt contaets must
be replaced. After a long period of use, the con-
taet lip can be worn and the spring fatigLied, so
thaI the contaets should be replaced if the distri -
butor for any reason is disassembled.
2. The contad plate must not be loose, worn or
have burr on .

Disfribufor shaff
l . The play between the distributor shaft and the
breaker camshaft must not exceed 0.1 mm (0.004").
2. The cams on the breaker camshaft must not be
scored or worn down so that the dwell ang le is
al,tered.
3. The ho les in the centrifugal weights must not be
oval or deformed in any other way.
4. The centrifugal weight springs must not be de- VOLVO
103318
formed or damaged. Fig. 3-54. Distributar shaft with centrifugal weights

3: 22
 REPlACING THE CONTACT BREAKER
The contad breaker can be replaced with the distri-
butor fitted, but it should be done with the distributor
dismantled.
l . Remove the distributor rotor arm.
2. Disconnect the eledric lead at the primary con-
nection.
3. Remove the screw for the contad breaker and lift
6
up the old contacts.
4. Lubricate the distributor according to the instruc-
tions given in Fig. 3-55.
5. Fit the new contact breaker.
6. Connect the electric cable at the primary connec-
tion.
7. Check that the contad breaker IS located cor-
rectly both vertically and horizontally.
VOLVO
103370
Adjustment should be made with a suitable tool,
Fig. 3-55. Lubricating scheme far distributor (for example, Bosch EFAW 57 A), but only the
Use Bosch lubricant (or equivalent) according to below. fixed contad may be bent. Wash the breaker
1. Ft 1 v 4. Place a littl e grease on the contact lip contads with trichlorethylene or chemically pure
2. Ft 1 v 26. Grease
3. 01 1v 13. lubricate
gasoline.
4. Ft 1 v 4. A very light layer of grease Run the distributor on a test bench and check
5. Ft 1v 26. Grease
6. 01 1 v 13. Fill with oil according to the "Specifications".

TESTING THE DISTRIBUTOR IN TEST BENCH

l . Run the distributor in its ordinary direction of
springs for the centrifugal governor. Fit the washer rotation (anti-clockwise) and adjust the contact
and circlip for the breaker camshaft. The circlip breaker dwell angl.e according to the "Specifi-
is plaoed into position by means of a suitable cations".
sleeve. Fit t,he lubricating felt. Adjustment is don e by slackening a little 1he screw
3. Fit the distrihutor shaft in the distributor housing for the breaker contacts and then inserting a
and install the driving collar on the distributor screwdriverin the reGess, Fig. 3-56, and turning
shaft. Make sure that the fibre washers come the screwdriver until the dwell angle is the corred
against the distributor housing. Fit the pin in the one.
colla r and check the axial clearance on the distri- Then tighten the screw for the contact br.e aker.
butor shaft. The clearance should be 0.1-0.25 mm
(0.004-0.010")_ Any adjustment can be done by
altering the number of adjusting washers on the
distributor shaft.
Fit the resilient ring on to the driving collar.
4. Fiit the breaker plate. Fit the lock clamps for the
cap. Fit the primary connection and connect the
lead from the breaker contads.
5. Fit the vacuum regulator and conned the pull rod
to ·t he breaker plate.
6. Check that the breaker contads are mounted
corredly both horizontally and vertically. Adjust-
ment should be made with a suitabl'e tool, (for
example, Bosch EFA W 57 A), but only the fixe d
contact may be bent. Wash the contads with
trichlorethylene or chemiwlly pu,re ga.soline.
Run the distributor on a test bench and check VOLVO ···
103320
according to the "Specifications". Fig. 3-56. Recess for adjusting the contac! breaker

3: 23
 3. Run the distributor at low speed and adjust the
prol:ractor so that a marking ,is obtained a,t 00.
Connect the vacuum hose to the bakelite connec-
tion on the vacuum regulator (the primary dia-
phragm) . Increase the vacuum g-radually and read
off the values on the prescribed graduations. The
difference between the risingjfalling vacuum must
not exceed l V2 0 • A certain adjustment of the max.
reading can be obtained by slackening the screws
for the vacuum regulator and moving the re -
gulator.
4. Mov,e over the vacuum hose to the metal pipe on
the vacuum regulator (the secondary diaphragm)
VOLVO
103319 and check that the ignition drop mechanism is
Fig. J-57. Driving collar for centrifugal governor
functioning satisfactorily. If the max. drop is too
great or too small, it can be adjusted by slacken-
ing the counternut and by turning the eccentric,
2. Run the distributor and set the protractor on the see Fig . 3-58.
test bench so that a marking comes opposite 00
at such a low speed (below 400 distributor r.p.m.) FITTlNG
that the centrifugal governor does not function. l . Place the distributor in position .
Increase the speed slowly and read off the values 2. Press the distributor downwards while turning the
at the prescribed graduations. A newly lubricated distributor arm at the same time. When the distri-
distributor should first be run up to maximum butor goes down about 5 mm (3/16") and it is no
speed several times. Permissible tolerance for the longer possible to turn the distributor arm, the
centrifugal regulator is ± 10. driving collar of the distributor is then in the
If the centrifugal governor curve is too high or slot on the distributor drive.
too low, this can be remedied by altering the 3. Turn the distributor housing so that it takes up
spring tension in the centrifugal governor. To do the same position it had before removal.
this, the distributor must be dismantled and the 4. Connect the primary lead. Fit on the distributor
distributor shaft lifted up (the breaker camshaft cap.
does not need to be removed from the distributor 5. Start the engine and set the ignition. (If the engine
shaft). The screws holding the driving collar are does not start, turn the distributor housing until
then released, see Fig. 3-57. If the driving collar it does so.)
is turned in the direction of rotation, the curve
rises, turning the driving collar opposite the di-
rection of rotation will lower the curve.
N.B. The governor curve must not be adjusted
by ben ding the spring clamps of the driving coli ar.

VO LVO
VOLVO 105434
103321
Fig. J-58. Eccentric for adjusting max. ignition drop Fig. J-59. Flywheel damper with graduation for ignition setting

3: 24
IGNITION SETTING 4. Start the engine and run it at the r. p.m . gi ve n In

the "Specifications". Use a tachometer for this

Ignition setting shovl,d always be oa~ried out whi,le
purpose. Point the ignition setting lamp at the
the engine is running and with the help of a Strobo-
graduation on the flywheel damper. Slacken t he
scope.
distributor (3, Fig. 3-47) and turn it until the firing
l. Clean the flyw heel damper so that the graduation
position agrees with that given in the "Specifica-
marks are visible, see Fig. 3-59.
tions". Tighten securely the distributor and check
2. Remov·e the hoses from the vacuum regulator.
that the firing position and speed has not been
(The hose for the intake manifold should be shut
off by, for example, bendingit or by sealing it altered .
5. Remove the Stroboscope and re-fit the hoses o n
with a suitable plug, so that the engine does not
the vacuum regulator.
draw in unwant.edair.)
3. Connect the Stroboscope to No. l cylinder spark
plug and to the ba,t tery.

3: 25
 GROUP 35

LIGHTING
DESCRIPTION

VOLVO
103324

Fig. 3·61. Rear light

Fig . 3·60. Headlights and foglights

The lighting consists of two full- and dipped-beam Switching between full- and dipped-beam positions
headlights, parking lights, rear lights and number is done by moving the turn indicator lever switch
plate light. Vehicles intended for U.S.A. are also fitted towards the steering wheel. This causes the stop relay
with side-marker lights and for all markets except (Fig. 3-79) to connect up the lighting. Up front the
U.SA the vehicles are fitted with foglights. parking lights are integrally built with the turn indi-
The headlights are fitted in the mudguards and the cato rs and are mounted on the front bumper at the
foglights are housed in the front end, see Fig. 3-60. corners.
Vehicles delivered to U.S.A. have small grille cover- The rear lights are provided with separate bulbs for
ings over the recesses instead of foglights. Extra lights rear lights, stop lights, back-up lights and turn indi-
can be installed in these recesses merely by removing cators, see Fig. 3-61.
the covers.

REPAI R I NSTRUCTIONS
HEADLlGHTS 4. Release the screws for the inner rim a couple of
turns, see Fig. 3-65, turn the rim and lift it off
REPLACING HEADLlGHT INSERT
together with the headlight insert.
l. Remove the screw and tak e off the plastic cover
5. Remove the rubber cove r from the old insert and
over the space behind ,th e headlight, see Fig. 3-63.
fit it on the new one.
2. Remove the connecting contact by pulling it 6. Fit the insert and inner rim. fit the outer rim by
straight backwards. hooking the lower section in the spring wire
3. Remove the outer rim by pulrling i,t vpwards-for- hol,ders, then lift the rim stmight up and hook
words, see Fig. 3-64. it on secure ly.

3: 26
 2 3 4 5 6 7

Fig. 3-62. Heodlight

1. Ouler rim
2. Inner r im
3. Headlighl inserl
4. Rubber cover
5. Holder unit
6. Adjusting screws
7. Plastic cover
8. Conneclor
9. Spring w ire holder
10. Attaching screw

10 9 8

7. Adjust the light according to current legisiation.

Adjustment is made by means of the two adjusting
screws, see Fig. 3-62. Use approved light adjusting
equipment.
8. Fi.t the plastic cover over the space behind the
headlight.

REPLACING THE BULB

l. Remove the screw and take off the plastic cover
over the space behind the headlight, see Fig. 3-63.

VOLVO
104 478
Fig . 3·64. Removing the outer rim

VOLVO VOLVO
103325 104 479

Fig. 3-63. Removing the plostic cover Fig. 3-65. Screws for inner rim

3: 27
 2. Remove the connector by pulling it straight out The headlights should be adjusted according to cur-
backwa rds. rent legisiation. Approved adjusting equipment should
3. Remove the rubber cover and the spring holding be used for this purpose.
the bulb, pull out the bulb, see Fig. 3·66. Ad justment is made by varying the two adjusting
4. Fit the new bulb. Make sure that the bulb collar screws behind the headlight, see Fig. 3-62. The , upper
fits into the socket in the insert. screw adjusts the headlight vertically and the screw
N.B . Do not touch the bulb globe wi,th your at the side adjusts the headlight laterally.
fingers .
5. Fit the spr,ing and rubber cover. Fit the connector.
6. Check the lighting adjustment. This is don e by
means of the two adjusting screws, see Fig. 3-62.
7. Fit the plastic cover over the space behind the FOGLIGHTS
headlight. REPLACING THE BULB
l . Remove th e scr'e w and take off the plastic casing
over the space behind the headlights, see Fig. 3-63.
CHECKING AND ADJUSTING THE HEADLlGHTS
2. Remove the electric wbl·e to the bulb.
The condition of the glass, ref lector and bulb of the 3. Squeeze the holder together and pull it straight
headlight should be checked. If the g lass ,is damageid out.
by flying g'r avel, eraeked or in any o,the,r way defec- 4. Take out the bulb.
tive,the insert shou ld be replaced. Glass whioh has 5. Fiit the new bulb. Make sure ~hat it is turned eor-
becom'e "sand-blasted" by flying ston,es, etc., will rectly. The bosse s on the bulb socket will only
considerably reduce the lighting effect and can give fit in the bulb housingif the bulb is fitted correotly.
rise to dazzling, irregular beams, etc. N.B. Never grasp the bulb globe with your fingers_
If the refleator is dull, buckled or damag,ed in any 6. Fit the holder and electric cables.
other way, the insert should be replaced. The inside 7. Check the light setting. To adjust vertically siaeken
of the bulb must not be oxidized to a black or brown the nut holding the lamp, see Fig. 3-68.
colour. T,he lighting effect normally deteriorates to 8. Fit the plastic cover.
such an exfent t,hat the bulbs should be replaced after
100-200 hou,rs of operation.
The voltage a~ the bulb with the headlights switched
on and the ,engine running at cha'rging speed should
be at least 12.5 volts if sufficient lighting strength is CHECKING
to be produced. See "Checking and adjusting the headlights".

Fig. 3-67. Foglight

VOLVO
104480
l , Holder
Fig. 3-66. Removing the bulb 2. Bulb electrical connection

3: 28
 Fig. 3-70. Bulb location in rear light
l. Directionol indicotor 3. Stop light
2. Bock-up light 4. Reor light
VOLVO
104483
Fig. 3·68. Foglight attachment

REAR UGHTS
REPtACING THE BULB
l. Slacken the two screws holding the glass and lift
PARKING AND Dl'RECTIONAL FLASHE,R off the glass.
LlGHTS 2. Replaoe the damaged bulb.
N.B. Do not touch the new bulb globe with your
REPLACING THE BULB
fingers.
l. Remove ~he screws holding the glass and lift off
3. Re-fit the glass and the screws.
the glass.
2. Replace the damaged bulb.
N.B. Do not touch the new bulb globe with your
fingers.
3. Fit the glass and the screws. Check that the sealing UOENSE PLATE UGHT
is fitted correctly. REPLACING THE BULB
l. Remove the screw holding the bulb glass.
2. Remove the glass and replace the bulb.
3. Re-fit the glass and the screw. Check that the seal-
ing is fitted correctly.

Fig.3·69. Parking and directional flasher light VOLVO

103327
l. Bulb for porking light 2. Bulb for direc!ionol flo,her Fig.3-71. License plate light with bulb glass removed

3: 29
SIDE MA'RKER LlGHTS
Two flasher ma'rking lights are placed on each side
of ,t he ear.
To replace the bulb, take off the glass. The glass is
fitted on the body by means of two screws.

VOLVO
104484

Fig. 3·72. Side marker light

3: 30
 GROUP 36

OTHER ELECTRICAL STANDARD

EQUIPMENT
DESCRI PT ION
DIRECTIONAL INDICATOR SYSTEM
The directional indicator system consists of a thermal-
type flasher relay, directional indicator switch, flash
lamps on the front bumper and bulbs in the rear lights.

The directional indicators can also be used as simul-

taneous warning hazard signal flasher lights, when the
specia l switch fo r this function on ,t he instrument panel
is switched on .

The f lashe r r,e lay is mounted on the switch for the

warning hazard signal flashers (see Fig. 3-73). The VOLVO
104395
directional indicator lever switch, see Fig . 3-74, which Fig. 3·74. Directi~nal ind icator lever switch and
has automa,tic parking, is placed under the plastic ignition switch

cover on the steering column .

IGNITION SWITCH Vehicles intended for U.S.A. are fitted with a special
The ignition switch is integrally built with the steering steering wheel lock with a warning device which
wheel lock. The switch has four positions : buzzes when the one of the front doors is ope ne d
O. Comple,t e electrical system disconnected and steer- and the ignition key is left in the ignition switch, in
ing wheel locked. other words, if the steering wheel is not locked.
l. Current to fusebox (Garage position). The buzzer is placed under the dashboard on the left-
2. Same as position l but also current to ignition coil hand side and is connected between the fusebox (via
(Driving position). the ignition) and the door switch on the driver's side.
3. Same as position 2 but also current to starter motor
sol,enoid (Starting position).
When the igni;~ion key is rele'a sed In position 3,
it returns automat·ically to posi,tion 2.

VOlVO VOL VO
104394 105 .20 1
Fig . 3-73. Switch with flasher relay Fig. 3-75. Ignition switch with connection for warning buzzer

3 : 31
 I ,....---,-----·--- l
I I
L .__ . 53 b 53 31b 53a
J
2

·. +-----..t=""'-l..lL
VOLVO
103355 .

Fig . 3-77. Wiring diagram far windshield wiper matar

Fig. 3-76. Buzzer

1. Contads 2. Armature 3. Coil
purpose of this switch is to return the blades to a
suitable, previously determined, parking position ir-
respective of where the blades are when shut off.
See Fig. 3-77.

The buzzer consists of a pair of contacts and a coil.

When current passes across the contacts and through
the coil, the armature is drawn down towards the
core of the coil. While thearma.t ure is being drawn WINDSHIELD WASHER
down towards the core, the contacts cut out the current The windshield washer, which is placed on the left-
and the armature springs back, etc_ This cycle is re- ha,nd wheel arch, is driven by an electric motor. The
peated continuously as long as ClJrrent is switch ed on, pump located at the bottom of the water container
that is, as long as the driver's door is open and the is connected to the motor by means of a shaft. The
ignition key is in the ignition. pump is of the centrifugal type.
Turning the windshield washer switch mounted on the
dashboard engages the windshi·eld washer.

HORN
The horn IS mounted on the support irons for the
front bumper. SWITCHES
One of the horns has a low frequency and the other All switches are of the pull-push type. The switches for
a high frequency. lighting, ventilation and rear window defroster have
The horns can be engaged via a controI relay by the three positions. The switch for the windshi.eld wiper
horn ring mounted inside the steering wheel. has also three positions but the washe'r is also en-
gaged by turning the knob on this switch. The switch
for the warning signal f1ashers and foglights have two
positions.

WINDSHIELD WIPERS
The windshield wipers are driven by an electric motor.
The motor is conne·oted to the wiper blades by means
of link arms. The motor, which has a permanently INTERIOR LlGHTING
magnetized field, has two speeds which a'r e se·l ected The interior lighting consists of a lamp located in the
by means of the switch mounted on the doshboard. middle of theroof. The lamp is switched on by means
The motor is fitted with 3 brushes, one negative of a swi·tch built into the light. The switch has three
brush and two positive brushes. The positive brushes positions. In ,its first position, the light is switched off
are connected up one at a time for full and half completely, in the second position the light is on when
speed respectively. The gear housing for the wiper any of the front doors is opened, and in . the third
unit contains an in<fegrally built parking switch. The position the light is on continuously.

3 : 32
 Fig . 3-79. ConIroi reloys
1. Reversing light relay (or start re lay for veh icles with automatie
traQsmission)
2. Horn relay
3. Step relay for dipped/fullbeam switching
4. Foglight relay
5. Fusebox for foglights

12 11 10
VOLVO
10520t

Fig. 3-78. Windshield wosher FUSES

1. Commutator 7. Connecting lip
2. Brush 8. Wiper fluid hose hol e
The fuses are mounted in o fusebox secured to a
3. Spring 9. Container brocket Htted on the car heoter behind an opening
4. Permanen magnet 10. Sh af t
5. Rotor 11. Pump housing
in the protection panel under the dashboord.
6. Flange 12. Pump impeller The fuses for the fog lights are mounted in o fusebox
on a holder situoted on the I,eft-hand wheel arch, see
Fig. 3-79.
CONTROL RELAYS
As standaird the car is fitted with five oontrol relays.
Four of them are mounted on a holder situated on the
left-hand wheel arch, see Fig. 3-79. One of these BRAKE LIGHT SWITCH
relays is a controi relay for the horn, another is a The brake light switch is placed on the pedal carrier
controi relay for the reversing light, while a third is beneath the dashboa rd. It is operated mechanically
a step relay for fullbeam and dipped headlights and by the brake pedal.
a fourth is a controi relay for the fog lights. The fifth
relay, for the electrically heated rear window, is
placed under the dashboard, to the right of the car
heater, see Fig . 3-80. The relay cuts out current to
the rear window, when the ignition is shut off, this
in order to prevent the battery from heing discharged
when the engine is switch ed off.
Vehicles withautomatic transmission are fitted with a
start rellay instead of a controi relay for the bO'ck-up
lights.

LUGGAGE/ENGINE COMPARTMENT
LlGHTING
The vehicle is eqipped with luggage and engine com-
pa rtme nt lighting which automa'tically switches on
when the luggage compartment lid or the engine
bonnet is opened. In a later type the automatic
switches for the lights have been provided with a stop VOLVO
104 399
to permit also manual switching on ond off. Fig. 3-80. Controi relay for rear window defroster

3 : 33
 REPAIR INSTRUCTIONS
REPLACING THE IGNITION SWITCH
Remove the plastic covers round the ignition switch.
Remove the ignition switch from the steering wheel
lock by taking off the two scr·e ws holding the igni-
tion switch to the steering wheel lock. Replace the
ignition switch and fit the new one on the steering
wheel lock . Re-fit the plastic covers.

REMOVING AND ADJUSTING

THE HORN RING
To rem ove the horn ring unscrew the two screws
underneath the steering wheel. Then turn the ring
about 30° and pull it upwards. The electric cable is
then accessible and can be removed.
Fig. 3·81. Screws holding the glass for direclionai flashers
The distance A, Fig. 3-82, should be .4-.6 mm (.016-
.024") if the horn ring is to function satisfactorily.
The distance is adjusted be means of the three self-
REPLACING THE DIRECTIONAL locking nuts (l, Fig. 3-82).
INDICATOR LEVER SWITCH
Remove the screws holding the plastic covers (one
screw for the upper cover, three screws for the lower
WINDSHIELD WIPERS
cover) and remove the covers. Remove th.e screws
holding the switch. (If the vehicle is fitted with an REMOVING THE WINDSHIELD WIPER UNIT,
overdrive, the bracket holding the switch for the COMPLETE
overdrive mus,t first be removed. ) Replace the switch Disconnect the negative (ground) battery lead from
and secure the new one firmly. Fit the plastic covers. the battery. Remov,e the wiper arms. Take off the

l Fig. 3·82.
1.
2.
3.
4.
5.
6.
Nut
Bush
Retainer
Plate
Spr ing
Washer
Horn ring

7. Co ntad plate
8. Bush
9. Horn ring

VOLVO
101995

3: 34
panel under the dashboard. Remove the heater switch. Release the five screws (2, Fig. 3-83) and bend the
lake off the combined instrument. See Group 38. cover (3) out of the way, ·t hen press out the plasti·c
~emove the intermediate defroster nozzle and its gear wheel. Remove the scr-ews (7) and pull out the
hoses. Remove the wiper motor. stator. Remove the screws for the negative brush and
Disconnect the controi cables for ifhe heater. Remove the washer on the ball bearing axial lock. Remove
the fusebox and disconnect the ground cahl,e s. Remove the washer for the axial lock. Move the brushes aside
the choke controI. Release the attaching screws for and carefu ll y pull out the rotor. Take great care with
the wiper frame and carefully pull out the fra me. the brushes since the ball bearing has alarger dia-
me,t er than the cummutator.
When assembling the motor, adjust the axial play
DISMANTLJNG THE WINDSHIELD of the plalstic gea'r wheel (6) by means of ~he adjust-
WIPER MOTOR ing screw in the cover.
Remove the nut on the outgoing shaft and tap loose
the crank arm .
FITTING THE WINDSHIELD WIPER
UNIT COMPLETE
Fit the wiper fra me. Insta ll the intermed iat·e defroster
nozzle. Re-fit the fusebox and secure the ground
cables. Secure the controi cabl,es.
Fit the wiper motor. ,Fit t.he choke con~rol and also
the combined ,instrument. Install the switch for the
heater. Fit the wiper arms and the battery lead.

REMOVING THE SWITCHES

To remove the lighting switch, first unscrew the switch
knob and release the nut with a crosshead screw-
driver, see Fig. 3-84.
The knob is screwed onto the threaded switch rod.
To remove early prod type switches for the wind-
shield wipers/washer, the plastic key in the knob
must first be taken out. This is done with by insert-
ing a wire in the switch rod slot and pressing out
the key. See Fig . 3-85. For re-fitting, just push the
key straight in.

Fig. 3-83. Windshield wiper motor

1. Terminal conlacl 8. End
2. Screw 9. Brush holder
3. Cover 10. Brush
4. Conlads 11. Rolor
5. Housing 12. Nul
VOLVO
6. Gear 13. Stator 104487
7. Screw Fig. 3-84. Removing the switch nut

3: 35
 VOLVO
104490

Fig. 3-86. Engine (or luggage) compartment light

VOLVO
1044 89

Fig. 3-85. Removing the lock key (early prod., knob)

REPLACING THE INTERIOR LIGHT BULB

Pull down t he glass at the short side opposite the
switch . Pull out the bulb. The glass is re-fitted by
hooking it securely at the side where th·e switch is
si.t uated a'nd then pressing in the glass firmly.

REPLACING LUGGAGE OR ENGINE

COMPARTMENT LIGHT BULB
Remov·e the plastic cover over the bulb by unscrewing
the sorew securing the cover. Replace the bulb. Re-fit
the plastic cover and scr·e w i.t on secure·ly. Make sure
that the tab on the plastic cov,er is fitted correctly. Fig. 3-87. Brake light contad

RJEPLACING THE BIMKE l'IiGHT CONTACT

When replacing the brake light contact, make sure
that the new contact is adjusted correctly so that it
fundions satisfadorily. The distance between the
brake pedal released and the threaded bronze hub
on the contact should be 4±2 mm (O.16 ± O.08") (A, Fig.
3-87). If the distance must be adjusted, release the
attaching screw for the bracket and move the bracket
until the corred distanoe is obtained.

3: 36
 GROUP 38

INSTRUMENTS
TOOlS

SVD 2935
VOLVO
105 226

Fig. 3-88. Special tools for re moving and filfing tank armature

DESCRI PTION

INrST~UMENTATION ture gauge and fuel gauge, warning lamps and 'r heo-
Instrumentation consists of a combined instrument, see stat controlled instrument lighting. The temperature
Figs. 3-89 and 3-90, comprising speedometer, mileo- gauge, fuel gauge, warning and instrument lighting
meter and trip meter, vo ltage stabi lizer f,e d tempera- lam ps, voltage stabilizer and rheostat for the instru-
ment lig,hting are mounted on a common bas'e plate,
see Figs. 3-91 and 3-92.

VOLVO VOLVO
;103282 104406

Fig_ 3-89. Combined instrument, front side Fig. 3-90. Combined instrument, reverse side

3: 37
 ·.
W}t09 VO LVO
Fig. 3-91. Mounting plate with instruments and warning lamps 104408
Fig. 3-92. Instrument base plate, reverse side, with warning
lamp and instrument lighting lamp

SPEED OM ETER ally. Meawrement is achieved by means of an indicat-

The speedome,fer is of the ed dy current type. In the ing inst·rument of bimetal .t ype and a pickup moun~ed
speedometer thereis a pe'rmanent magne,t which is me- in the fu,el ta'nk. Current is fed through the same
chanically connected with a speedometer table driven voltage stabilizer as for the tempera,ture gauge. The
from a worm gear on the gea,rhox. Surrounding the pickup consists of a variable resistor, a lever and a
magnet is a drum, coil spri'ng and roller mounted on float. Depending upon the amount of fuel in the tank
a separate shaft. Rotation of the magnet generates and, corr,e spondingly, the position of the float, a large
eddy currents which produce a turning torque on the or lesser part of the pickup resistor is in circuit. The
drum . The coil spring limits the degree of torque when bimetal instrument used here is of the same type as
the speed of the magnet increases. The effeot of that in t he temperature gauge.
magnet and coil spring is balanGed so that the rota-
tional speed of the roller gives a reading propor-
tional to ,t he speed of the ear. VOLTAGE STABILlZER
The mileomefe'r and trip meter are driven by a gear Th,e temperature and fu.el gauges are powered by a
drive in the combined instrument. v,oltage of approx. 5.1 volts and are fed through a
voltage stabiliZ)er. This stabilizer contains a bimetal
spring and a contact breaker. When the ignition is
TEMPERATURE GAUGE switched on, current flows through the stahilizer and
Temperature ismeasured electrically by means of an out to ~he inskuments. This heats the bimetal spring
instrument of bimetal type. This unit consists of a of the stabilizer whi'ch bendsand thus hreaks the cir-
sen der, fitted to the engine, and a registering instru- cuit. As the spring cools down it returns to its original
ment, mounted in theeombined instrument, whiGh is position and the circuit is closed again . This cycle is
fe·d through a voltage stabilizer. The sende,r is of the repeated continuously, thereby producing aregulated
semi-conductor type, i.e. it contains a semi-oonductor, effeat corre's ponding to a consfant vOlHa'g.e of approx.
the dedrical resistance of which alters with the am- 5.1 volts. The breaking and making of the circuit is
bi,ent temperature. The amount of current passing not vis ible on the instruments due to ,t heir inertia. The
through t,he sender is proportional to the temperature stabilizer is mounted on the reverse side of the com-
r,e gistered by the instrument. bined instrument.
The amount of current passing through the sen der
and instrument determines the deg'ree of heat in the
bimetal of the inst'rument an·d, conespondingly, the
WARNING LAMPS
reading. As the engine warms up, a higher current is CHARGING
passed ,t hrough the sender and results in a higher The charging waming lamp is conneded ,to D + (61)
instrument indicati·on. on the altemator. The warning lamp lights up when
t,he alternator voltage is lower than the batfery volt-
age. As the al~ernator voltage rises and commences
FUEL GAUGE to charge ,t he battery, the warning lam p is exting-
The amount of fuel in the tank is measured electric- u'isheid thus indicating that the alternato'r is charging.

3: 3a
DIRECTIONAl INDICATORS
The controi lamp for the directional indicators flashes
when the indicators are engaged. It also flashes when
the warning signaf flashes are switched on, since the
controi lamp for the's e f1ashers is located in the knob
of the traffi,c indicator switch.
The controi lanip for the directional indicators is con-
nected between the flasher senderconnection P(c) and
the body.

BRAKES
The brake warning lamp recelves current from the
ignHion lock and can be ·e arthed by ,two procedures.
W hen the parking brake is applied the warning lamp
is earthed by a switch, Fig. 3-93, and thus lights, and Fig. 3-94. Warning valve

continues to do so, as long as the parking brake is

applied. Should a fault occur in one of the circuits
of the hydraulic brake system so that the difference
in pressure between the circuits, on application of the
open. When the oil pressu're sinks below a pr-e-dere'r-
b~akes, rises to more ifhan 8-10 kg/cm 2 (114-142
mined value the pre,ssure sensitive valve closes the
p.s.i.), a waming vdve, Fig. 3-94, c10ses and the
circuit and the warning lamp lights.
warning lam p is lit. The warning lamp signals until
the fauIt in the brake system has be,en re medied and
OVERDRIVE
the warning valve is reset. Con'cerning resetting the
warning valve, se'e Part 5, Brakes, Group 52. The controi lam p for the overdrive is lomt,ed on the
combined instrument and lights during the time the
FUll·BEAM HEADLlGHTS overdrive is engaged. It is connected between the
switch f.or the overdrive and body.
A warninglamp for full leadlights is lit simultaneous
to the full-beam headlights. The warning lamp is con-
ELECTRICALLY HEATED REAR WINDOW
nected i'n pa'rallel with the full-beam headlights at
the step relay. The controi I.amp for the electrically heated rea'r Wln-
dow is mounf.ed in the switch knob. It lights when the
Oll PRESSURE heating is engaged for the rea'r window.
The warning lamp for oil pressure receives current
via the ignition lock and is earthed through a pres- CLOCK
sure sensitive valve on the engine. With the engine Vehicles for markets except U.S.A. are fitted with a
running and at normal pressure, the connection be- electric clock which is located in a panel on the
tween this lamp and earth, through the engine, is propeNer shaft tunnel.

11:l~~--2

~~-3,

VOLVO
105225
Fig. 3-95. Electric clock, front and reverse
VOLVO
104491
1. Baffery ferminol 3. I nching screws
Fig. 3-93. Switch for handbrake warning lam p 2. I nsfrumenf lighf bulb 4. Ground ferminol

3: 39
 REPAIR INSTRUCTIONS

During work - under the dashboardand instrument

panel, the · negative cable should de disconnected
from the battery to avoid ~hort circuits.

VOLVO
102055
REMOVING THECOMBINED INSTRUMENT
Fig. 3·96. Rheostat for instrument lighting
Remov,e the panel below the dashboard by loosening
the fwo fixing screws, one on the I-e ft·hand side of
the body and one beside the glove compartment.
Then pull the upper section of the panel rearwards
so that it 10Qsens from the clips in the dashboard and REMOVING THE FIXING PLATE FOR SP,EEDO-
loosen the panel from the bonnet rdease mechanism. METER AND MILEOMETER/TRIP METER
Remove the con,trols ror the heater unit and the
Loosen the snap rings for the attaching nu!ts and re·
speedometer cable, and also fl an ge nuts for the in·
move the nuts. Loosen the five screws which hold the
strumenlation. Turn the instrument 1/4 turn so thaI the fixing pla~e. The fi~ing plate can be lifted out after
reverse side of the instrument fa-ces upwards. De· all screws for the instrument plate have been removed
tach the electrical connections from the instrument.
and the plate is on ly held in pla'ce by the rheostat
The ins~rumen~ can then be nned out through the shaft.
opening in rthe panel. Any repairs or adjustment to ,t he speedometer should
always be carried out by an authorized instrument
workshop.

RJEPl:A,CING WARNlING LAMPS

AND INSTRUMENT LlGHTING
LAM PS CHECKING THE SPEEDOMETER CABLE
The lamps on the instrument panel, see Fig. 3·92, are It is most important thar the speedometer cabl'e is
mounted in holders which are turned anti·clockwise correctly fi,t ted if the speedomefer is to funotion with·
for removal. The bulbs are released from their holders out trouble. It is vitally importont that the cable is
by pulling them straight out. not bent too sharply. At no point must the rad ius of
The warning lamp for the overdrive is accessible by a bend be less ,t han 100 mm W). If the bending radius
pulling the holder straight out.
The switch knob must be screwed off in o,rder to reach
the warning lamp for heating the rear window.
To replace the warning I'amp for the emergency signal
flashers, first remove the glass and then the circlip
in the switch knob.
•

REMOVING THE INSTRUMENT BASE PLATE

Pull loose the controi knob for t,he rheostat. (This
kn10b i,s damaged by IremoY'al and must always be ex·
chang,e,d for a n,e w one. It may be nece's sary to break
the knob with, e.g., pliers. (The new knob is fitted by
pressing it onto the shaft from the rheostat.) Loosen
the screws for lfhe rheostat and pull it ou,t from the
spade terminals. Loosen the five remaining screws and
i VOLVO
103286
lift up the instrument base plate. Fig.3·97. Speedometer with mileomeler and trip meler

3: 40
- - - - - --- - - - - -- -

is less than this, vibration and noise can occur in the should show a corresponding temperature. A che'ck
instrument. The drive co,uplings must run true in the can suitably be made with (1 thermometer (sender and
outer casing of the cable. This is checked with the thermometer submersed in heated water). Checking
cable rotating. values are as follows:
Beginning of green area (at ("C") 40° C (105° Fl
At dividing line between green areas 70° C (150° F)
REMOVING AND CHECKING At dividing lin'e between green and
THE TEMPERATURE GAUGE red areas 100° C (212° F)
The sende,r and indicating instrument are not repair- If checking is carried out with on instrument which is
able and the entire unit must be replaced if damaged . mounted on the instrument plate, then a 12 volt su pply
The indiwting instrument can be separated from the should be conneded to te rm inal 2 on the instrument
detached instrument panel when the voltage stabilizer pl-a te (sele wiring diagram), the sender to terminal 8
has been removed and the nuts hol,ding the instru- and the ground cable to terminal 16. Do not forget
ment are accessible. to ground the sender.
The indica~ing instrument should be checked with an
ohmmeter. The resisf.ance shou ld be approx. 12.5
ohms. Measurement is suitably carried out between REMOVING AND CHECKING
the nuts on the revers,e side of the instrument pla,te. THE FUEL GAUGE
On no account should the indicator instrument be
The pickup and fuel gauge are not repairable and
checked by conneding the sende'r cabl e to the car
must be exchanged if faulty or damaged.
chassis as this will damage the instrument mechanism
The gauge can be removed from the detached instru-
(too high a voltage Oh the instrument resisfor and
ment panel when the voltage stabi lizer and rheostat
overheating of ~he bimetal spring). If no ohmmeter is
have been loosened and the nuts to the instrument are
availab l-e , the above test can be carried out by placing
accessible. The fuel gauge should be checked with
a 10 ohms resistance between the sender cable and
an ohmmeter. The resistance shou ld be approx. 12.5
the ground connection on the chassis.
ohms. Measurement can suitably be carried out
The sender shoul,d also be checked with an ohmmeter.
between the nuts on the rear side of tlie instrument
Resistance in the sender should, at room temperaofure,
plate.
be approximately 200 ohms.
Checking of the gauge by connecting the pickup lead
The indiwting instrument wn al so be checked by
to earth is not permitted as this will damage the
connection to a 12 vo lt battery, via a voltage stabili-
gauge (excessive loading on the resistor wire and
zer, and with a previously checked pickup coupled
overheating of the bimetal spring). If no ohmmeter is
in series. On heating ~he sender both the instruments
available the test can be carried out by connecting
a 10 ohms resistor between the lead and grounding
point on the chassis.
The pickup, Fig. 3-99, can be removed afte r the carpet
and wooden fibre boa rd in the luggage compartment

VOLVO
105204

Fig. 3-98. Bimetal type registering instrument Fig. 3-99. Pickup for fuel gauge

3: 41
 suspended in a rubber block and connected to the
combined instrument by means of three cables.
A functional test on the voltage stabilizer can be
carried out with a temperature gauge or a fuel gauge.
The instrument (temperature or fuel gauge), is con-
nected in series with a resistance of approximately 12
ohms (instead of pickup) and a constant direct current
voltage of 5.1 volts. The reading is then noted . After
this the constant direct current is repl'a ced by a 12 volt
battery and a voltage stabilizer. Do not omit to con-
nect the cover of the stabilizer to earth. During testing,
the stabilizer must lie in the same position as it does
in the ear. A damaged stabilizer must be replaced by
a new unit since it cannot be repaired.
Fig . 3-100. Tool for removing pickup

have been lifted out. The pickup is a11tached by means

of a bayonet fitting. When removing, use tool SYO
2935 as shown in Fig 3-100. The pickup should be
checked with an ohmmeter.
Nr the upper s~op the pickup should have a resistance
of approx. 10 ohms and a,t the lower, approx. 60-85
ohms. Movement of the f10at arm should not result
in a break in the circuit (reading).
Fig . 3-101. Voltoge sfobilizer

CHECKING THE VOLTAGE STABILlZER

The voltage stabilizer, see Fig. 3-101, is spring-

3: 42
 1. Dir. ind. flashers 32 cp
2. Parking lights 5W
3. Headlight dipped beam 40 W
4. Headlight mainbeam 45 W
5. Distributor f iring order 1·5-3·6·2·4
6. Battery 12 V 60 Ah
7. Conn. at instrument
8. Junction
9. Part of 6-pole connector
10. Harn r i ng
11. Ignition co il
12. Relay for horn
13. Starter motor 10 h .p.
14. Broke warning valve contact
15. Resistar
16. Relay for heated rear w indow
17. CigareHe lighter
18. Dipped relay for main and dipped beams
and headlight flasher
19. Alternotor 12 V 55 A
20. Horn
21. Mai nbeam controi lamp 1.2 W
22. Fusebox
23. Wiring of foglights
24. Engine camp. lighting 18 W
25. Charging controi unit
26. Switch glove camp. lighting
M
rf e- U
{EJ
g
!il
6507&&
~~
27.
28.
Glove compartment lighting
Emergency warning flashers
2W

l
o"'
h i l ' .. 10 BL
<

C"~
F Si
&l~

~I
_ l.'-'l_ lj~i

•
o
:lI
45
I
I
I
29.
30.
31 .
Brake contacf
Brake warning lamp
Oil pressure warning lamp
1.2 W
1.2 W
1.2 W
~I,J
n -
GO lO S8 32. Charging warning lamp

Y
I
~fU OJ ... 1 ~I 33. Oil pressure tell tale
~J ]ll
~D ~ ~l:~
o ~;
-\ " .Ja 34. Switch for headlight s ig na lli ng and turn . ind.
~ I
<- 10 Gk
35. Vo ltage reg ul ator
n~ 'u
~
~ I
10 GR "-
~
O 6R
+
m
iD' l "R ~
IL __
36. Fuel gauge
L!: !il 37. Temperature gauge

or-
"o I :lI 38. Temperature gauge sens itive head
- :lI
39. Emergency f1ashers warning lamp
8~
R~
10 se ~
•
;r I = Ö
-y~
I Y .JL
~
1 R
Y
I
I
~ ~
~
~
~
10'
40.
41.
Instrument lighting
Heater contral lighting
1.2 W
2X3 W
3x1.2 W
~ @
O~O
Hl GR
50R r -f---- ----f----
i
42.
43.
Lugg.a ge camp. light
W,i ndscreen wi pers
18 W

r"RLhl
"GN 44. Heater
I 45. W i ndscreen washers
OR
I 46. Interior light lOW
,,~ +J >SR "R 47. Switch for heater
. 48.
49.
50.
Switch for w in dscreen wipers a nd washer
In strument lighting rheostat
Lig ht switch

tf
51. Ignition switch
52. Door contael
53. Switch f. elec. heated rear w in dow
54. El ec . heated rear w ind ow
55. Switch for parking brake controi
56. Fuel gauge tank unit
57. Reversing lights 15 W
58. Brake stop lights 25 W
59. Rear ligh ts 5W
60. Number plate light ing 2x5 W
61. Overdr. warn ing lam p 1.2 W
62 . Swi tc h for overdrive
63. Switch f. overdr. on gearbox
64. So lena id f. overdrive
65. Sw itc h on gearbox BW 35
66. Sw itch for reversing lights o nl y for M 400
a nd M 410
67. Re lay for reversing on M 400, M 410 and
starter relay on BW 35
68. Sid e marker lamps 5W
69. Buzzer, ign iti on key
70. Door confacf on driving seat side
71. Foglights
72. Fu sebox for foglights
73. Relay for foglights
74. Switch for foglights
75. Clock

Colour code
SB Black
W White
y Ye ll ow
GN = Green
GR Grey
BL Blue
R Red
BR Brown

Illustration 3-A. Wiring diagram

 Part 4

POWER TRANSMISSION
REAR AXLE
 (ONTENTS
Group 41 Clutch Group 44 Automatic Transmission {BW-35}
T'o ols . ... . .................... . .... . ......... 4:l Tools .. .. ........... ..... ..... . .. ..... ... . .. 4 : 23
Description .. ... . .. . .... .. . ... ......... .. .. .. 4: l Descripti·on .. . ... . .... ........ ....... . 4 : 24
Repair Instrudions ..... . . . ........ . . . .... .. .. 4:2 Re pa ir Instructions . .. ... . . . ...... .. ... . . . ... 4: 27
Adjusting the c1utch pedal play ... .... ... . . .. 4:2 Cheoking f1ui·d level .... . . ..... ... ... . . . .. . 4: 27
Repla'cing the c1utch wire . . .. ...... .. . . . ... 4:2 Removing and fitting controi syste m . . .. .. .. 4: 28
Replacing .t he c1utch pedal or bushes ........ 4:2 Adjusting selector oontro ls .. .... .. .. . .. . .... 4: 28
Removing . . .. . ...... .. . . ... . ..... . . . . . ..... 4:3 Adjusting throttle cable .... . ... . . ... . . ... . . 4: 28
Reconditioning releasecomponen:ls . ......... 4: 3 Adjusting starter inhihitor swi,tch .. . .. . . . . .. 4: 29
Replacing :input shalit pillot bearing ..... . . . . 4 :3 Adjusting rea r hrake band . . .. . . ... .. ..... . . 4 : 30
Inspecting .... .. . ..... ............ ... . . . . . . 4 :3 Air pressure checks ........ . . ......... .... 4: 30
Fitting ' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4:3 Removing .. ......... .... . . . ... . .. .. . . . .... 4 : 31
Clutch controis, vehicle with right-hand Dismantling .. . . . . . ... .......... . . . . .... ... 4: 31
drive .. . ...... ..... .. .. . .. .. .. . .. . .. .. . . .. . 4: 4 Inspecting .. ..... ... .. .... .. .... . . .. . . . .. .. 4: 37
Assembling . ... ..... . . ..... . .. .. . . . . ..... . . 4: 37
Selector controh . . . . . . . . . . . . . . . . . . . . . . . . . .. 4: 44
Fault Tracing . . . ..... . . . . . . . . . .. .. .... .. ..... 4 : 45

Group 43 A Gearbox Group 45 Propeller S h a~t

Toois . .... .. .. . ... . ...... .. .. . . ....... . . .. . 4:5 Description . . . . .. . ... . . ... .. ..... .. .. .. . . . . .. 4 : 48
Description .. ... . ... . . . ....... ... . . . . . . . . .. . . 4:6 Repair Instrudions ... ... . . .. . . .. . ..... .. . .. .. . 4 : 49
Repair Instructio:ns . . .... .. .... . ... .... . . ... . . 4:6 Replacing the support bearing ..... . ... . .... 4 : 49
Repl,a.cing oil seal . ... . . . . . .. .. . .. . . .... . .. . 4:6 Removing ... . .......... .. . . ... . .. . . .. . .. . . 4: 49
Removing . ......... . . . .. . . . .... . .. . . .... .. . 4:6 Dismantling ... . .. .. ....... . .. . . .. . ........ . 4 : 49
Dismantling .. . . . . ... . .. . . .. .. . . . . . ... . . . . . . 4:7 Inspecting .. ... . . ... . . . . .. .. . ....... . . . . . . . 4 : 50
Inspecting ... . ... . .............. .. . ... . .. . 4:9 Assembling . . . .. . .... ... . . .... .. .... .. .. . . . 4 : 50
Assembling .... .. ... . ....... . ... .. . . ... ... . 4:9 Fitting ...... . ........... . ... . .... ... . . ... . . 4 : 50
Fitting .. .. ... . ....... . .. . .... . . . . . .. .. . .. . 4: 11
Group 46 Re ar Axle
Toois ....... . ........ ... . .. .. .. . . .. . . ... .. . .. 4 : 51
Description .. . . ....... . .. . . . ... . . . .. ..... .... 4 : 52
Group 43 B Overdrive Repair Instructions . . . . . . .... .. . ... ...... . . 4 : 53
Toois .. . .. .... . ....... . .. . .. . .. . .. . .......... 4: 12 Replacing pinilon oil seal . .. ...... . .. . .. . .. . . 4 : 54
Description ..... . ........ .. ....... ..... ... .. . 4 : 13 Removing .. . .. .... ... . .. . .... ...... .. .... . . 4 : 55
Repair Instrudions .. ...... .. ... . .. . ..... . . ... 4 : 17 DismanHing .. . ..... . . . ... . .... . . . . ........ . 4 : 55
Checking the oil pressure ... ... .. .. . .. ..... 4: 17 Inspecting .. .. ..... . ......... . ...... . . .. . . . 4 : 56
Replacing the solenoid and operating valve . . 4 : 17 Assembling . . . . .. ... .. . ..... .... . .. .. . . .... 4 : 62
Checking and replacing relief valve ........ 4: 17 Fitting ..... .. . .. ... ... .. ......... . .. . .. . .. . .. 4 : 62
Oeaning the orifice nozzle . ...... .. . . . .... 4 : 18
Checking and replacing che·ck valve . . . . . . . . 4: 18 Quick-reference fault-tracing chart for automatic
Cleaning the filter . . . ..... .. .. ...... . . . .. . .. 4: 18 transmission
Removing ... ... . . .. ... . . . . . . . . . . . . . . . . . . . .. 4: 18 IIlustra;tion 4-A. Clutch and clutch controls
Dismantl.ing .. . . ... . . . ....... . .......... .. .. 4 : 19 Illustration 4-B Gearbox
Inspeding .......... . ..... .. . . .. . .... . ... 4 : 19 Illustration 4-(, Overdrive
Assembling . . . ... . . . ...... . ........ . .... . .. 4: 20 Illustration 4-D. Automatic transmission BW 35
Fitting . . . . . . . .... .. ... . ........ . ......... . . 4 : 22 Illustration 4-E. Final drive
 GROUP 41

CLUTCH
TOOLS

The following tools are used for repairs on the c1utch

e-
j
~ --===C;l .c:]
SyO 1426 SYO 2824

SYO 4090
VOLVO
103171

Fig . 4-1. Special lools

SYO 1426 Drift for pilot bearing in flywheel
SYO 2824 Mandrel for centering clutch plate
SYO 4090 Puller for ball bearing in flywheel

DESCRI PTION
The c1utch is of the diaphragm spring type. It consists
mainly of a pressure plate, diaphragm spring and a
sh e eif"-metall casing. The diaphragm spring has a
double function, that of a c1vtch lever when declutch-
i·ng a'nd a pressurespring when engaging.
The c1utch ,o peration tak,es place by means of the
c1utch pedal, and on left-hand steered vehicles its
movements are lIransferred to the c1utch via a wi're,
a lever and a release bearing. On right-hand steered
vehicles, the movements are transmitted with the
help of a hydrauli:c contra!.

Fig . 4-2 . Clulch

4: l
 REPAI R I NSTRUCTIONS
WORK WHICH CAN BE CARRIED OUT for examp l·e , because of rep locement of the c1utch
WITH THE CLUTCH INSTALLED wire, the sle,eve a,ttachment to the c1utch casing is
ADJUSTING THE CLUTCH PEDAL PLAY moved by means of the nuts (1).
For right-hand steered vehicles, the corresponding
Correct clvtch pedal play is obta in ed by adjusting the
play should be 2-3 mm (0.08-0.12") and adjustment is
'r elease lever so that on left-hand steered vehicles a
made by c itering the length of the t hrust rod.
play of 4-5 mm (0.16-0.20"), A in Fig. 4-3, is obtained.
Play ,is adjusted by unscrewing or screwing in the for k
(3) on the c1utch wire . .If this adjustment is insufficient,
REPLACING THE CLUTCH WIRE
l . Unhook the return spring for the r-elease lever.
Disconnect the wire from the lev'er.
2. Unscrew the rear nut and remove ,t he wire sleeve
from the dutch casing.
3. Disconnect the wir-e from the c1utch pedal. Un-
screw the nut for the wire sleeve and rem ove the
wire.
4. Fit the n·e w wire in reverse order to rem oval.
Adjust the pedal play.

REPLACING THE CLUTCH PEDAL OR BUSHES

The description given below is applicabl,e if it con-
cernseither the replocement of the pedal or of the
bushes.
l . Rel'ease the holts and remove the stop braeket
for the pedal.
Fig. 4-3. Release lever play
2. Unhook the wir'e horn the pedal. Remove the cir-
A = 4-5 mm (0.16--D.20")
dip ond lift off the pedol.
l. Adjusting nuts 2. Locknut 3. Fork
3. Drive out the old bushes with a sui,t able drift.
Press in the new bushes. Lubricate them w.ith
9'rease.
4. If the pedal shaft is worn, repl'ace it. It is fixed
by means of a bolt.
5. Place <the pedal on the shaft and fit the .circlip.
10
6. Hook on the wire to the pedal. Fit the stop bra,c-
11 ket. Adjust the pedal play.
12

..lII-_--13

Fig. 4-4. Pedal carrier

l. Rubber bushing 6. Rubber stop 1l. Pedal shaft
2. Washer 7. Clutch wire 12. Boll
3. Nut 8. Stop brocket 13. Clutch pedal
4. Lock washer 9. Brackel
5. Washer 10. Bush Fig . 4-5. Removing the e1utch

4:2
 VOLVO
102087

Fig. 4-7. Checking the curvature of the pressure plate

Fig. 4·6. Release components

l. Release bearing 4. Return spring
2. Release fork 5. Washer
3. Release shaft and lever 6. Circlip

REMOVING THE CLUTCH

l. RemO've the gearbO'x in accO'rdance wi~h the in-
strudiO'ns given in GrO'up 43.
2. Slocken the hO'lts hO'lding the clutch tO' the flywheel Fig. 4·8. Fitting the clutch

by IIO'O'sening them crO'sswise a cO'uple O'f turns at

a time tO' pre'l'ent wa,rping . RemO've the clutch and
clutch plate.
ru ler, which is placed diagO'nally O'ver the friction
RECONDITIONING THE RELEASE surface O'f the pressure pla,t e. Then measu re the di-
COMPONENTS stance between the straight edge O'f the ruler and
the inne r diameter of the pressure plate. This measu,re-
l . RemO've the bO'lt in the release fO'rk. Take O'ut the
ment must nO't exceed a maximum O'f 0.03 mm (0.0012"),
release be,a ring. PuJ.l O'ut the rel'ease shaPt.
see A Fig. 4-7. There must be no "crO'wning", that is,
2. Drive O'ut the O'I,d bushes with a suitable drift.
clearance betwe,e n the straight edge of the fUll,er and
Press in t.he new bushes.
the O'ufer diameter O'f rthe pressure plate. The check
3. eO'at a thin ,I,ayer O'f grease on the sleeve O'f the
shoul·d be carried O'ut at sev,e ml PO'ints.
re·lease bearing and theninstall the bearing in
PO'sition .
4. HO'ld the release fO'rk in i-ts place and insert the
FITTING
release shaft.
BefO're fitting, check that the dutch facings, the fly-
wheel an·d the pressur,e plate are completely free
REPLACING THE INPUT SHAFT
from oil. Wash them with clean petro.I (gasoline) and
PILOT BEARING
wipe O'ff weil with a dean piece of dO'th.
l. RemO'V'e the cirdip for the bearing. Pull out the
l. Set up the clutch plate (the longest side of the
bearing with puller SYO 4090.
hub facing backwards) tO'gethe1r with the clutch
2. Pack the bearing wi!th heat-resistant gre:a se. Then
against the f1ywheel and inse rt the centering
fit it with the help O'f drift SYO 1426. Fit the cir-
mandrel SYO 2824 so that the guide journal O'n
clip. this centers the pilO't bearing in the f1ywheel, see
Fig. 4-8.
INSPECTING 2. P,loce in the ,six bO'lts which hO'ld the c1utch and
Check the dutch thO'roughly. The pressure plate should tighten them crosswise a couple O'f turns at a time.
be checkad for heart damage, cracks, scoring O'r other Remove the centering mandrel.
damage to the frictiO'n surface. Check the curvature 3. Fit the gearbO'x acoO'rdi!ng tO' the instructions given
O'f the pressure plate with a 240 mm (9.45") long steel in Group 43. Adjust the clutah pedal play.

4:3
 Fi g. 4-10. Master cy linde r
l. Rubber cover 5. Cylinder 9. Rubber cover
2. Ve nting nipple 6. Thrust sleeve 10. locknut
3. Piston seal 7. Circlip 11. Thrust rad
4. Piston 8. Stop ring
Fig. 4·.9. Ma ster cylinder
l. Cylinder 6. Connection pipe
2. Piston for fl uid container
3. Washer 7. Pistan seal FiHing
4. Piston seal 8. Washer
5. Spring 9. Circlip Fitting IS In reverse order to removo l. Fill with b ra ke
fluid a nd bleed the system.

MASTER CYLINDER
CLUTCH CONTROL, RIGHT-HAND
DRIVE . Removing
Dis.c onnect the pipe from the hose. Release the hose
MASTER CYLI NDER
from the container. Unhook the return spring. SIaeken
Rem ovin g
the bolts and tift off the mast,e r cylinder.
l . Remove the hose from the oIutch fluid contali ner
and allow the fluid to run out into a dean vesse l.
Disconned the pipe hom the master cylinder. Dismantling

2. Remove the bolt in the c1utch" pedal. Release the Remov,e the rubber cover and the thrust rod. Take
bolts and remov,e the master cyl,i nder. off the cirolip and a.Jso the piston.

Inspeding
See under the heading "Inspecting the master cylin-
Disma ntling
der", whioh applies where pel-evant.
l. Remove the rubbe'r cover and the thrust rod.
2. Remov·e the cirolip and take out the washer, piston,
piston seal and peturn spping . Assembling

3. Remove the outer piston seal ·from the piston. Dip the piston and seall in bra~e fluid and place the
sealon the piston. Fit the piston in the cylinder. Fit
the ai,rdip, the -t hrust rod and the dust cover.

Insped ing Fitting

Clean '011 the parts in white spirit and check them for Fitting is in reverse order to removal. Bleed the ' system
wear or other damage. and adjust the free travel of the dutch lev,e r.

.BLEEDING THE HYDRAULIC SYSTEM

Check to make sure that the flui'd container is fil-led
A ssem bling with brake fluid . Remove the rubber cap on the bleed-
l . Dip the piston seals and the piston in brake fluid . er valve on the master cyl.i nder. Fit a bleeder hose
Fit the outer sea-lon the piston . to the va,lv.e a,nd inse-rt the hose down into a con-
2. Fit the return spring, piston s·ea,l, pIston and tainer with brake fluid . Open the bleeder valve and
washer in the cy,l inder. Fit on the ci.rclip. depress the dutch pedal. Sh ut off the bleeder valve
3. Fi,t the thrust rod and the rubber cover. Make while the pedal is fu/lly depr-essed. Then release the
sure that the venting ho le in the rubber cover pedat Repe-a t this proaedure until fluid fre-e from air
fa oes downwards. bu b hl,es fl ows out. Ri ll the conta iner with br ake f1 uiq.

4:4
 GROUP 43 A

GEARBOX
TOO LS
The follo w ing specia l tool s are used f o r repairs o n t he gea rb ox

I,
1801 1845 2261 2337
il ~
2412

2837
2826
'~'
&
2827 2828
J
2829

2832
4030

I
2831
2853
2830
CD
A
2851 2852
@ © ©
Fig . 4·11. Specia l loo ls

SYO 1801 Standard handle 18x200 mm n-~

SYO 1845 Press tool for fitting the flange
SYO 2261 Puller for flange \L~SV02825
SYO 2337 Drift for removing oil seal in cover for input shaft --c;
SYO 2412 Drift for fitting oil seal in rear cover
SYO 2520 Stand, see Fig. 4·12. Used tagether with fixture SYO 2825
SYO 2727 Tool for suspending engine when removing and fitting
gearbox, see Fig. 4·16
SYO 2825 Fixture for holding gearbox. Used tagether with stand
SYO 2520
SYO 2826 Puller for front bearing on intermediate shaft
SYO 2828 Puller for rear bearing on mainshaft, M 400
SYO 2829 Device for lifting and installing the mains haft in gear-
box
SYO 2830 Pu lIer for reverse shaft
SYO 2831 Press too I for fitting bearing on intermediate shaft and
rear bearing on mainshaft
SYO 2832 Puller for rear bearing on mainshaft, M 410
Used tagether with SYO 2828
SYO 2833 Fixture for gearbox. Used on garage jack when remov-
ing and fitting gearbox, see Fig. 4-17
SYO 2837 Counterhold for flange (handle used only for auto-
matic transmission)
SYO 2851 Drift for fitting oil seal in cover for input shaft
SYO 2852 Cushioning ring for filting bearing on input shaft and
synchronizers on mainshaft VOL VO
103100
SYO 2853 Ring for dismantling maioshaft
SYO 4030 Puller for oil seal at flange Fig. 4-12. Sla nd SVO 2520 wilh fixlure SVO 2825

4 :5
 DESCRI PTION
(For gea'rbox wi,th overdrive, see also Group 43 B, Overdrive)

The gearbox ·is four-speed and fully synchronized. Its mainshaft gea'r is j'o umalled wi,th needle bearings.
design and construction are shownin Fig. 4-13 and When a g,ear is engaged, the corresponding gear
Illustration 4 B. All gears except reverse a-re in con- wheel is connected to the. mainshaft by means of an
stant mesh with one another. For this reason, the engag'ing sleeve.

. ,
REPAIR INSTRUCTIONS
WORK WHICH CAN BE CARRIED OUT 4. Press on the flange wi,th tool SYO 1845, see Fig.
WITH THE GEARBOX INSTALLED 4-15. Fit the other parts.
REPlACING THE Oll SEAl
l. Carry out where applicable operations 1-6 under
REMOVING
the heading "R,emoving". l. Secure lift tool SYO 2727 to the engine as shown
2. Release the ,nut for the fl ange. Pull off the flange in Fig . 4-16. The lifting hook is secured round the
with puHerSYO 2261, see Fig. 4-14. exhaust manifo,ld.
3. Pull out the old seal with pul,ler SYO 4030. 2. Jack up the vehicle and place blocks undernea,th.
Fit the new oil seal with the help of sle'e ve SYO Remove the oi·1 kom the gearbox.
2412. 3. Remove the gear lever. Disconnect the following :

vOLVO
103293
Fig. 4·15. Fitling the flange
Fig. 4-13. Gearbox M 400

VOLVO
VOLVO
22720 103101
Fig. 4-14. Removing the flange Fig. 4-16. Suspending the engine

4:6
 VOLVO
103103
VOLVO Fig. 4-18. Removing intermediate shaft front bearing
103102
Fig. 4-17. Fixture for removing gearbox

The upper anchorage bolts for the radiator, the

nuts for the e~haust manifold flange, the battery
lend, the throttle shaft and dutch wire from the
flywheel casing.
4. Release and rem ove the supporting member under
the gearbox. Disconnect th,e braeket for the ex-
haust pipe. Disconnect the speedometer cable.
Disconnect the propeller shaft.
5. Lower the rear end of the engine about 4.5 cm
(1.8" ) and then siaeken .t he lines for the reversing
lights and over drive if fitted.
6. Replaoe the lifting plate on the jack with fixture
VOLVO
SYO 2833. The pin in the fixture shou1ld ~hen be 103104
Fig. 4-19. Removing intermediate shaft rear bearing
located in its front posi1ion for gearbox M 400
and in the rear position for the M 41 gearbox.°
Support the gearbox with the fixtvre. SIaeken the 2826, see Fig. 4-18. Remove the rear cover and
bolts in the clutch casing. Pull the gearbox rear- then pull off the reaor bearing of the intermediate
wards and then lower it, see Fig. 4-17. shaft with tool SYO 2827, see Fig. 4-19.
6. Restore the g,earbox to its normal position. While
doing this ensure that the te,e,th of the inte r-
DISMANTLING mediate shaft are not darmaged when it drops
Applies olso to M 410 after the overdrive has been down into the bottom of the gearbox.
removed. 7. Unscrew the bolts for the selector fo,rks. Push the
l. Fit fixture SYO 2825 in stand SYO 2520, se'e Fig. selector rails baoekwards ond driv-e out the ten-
4-12. Sewroe the g'e arbox in the fixture . sioning pin in the flange of the sel,e cto'r rails.
2. SIaeken the bolts and lift off' the gea'rbox cover. Push out the selector rails. When doing this, hold
Remove the springs and the interlock balls for the seledor forks so that they do not come askew
the selector mils. and jam on the rails. R'emove the s·e lector forks.
3. SIaeken the nut for the flange . Use for this tool 8. Remove the speedometer gear. Pull out the rear
SYO 2837. Pul,1 the flange off with puller SYO bearing of the mainshaft with tool SYO 2828, see
2261, see Fig. 4-14. Fig. 4-20. If the hearing sticks in the gearbox
4. Remove the release bearing. Release the bolts housing, push the mainshaft forwards so that its
and remove the cover for the input shaft. Then drive and synchronizers go against the drive of
release the bolts for the clutch casing and remove the intermediate shaft. To prevent this, place a
the casing. pieceof Hat iron or similar between the front end
5. Turn the gearrbox upside down. Pull out the front of the mainshaft and the gearbox housing.
bearing of the intermediate shaft wi~h tool SYO For the M 410, remove the bolt in tool SYO 2828

4:7
 VOLVO
103 lOS

Fig. 4-20_ Removing the mainshaft rear bearing, M 400

VOLVO
\03108

Fig. 4-23. Removing the reverse sh af t

and replace it with SYO 2832. Then pull off the

rear bear-ing in the same way as for the M 400
unit, see Fig. 4-21 .
9. Pull out the input shaft and remove the synchroni-
zing ring. Remove the thrust washer from the
mainshaft rear end. Fit lifting tool SYO 2829
on the mainshaft. Push the engagi'ng sle,e ve for
1st and 2nd speed rearwards. Lift up the main-
shaft as shown in Fig. 4-22.
10. Pull out the reversing shaft with puller SYO 2830,
see Fig . 4-23, and r-emove the reverse g,e ar.
11. Pull out the oil seals kom the front and rear
aovers with drift SYO 2337.

VOLVO
103106

Fig. 4-21. Removing the mainshaft rear bearing, M 410

VOLVO VOLVO
103107 103109

Fig. 4-22. Lifting out the mainshaft Fig. 4-24. Dismantling the mainshaft, I

4:8
 Fig. 4-26. Asse mbling the synchronizing

VOLVO
103110
Fig. 4-25. Di smantli ng the mainshaft, II
wheel and needle bearing. Make sure that the
synchronizing flange locates correctly in the
DISMANTLING THE MAINSHAFT grooves in the synchronizing cone. Press the main-
l . Remove the lifting tool and then l s,t spe,ed gear shaft into the synchronizing hub as shown in Fig.
wheel, the needle bearing and the synchronizing 4-27. When doing this, turn the 3rd speed gear
con'e. wheel in orde'r to check that this gear as weil as
2. Remove the engag·ing sleeves and the f1anges the need le hearing fit correctly. T'ry out a circlip
for the synchronizers. Remove the circlips for the which fills the g,rpove weil and fit the circlip.
synchronizing hub. 3. Place l st-2nd speed synchronizer, synchronizing
3. Fit tool SYO 2853 on to the mainshaft. Place the cone, 2nd speed gear wheel, and need le bea ri ng on
shaft in a press and support it with the tool as ring SYO 2852. Make sure that the gear ring on the
shown in Fig. 4-24. P-ress off 2nd speed gear wheel engaging sleeve comes forwards and that the
and l st and 2nd speed synchronizing hub. flanges fit correctly in the gm'oves of the syn-
4. Revert the shaft ond place it in the press as shown chronizing cone. Press in the mainshaft, see Fig.
in Fig. 4-25. Press off 3rd spe-e d gear wheel and 4-27. When doing this, turn the 2nd speed gea,r
4th speed synchronizing hub. w heel to prevent it from f.astening. Try out a cir-

INSPECTING
Afte-r the dismantling, clean all ,t he parts in white
spirit and -check for wear or other damage.
Check the -gea'r whe·els particularly for cmcks or
scoring on the te·eth surfaces. Damaged or wom gear
wheels should be replaced .
Check the synchronizing cones, also the other parts
of the synchronizing devices. DClmaged or worn parts
should be r.eplaced.
Check the baH beafings espeoia'lIy for scoring or
cmcks in the bearing races or on the balls.

ASSEMBLlNG
ASSEMBLlNG THE MAINSHAFT
1. Assemble 1st-2nd and 3rd-4th speed synchronizers.
Fit the snap rings correctly, see Fig. 4-26.
2. Place ring SYO 2852 ,in a press. Place on 3rd-4th
synchronizer, syn-ohronizing cone, 3rd speed gear Fig. 4-27. Fitting the synchro nizin g

4:9
 SVD

SVD 2852 ..
VOLVO
103113

VOLVO Fig. 4-30. Fitting intermed iate shaft bearing

103230
Fig . 4-28. Fitting the ball bearing on the input shaft A. I nsert drift

clip which fits weil inta the groov,e on the shaft 3. Place the intermediate sh aft in the bottom of the
and fit the 6rclip. gearbox housing. Fit the mainshaft ,in the housing .
4. Fit l st speed gea1r wheel with needle bea'r,ing and TtOke off the lifting tool and place the thrust
synchronizing cone on the mainshaft. Fit on lifting washer on to the mainshaft.
tool SVO 2829. 4. Fit the rear ball bea,ring on to the mainshaft. Fit
press tool SVO 2831 over the bea,ring and the
mainshaft as shown in Fig. 4-29. Press the bearing
ASSEMBLlNG THE GEARBOX on to the shaft. If the bearing does not locate in
l. Pr,ess the oil se'als on to the front and rear covers the housing, the spindl,e on ~ool SVO 2831 can
with drift SVO 2851 ond SVO 1801 as weil as SVO be screwed out and a flat iron piece placed bet-
2412. P'ress the ball be,a ring on to the input shaft ween this and the front end of the housi'ng. The
with the help of the cushioning ring SVO 2852 bearing can then be pressed into position with
and drift SVO 2851, see 4-28. Try out a cirrclip the tool.
which fits weil in~o the groove and fit the circlip. 5. Fit the needle bearing in the input shaft. Install
2. PICloe the gear I'e ver for the reverse shaft on to the loose synchronizing cone in the synchronizer
the bearing pin in the gearbox housing. Fit the for the 3rd-4th speeds. Place it corr'ectly so that
reverse gear and the reve,rse gear shaft. The re- the flanges take up in its grooves. Push the input
verse g,e ar shatt should li,e level with the rear end shaft into the housing and on the pin of the main-
of the housing or a maximum 0.2 mm (0.08") below. shaft.

-
t !!-~t~=1 ~
1-t I~";; ~ ~.i-l~
'M" • \~~,~~= .r~.
'4

, A
,t... ;,,,_ ._.l. _.
~

VOLV.O
103112
Fig. 4-31. Clearance for intermediate shaft
Fig. 4-29. Fitting the mainshaft rear bearing A = 0.00-0.05 mm (0.002")

4: 10
6. Turn the gea rhox upside down . Press the insert 9. Fit on the larg,e speedomete,r gealr. Fit t he rear
drift into press tool SYO 2831 . Then pr,ess on the cover with a new gasket. When fitting, compress
bearings for the intermediate shaft with the press the gasket and ensure that the intermedi'ate shaft
tool, see Fig . 4-30. Fit the clutch casing . with a new has the correct clearance, 0.20-0.25 mm (0.008-
gasket. 0.010").
7. Fit seledor forks, flanges and sel,e ctor r ails. Make 10. Press on the flange wi~h tool SYO 1845. Fit the
sure thai the flange for the reverse g,e'a r fits COf- washer a.nd nut. Tigh~en the nut to a torque of
redly i,n the gear lever. Fit the bolts and tension- 11-14 kpm (80-110 Ib.ft.).
ing pins. Use new pins. 11 . Place the interlocking bal/sand springs in position.
8. Turn the geaThox with the rea'r end upwards. Fit the gealrbox, cov,e'r and gasket. Fi,t ~he cover
Drive forwards the int,e rmediate shaft so that its over the input shaft. Fit also the re'lease bearing.
front heor,ing /j,e s against the clutch casing. Fit
in shims for the infermedia'te shaft rear bear.ing FITTING
so that they lie evenly ' with or up to 0.05 mm Fitting of the gearhox lis in reverse order to removal.
(0.002") under the rear end (see A, Fig . 4-31). Fi," wi,th oil.

4: 11
 GROUP 43 B

OVERDRIVE

TOOLS
The following special tools are required for work on the overdrive unit

åi
l

~
1797 18'01 1845 2261 2412
Il

2417 2423

2834 2835 2836

VOLVO
103262
Fig . 4.32. Special taols
SYO 1787 Drift for removing rear bearing, output shaft
SYO 1801 Standard handle
SYO 1845 Press tool for fitting flange
SYO 2261 Puller for flange
SYO 2412 Sleeve drift for fitting front and rear bearings on out·
put shaft and oil seal at flange
SYO 2417 Drift for fitting bush in output shaft
SYO 2423 Puller for bush in output shaft
SYO 2834 Pressure gauge for checking oil pressure
SYO 2835 Centering mandrel for splines in planet carrier and uni·
directional clutch
SYO 2836 Socket for removing and fitting plugs for fine filter,
oil pump and relief valve
SYO 4030 Puller for oil seal at flange

4: 12
 DESC RI PTION
The overdrive unit is of theepicydic <type and is the help of the pistons (27, Fig . 4-41) in the hydraul ic
attached to the reor end of the gea'rbox. Itsdesign cylinders. This a lso locks the sunwhed. Since the
and constructionare shown in Figs.4-33, 4-41 and planet ge·ar retainers are linked to the mainshaft
lIIuskation 4-(, The working principle of the over- through the splines, the planet g,ears are force d to
drive is as follows: rotate around the sunwheel. As a result of this, the
output shaft will ,rotate at a higher speed than the
mainshaft.
DIRECT DRIVE POSITION
When trave ll,ing forwards the power IS transmitted
from the gearbox mainshaft throug'h the uni-direc- ELECTRICAL SYSTEM
tional clukh to the output shaft of the overdrive. At
The overdrive is engaged by electro-hydraulic means.
the same time the clutch sliding membe'r (position l,
On the gea'rbox cover thereis a contact which cuts
Fig. 4-34) is pressed by fou'r springs against the
in when 4th speed is engaged. Thus the overdrive
tapered part of the output shaf.t. When reversing or
can on,ly be engag'ed when this speed is engaged.
when the engine acts as a brake, the torque is trans-
It is switched on by means of a switch p laced under-
mitted through the clutch sliding member.
neath the steering wheel. This switch closes the cir-
cuit vi a the switch on the gearbox to a solenoid on
OVERDRIVE POSITION the ove,r drive. The sol,enoid armature is thus moved
In the overdrive position the clutch sliding member is and this operates the controlvalve ' to the position
pressed against the brake ring (see II, Fig. 4-34) with for overdrive.

HYDRAULIC SYSTEM
The hydraulic system consists of the following main
parts: Pre-filter, plunger pump, fine filter, hydraulic
cylinders and plunge'rs, relief valve and a controi
valve whichis operated by the solenoid.
The relief valve has a special construction with a
hydrau,lic piston and four different springs. It has three
different functions: It must maintain a low pressure
in the system with direct drive, a high pressure with
overdrive, and also provide smooth changing when
shifting from overdrive to direct drive and vice versa.
VOLVO Its function is desoribed in more detail below.
103263
Fig. 4-33. Gearbox M 410 The oil flow with dired drive is shown in Fig. 4-38.

• Non-rotating parts
Parts rotating at a higher speed than the input shaft

Parts rotating at the same speed as the input shaft

Fig. 4-34. Working principle of the overdrive Fig. 4-35. Elec!rical circuit diagram
I. Direcl drive posit ion 1. Lead from fusebox
II. Overdrive position 2. Switch for overdtive
3. Indicator lamp for overdrive
4. Switch on gearbox
5. Solenoid on overdrive

4 : 13
 8

~1t51,~~~--9
Vlt1iH-i-!H--10

11

VOLVO
103173
Fig . 4·37. Oil pump
l. Mainshaft 8. O·ring
VOLVO 2. Eccentric 9. Valve sea t
103223
Fig. 4·36. Relief valve 3. Cennecting red la. Spring
4. Gudgeen pin 11 . Plug
l. O·ring 9. Spring 5. Pisten 12. O· ring
2. Cylinder la. Small pisten unit 6. Cylinder 13. Pre·filter
3. Large pisten unit 11. Nezzle 7. Ball
4. Spring 12. Channel frem
5. Valve ball centre I valve
6. Channel fer eil pump 13. Plug
7. Channel te mainshaft 14.0·,-ing
8. End piece

Fig. 4·38. Function with direct drive

l. Nazzle 9. Eccentric
2. Channel, centre I la. Channel, relief valve
valve·relief valve mainshaft
3. Relief valve 11 . Pisten
4. Pre·fi Iter 12. Channel, eil pump - hydraulic
5. Oil sump cylinder - contrei and relief
6. 0il pump valves
7. Fine filter 13. Centrel valve and seleneid
8. Gearbox mainshaft

4: 14
 Fig . 4·39-. Overd rive in funclion

The oil is drawn through the pre-filter by the plunger on,e outer position to the other. This time is so adapt-
pump and is conveyed under pressure through the ed that a smooth engagement occurs with out any
fine fi,lter. From here the oil Hows fudher through the slipping of gears.
hydraulic cylin,de'rs to the relief and controi valves. Oil passing the small piston of the rel,ief valve is
The controi va.lveis c10sed and the I'arge piston of conveyed through the channel and a drilJ.ing in the
the relief valve is in its lower position. This off-loads mainshaft to the uni-di'rectional c1utch and the needle
the springs so that only a low preswre is required bearing shaft. The'reafter the oil is caught up by a
to press down the small piston of the relief valve. plate and I'ead via the planet gear back to the gear-
Oil then flows past the small piston out into the box housing, see Fig. 4-40.
channel to the ma,inshaft.
When the overdrive is engaged, the controi v,a lve is
displa'c ed and oil f10ws through the oilway and
operates the ,I'a rge piston of the relief valve. This is
tb.en moved upwards and causesl1he springs to ten-
sion . The more the springs tension the greater the
force ,is requi'red to press down th,e small piston, this
causing the hydraulic pressure to rise. The pistons are
thereby displaced in the hydraulic cylinders, the c1utch
sliding member is puMed forwards and contact made
with the brake ring .
With disengagement of the overdrive, the connec-
ti,on between channels 12 and 2 is c1osed. Instead, the
connection between channel 2 and the sump is opened.
This permits oi,l under the large piston of the relief
valve to flow ourt into the sump, the pressure in the
system drops and direct drive ,is engaged. Because of
the orifi'ce nozzle in the channel and owing to a suit-
able bolandng of the spring force, a certa'in time VO LVO
103 174
passes for the piston of the relief valve to move from Fig. 4-40. Lubricating system

4 : 15
 36 35 34 33 32 31 30 29 28 27 26 25 24

Fig. 4·41. Overdrive

l. Output shaft support bearing 17. Thrust washer 34. Small piston
2. Thrust bearing retainer 18. Speedometer driving gear 35. Base plate
3. Sunwheel 19. Spacer 36. Check valve for oil pump
4. Clutch sliding member 20. Ball bearing 37. Pump cylinder
5. Brake ring 21. Output shaft 38. Magnet
6. Clutch member outer lining 22. Oil seal 39. Pre-filter
7. Planet gear 23. Coupling flange 40. Fine filter
8. Needle bearing 24 . Rear cosi ng 41. Pump plunger
9. Shaft 25. Solenoid 42. Connecting rod
10. Planet carrier 26. Piston seal 43. Front casing
11. Oil thrawer 27. Piston 44. Input shaft
12. Uni-directional clutch 28. Operating valve (gearbox mainshaft)
rollers 29. Orifice nozzle 45. Eccentric
13. Uni-directional clutch 30. Cylinder top 46. Bridge piece
14. Oil trop 31. Cylinder 47. Spring
15. Ball bearing 32. Spring
16. Bush 33. Large piston

4: 16
 REPAI R I NSTRUCTIONS
WORK WHICH CAN BE CARRIED OUT of the relief valve, then ~he spring and spring
WITH THE OVERDRIVE INSTALLED reta,iner. Even the low-pressure spring willoiso be
CHECKING THE Oll PRESSURE included in the removal. Then pull out the sma'I,1
piston with its spring and spring re,t ainer, also the
The oil pressure can be suitably checked when driv-
cylinder and end washer. Use a pair of pliers
ing en test rollers or on a motO'rway. The check can
with naHOW jaws for the piston un,it ond aleap,
al,s o be made with the vehicle j'a cked up but this
see Fig. 4-44, for the cylinder and washe'r.
sheuld be aveided for reasons ef safety.
3. Wash all the parts in white spirit and blow them
Checking is as foHows ,
dry with compressed air. Check them carefully
l . Remove the plug unde,r the operation va,lv'e and
for wear and damage. The pistons should run
oennect the pressure gauge SYO 2834, see Fig.
easily in their cylinde,rs. Faulty pads must be re-
4-42.
placed . N.B. The following units are av'ail'able as
2. Read eff the preswre when driving on dir,e ct drive
spare parts: End washer, cylinder, the small piston,
at abeut 40 km.p.h . (25 m.p.h.). The p'ressure sheuld
adjuster washer, lew-pressure spring, I'aorg'e piston,
then be abeut 1.5 kp/mm 2 (21 p.s.i.).
plug and the O-rings.
3, Eng'a'g e the everdrive and check that the pressure
rises te 3~9 kp/mm 2 (510-550 p.s.i.).
4. Disengag'e the everdri~e ,a nd check the time fer
the pressure te drep te 1.5 kp/cm 2 (21 p.s.i.). The
time must net exceed 3 secends.

REPlACING THE SOLEN OlD

AND OPERATING YAlVE
The selenoid and eperating valve are inregrally built
Qo~ ene unit, which is repla,c ed complete. Fer remeving
and fitting, use a 25 mm (l U) fixed spanner. Use a new
sea,l and O-,rings when fitrting . The tightening torque
sheuld be 4.2-5.5 kpm '( 30-40 IbJt.).

CHECKING AND REPlACING THE RELIEF VAlVE

1. Remeve the base plat,e and the pre-filter. Cellect
the eil in an oil conta,iner. Warning. If the vehicle
VOLVO
has belen driven 'recently, the oil may be hot and 103114
Fig. 4-43. Removing the plug
sca Id if it comes inte contact with yeur skin.
2. Remov'e The plug under the relief valve with tool
SYO 2836, see Fig. 4-43. Pull out the large piston

SVD 2834

Fig. 4-42. Checking the oH pressure Fig. 4-44.

• VOLVO
103234

Removing the relief valve

4: 17
 VOLVO
103115 VOLVO
10311&
Fig. 4-45. Blowing the orifice nozzle clean Fig . 4·46. Fine filter
l. Filter 2. Seal 3. Plu g

4. Before fitting the parts of the relief valve, it may 5. Re-fit the pre-filter and base plate together with
be suitable to blow the orifice nozzle clean with a new gasket. Do not forget the magnet on the
compressed a·ir, see Fig . 4-45. bottom plate. Fill with oil.
5. Fit the new O-rings on the end washer, cylinder
and plug. Lubricate the pa-rts with oil. Then install
them in <the following order: End washer, cylinder,
CLEANING THE FILTER
small piston, low~pressure spring, largle piston and
plug . Tighten the plug to a torque of 2.2 kpm l. Remove the base plate and the p~e-fil/ter. Collect
the oil in an oil containec W,arning. If the vehide
(16 IbJt.).
6. Fit the pre-filter and base plat·e with a new gasket. hCls been recently driven, the oil may be hot and
cau~e damage if contact is made with your skin.
Make sure that the magnet is in position on the
2. Remove the plug and take out the se-al and fine
base plate. Fill with oil.
filter, see Fig. 4-46.
3. Clean all the parts in white spi rit. Then blow them
dry with compressed air.
4. Fit the fine filter, a new seal and th-e plug. T,ighten
CLEANING THE ORIFICE NOZZLE
the plug to a torque of 2.2 kpm (1 6 Ib.ft.).
The orifice nozzle is accessible after the cylinder of
5. Re-fit the pre-filter -and the base plate with a new
the relief valve has been removed according to
g·a sket. Make sure that the magnet is in position
above. Blow the orifice nozzle dean with compressed
on the base pl'ate. Fill with oil.
air, see Fig. 4-45.

REMOVING THE OVERDRIVE

CHECKING AND REPLACING THE CHECK VALVE To fa,a ilitate re moval, the vehicle should first be driven
l. Remove the base plafe an·d pre-filter. Col/ed the with the ovelrdrive engaged and then with it ,disen -
oil in an oil container. Warning. If the vehiole has gaged with the clutch pedal depressed. The last-men-
been recently driven, the oil may be hot and tioned is important in order to avoid torsionai tensions
scald if contact is made with your skin. in the shaft between the pl-anet ca'rrielr and uni-direc-
2. Remov·e the plug with tool SVO 2836. Take out tional dutch. Any stresses will disappear even if oil
the non-return valve spring, non-return ball and with pressure of 20-25 kp/cm 2 (284-335 p.s.i.) is
non"retum body. connected to the output at the operating valve. The
3. Clean all the parts in white spi rit and blow them overdrive is engaged and disengaged with this pres-
dry with comp!1essed air. Check the parts for sure.
·damage and wear. Replace faulty parts. Removal is as f.oHows:
4. Fit a new O-ring on to the pl-ug and then re-fit l. Carry out ope,~ations 1-5 under "Removing" in
the non-return body, ball, spring ·a nd plug. Tighten Group 53 a.
the plug to a torque of 2.2 kpm (16 Ib.ft.). 2. Disconnect the cahles to the soleno·id.

4: 18
 3. Unscrew the bolts holding the overdrive unit to 3. Press down and pull ou,t the pump cylinder. Then
the int'ermedia1e flange . Pull the overdrive straight take out the connecting rod and pump plunger.
out backwnrds until it goes free from the gear-
box mainshaft.
DISMANTLING THE CLUTCH UNIT
l. Remove the circlip for the sunwheel. Pu,11 out the
DISMANTLING THE OVERDRIVE sunwheel backwards.
Maximum cleanliness must be observed when work- 2. Remove the inner circlip for the bearing. Hold
ing with the overdriVle unit. Before the dismantling, the bearing body 'a nd tap loose the clutch sliding
dean the ou1side of the unit thoroughly. Then first member with a rubber mallet.
dismantie the main parts as fol'lows: 3. Remove the outer circlip and press the bearing
l. Placce the overdrive vecrtiwlly In a vice provided o~t of the bearing housing.
with copper jaws. Remov,e the solenoid and
operating va lve.
DISMANTLING THE REAR CASING
2. Bend down the locking tab, unscrew and rem ove
the nu1s ~or the piston bridge pieces. Remove the l . Remove the bolt and puH out the retainer, the
bush and the speledomete,r pinion.
bridge pi,e ces.
3. Unscrew the nuts holding the brake ring, front and 2. Remove the nut and pU11I off the flange with

rear casing. Loosen the nuts successively all round puller SYO 2261. Place the hou's ing in a press
and press ou,t t.he output shaft.
in o'rder to avoid any distocrtion from the springs.
3. Remove the spacer, the speedomete,r driving gear.
Lift off the fron1 casing and brake ring, see Fig .
Pull out the beming on the outpu,t shaft, suitably
4-47.
4. Tap loose t,he brake ring from the ~ront casing with a so-call,ed knife extrador. The rear bearing
and oil seal are pressed out of the housing with
with thehe'lp of a copper drift and hammer.
5. Remove the springs for the clutch sli,d ing member. drift SYO 1797 and handle SYO 180l.
4. Remove the circlip and ,the oi l thrower, which
Lift out the clutch sliding member complete with
hold the uni-di'rectiona,1 clutch on the output shaft.
thrust bearing and sunwheel.
Lift out the uni-dir'ection,al clu~ch co mponents.
6. Lift out the planet gear canier complete.
Remove the thrust washer. If nece swry pu ll the
bush on the output shaft ou,t with pul ler SYO
REMOVING THE FRONT CASING
2423, see Fig . 4-48.
l. P,lacce the casing wi<f1h the front side downwards
on a ben ch. Connect compressed air to the ho le
fo,r the opemting valve and blow out the pistons. INSPECTING THE OVERDRIVE
2. Disconnect the base p late and rem ove the pre-
Befolre inspecting, clean a ll the parts In white sp irit
filter. Then rem ove the plugs and take out the
and then blow them dry with oompressed a ir. Pay
parts for the ~espeotive fine filt'e r, relief valve and
particular attention to the clean'ing of the fi,ite rs and
pump check va lve. See a:lso under the heading
"Work which oan be ca:rried out with the over-
drive installed".

VOLVO Fig . 4-48. Removing the bush, output shaft

103117
Fig. 4-47. Dismantling the overdrive 1. Pull erSVO 2423

4: 19
all the oilways. Check that the orifice nozzle in the
channel between the relief and operating valves is
clean. If it is not possible to blow the nozzle clean,
it can be cleaned with a pointed wooden stick or
suchlike. Hard objects must not be used since these
can alter the graduation.
Check also that the groove inside the ring gear on
the output shaft is prope,rly cleaned. Dirt collects here
due to the centrifugal force. After cledning, check all
the parts carefully for wear, cra·cks or other damage.
Pay particular attention to the following :
Check the solenoid w ith the help of a 12 'volt battery
and an ammeter. CUHent consumption should be
about 2 amperes. Check the movement of the valve
during engagement and di~engagement.
Check to make sur,e that the filters are not damaged.
Also check the pistons of the hydraulic sysf.em for YS'2W
abra's ion and wear. Check the v·alves for wear. Make Fig. 4·50. Fitting the output shaft
sure that all the springs are not damaged. Check all
the ge'a rs and ball bearings for c~acks and wear.
Make sure that the bush on the sunwheel is not worn.
With Ifeplacement, change the sunwheel comple,t e
with bush. The bush must be concentr-ic with the gear ASSEMBLlNG THE REAR CASING
wheel, and this is difficult to bring about ou,t side a l . Push the bush on to the output shaft with drift
workshop. SVO 2417, see Fig. 4-49. Press the front be<lring
Check the brake ring fO'r abrasion, cracks or wear. to the output shaft with drift SVO 2412.
Check to make sure that the linings on the clutch 2. Press the rea'r bearing on to the rear Gasing se c-
sliding member 'a re not burnt or worn. tion with drift SVO 2412.
3. Place a wooden block under the Ol)tput as sup-
port. Fit the speedometer driving geer and spacer.
Press on the rea'r casing with drift SVO 2412, see
ASSEMBLlNG THE OVERDRIVE Fig. 4-50.
Use new gaskets, O-rings, lock washer and seals when 4. Press in the oil seal with drift SVO 2412. Fit the
assembling. Observe ma~imum cleanliness since the coupling flange, the washer and nut. Tighten the
hydraulic system is sensitive to impuriti,es. nut to a torque of 11-14 kpm (80-100 IbJt.).

VOLVO
Fig. 4·49. Fitting the bush, output shaft Fig. 4-51. Assembling the uni-directiona1 dutch, 1 24688
l. Drift SYO 2417 1. Spring 2. Cage 3. Uni-directional clutch hub

4: 20
 Fig. 4·52. Assembling the uni·directional clutch, "
Fig . 4·54. Fitting the oil t hrower
1. Key
1. Oi l thrower plate 2. Circl ip

5. Assembl·e the uni·directional clutch, spl1ing and

roller cage, see Fig. 4·51. Tum the roller cage
olockwise as far as it will go and lock H in this
2. Fit the bolts on the bearing retainer. Then press
position with a key as shown in Fig. 4-52. Place
the bearing with retainer on to the clu·toh sliding
in the Toners. Tie a piece of rubber band or string
member. Fit the circlip.
round ~he rollers.
3. Fit the sunwheel on to the clutch sl.iding member.
6. Fit the th rust washer and then the uni·directional
Fit the circlip.
clutch in posi~ion on the output shart, see Fig.
4. Install the clu,tch unit in position on the output
4·53. Fit the oil thrower and install the circlip, see
shaft. Fit the four thrust springs on to the bolts.
Fig. 4-54.
7. Fit the spe,edometer pinion and bush. Fit the re-
tainer and bolt.
8. Place the planet carrier complete with planet gear
in position on the outpu·t shaft. Guide up the
splines into the plan.e t wrrie'r and uni,dil1ectional
clurtch with drift SYO 2835, Fig. 4-55.

ASSEMBLlNG THE CLUTCH UNIT

l. Press the ball bearing into the retainer and fit the
circlip.

Fig. 4·53. Fitting the uni·directional clutch Fig. 4·55. Fitting the planet gear

4: 21
 VOLVO
103119
Fig . 4·57. Fitting the front casing

Fig. 4·56. Fitting the fine filter, oil pump check

valve ond relief valve

ASSEMBLlNG AND FITTING FRONT CASING 4. Fit the operating pistons in their cylinders.
l . Fit the fine filter. Also fit the relief valve parts 5. Install the brake ring on the front casing. Place
in the following order: End washer, cylinder, the front casing on the rear one. Fit washers ·a nd
small piston, low-pressure spring, large piston nuts, see Fig. 4-57. Note that both the copper
and plug, see 4-56. washers should be fitted on the upper bolts. Tigh-
2. Place the conneoting rod and pump plunger in ten the bolts a I,ittle at a time until they a're tigh-
position in the casing. Then push in the cylinder. tened evenly aM around.
After thatfit the non-return body, non-return ball, 6. Fit both the thrust washers. Tighten and lock the
spring and plug. nuts. Fit the operating vdve and solenoid.
3. Tighten the plugs for the fine filter, relief "alve
and pump check va lve with torque wrench and FITTING THE OVERDRIVE
tool SYO 2836. The tightening torque is 2.2 kpm Fitting the overdrive is in revers·e o'rder to rem oval.
(16 Ib.ft.). Fit the pre-filter, magnet, gasket and Fill with oi!. Check the oil in the gearbox after the
base plate. vehicle has been driven 10-15 km (6--9 miles).

4: 22
 GROUP 44

AUTOMATIC TRANSMISSION
TOOLS
The following special tools are required for repairing the automatic transmission

svo 2530. SVO 2531 SVO 2532 SVO 2533

o SV02534

n
SVO 2535
O
SV02537
C
SVO 2538
.~
SVO 2748 SVO 2837
oSVO 2900

VO LVO
105438

Fig. 4-58 Special taals

SYO 2530 Fixture for dismantling and assembling the transmission. SYO 2535 5/16" square socket for adjusting rear brake band.
SYO 2531 Manometer complete w ith hose and connection for SYO 2537 Spacer for adjusting front brake band.
checki ng the oi I pressure. SYO 2538 Spanner for locknut on contact for starter inhibitor
SYO 2532 Attaching plate for magnetic holder when measuring and reversing light.
end float of input shaft. SYO 2746 Transmission fixture when removing and fitting, see
SYO 2533 Press tool for compressing c1utch when removing and Fig. 4-76.
f itting the sno p ring. SYO 2748 Dynamometric wrenc h for adjusting front brake band.
SYO 2534 Ring for fitting piston in rear c1utch. SYO 2837 Counterhold for flange.
SYO 2900 Ring for fitting piston in front c1utch (used tagether wi!h
SYO 2533)

4: 23
A B c D E F G H J K L

p o N M VOLVO
102634

Fig. 4-59. Sectioned view of the transmission

A. Turbine E. Front elutch I. Rear brake band M. Reverse sun gear
B. Stator F. Rear elutch J. Planetary gear set N. Forward sun gear
C. Impeller and cover G. Front brake band K. Rear pump O. Controi system
D. Front pump H. One-way elutch in gearbox l. Governor P. One-way elutch in converter

DESCRI PTION
The Volvo automat/ie transmission for ears is of Borg- eoupling eapable of torque mult-ipl>ication at an
Warne'r manufadure, type 35. If consists of two infinitely variable rate between 2:1 and 1:1.
ma,in eomponents: 2. A hydraulieally operated gearbox comp'rising a
1. A three-element hy,d rokinetie torque eonverfer pl'a neta1ry gear set with a valve system whieh
automatical,ly selects a suitable gear in relation to
the speed of .the ear and position of the aceelera-
~or pedal.
There is also a selector eontroi with positions "L",
"D", "N", "R" ond "P", see Iiig. 4-61.

THE TORQUE CONVERTER

The torque eonve,rte'r serves both as a dutoh and as
an extra (hydraulic) gear between the engine and
gearbox. It provides a means of obtain'ing smooth
applioation of engine power to the driving wheels
and additional engine torque mull1iplication to the
1st and 2nd gears of the ge'a rbox. The oonverter a,lso
prov ides extreme low-speed flexibHitfy when the gear-
Fig_ 4-6D_ The Borg-Warner Automatic Transmission type 35 box is in 3rd gear and, due to the a-bility of multi-

4: 24
 {

l
VOLVO
27978

Fig. 4-63. Function of converter

The conVle'r ter fundions as follows :

VOLVO
102 564 The impeller is rotated by the eng,ine and converts
the engine powerinto hydrokinetic energy. The fluid
Fig. 4-61. Selector lever positions
flows from the impeHer vones to the turbine vanes
and return s to the impeller through the stator ",anes,
see Fig. 4-63. The curvature of the v'a'rious vanes is
plying engine torque, it provides good acoeleration so designed that when a speed diHerential exists
from very low ·road speed withou·t haViing to resort between the impeller and ~he turbine, the angle of
to a downshift ,in the gearbox. the fluid flow fr'om the turbine is changed by the
The converter consists of three main components - stator vanes in such away that the discharge of fluid
an impdler connected to the engine orankshaft, a from the stator assists in driving the impeHer. Under
turbine connected ~o the input shaft of the gearbox, su'ch conditions, to·rque mul,tiplication occurs and varies
and a stator mounted on a sprag-type one-way c1utch from 2: 1 when the turbine is stalled (Le. when, with
supported on a fixed hub projeding from the gear- any of the driving ranges selected, the vehicle is held
box case. stationary and the engine is operating at ma·ximum
throttle opening) to 1 : 1 when the turbine reaches
a speed approximately 90 % of th~t of the impeller.
When this speed differential be,t ween the impeller and
turbine is achi,e ved, the fluid flow angle from the tur-
bine is such that the stator is driven in the same
direction as the turbine and the impeller. Under these
cirwmsta nces, the converfer becomes a fluid flywheel
or coupling and there is no torque iffiultiiplication.

GEARBOX
The gearbox consists of a mechanical powe'r !Tans-
mission system - planetary geor, two c1utches, two
brake bands and a one-way c1utch -and a hydraulic
system - front and rear pump, oentrifug'al governor
anda controi 'talve system which regulates the fluid
VOLVO pressure and directs the fluid to the various gearbox
105377

Fig. 4-62. The converter components.

4 : 25
 Fig. 4-65. Planetary gear, clutches and brake bands

Fig. 4·64. Planetary gear

and provides the l st gear rotio of 2.39: l and, in re-

verse, a rotio of 2.09:1. The front band holds the
MECHANICAL POWER TRANSMISSION r,eve,rse sun gear stotionary to provide the 2nd geor
SYSTEM ratio of 1.45: l.
PlANETARY GEAR
The planetary gear set oonsis,ts of two sun g,ears, two
ONE-WAY ClUTCH
sets of pinions, a pinion oorrier and a ring gear, see
Fig. 4-64. Helical involute tooth forms a 're used In the drive position HD", a one-way clutoh is used
throughout. In al'l forwa'rd gea-rs, power enters through in place of the rear band to prevent the pinion ca"rier
~he forwa'rd sun g,ear; in reverse, powe,r enters through from tuming opposite to engine rotation, thus also
the reverse sun g'ear. Power leaves the geor set by providing a l st gear ratio of 2.39: l. This one-way
the ring gea:r. The pinions are used to transmit power clutch, allowing the gearbox to freewheel in 1st gear,
from the sun gems to the ring gear. In reverse, a provides smooth ratio changes from l st to 2nd and
single s,et of pinians is used which oauses the ring gear vice versa.
to rotate in the opposite di-rection to the sun gear. In
forwa'rd gears, a double set of pinions i,s used to cause
the ring geClr to rotate in the same direction as the sun Oll COOLE R
gear. T,he carrier looates the pinions in their corred The automatic gearbox is connected to an oil cooler.
positions relative to the two sun gears and the ring This is housed in the bottom tank of the engine ra-
g,eClr (and also forms a readion member in certain diator and is connected as shown in Fig. 4-67. The oil
con-ditions). The va-rious mechanical rati os of the gear cooler is connected to the nipple (Fig. 4-66) on the
set are obtained by the eng'agement of hydraulically right-hand side of the georbox.
operated multi-disc clutches and broke bands.

ClUTCHES
The clu_tches, see Fig. 4-65, consist of multi-disc units
ope'rated by hydraulic pistons. In all forward gears
the front dutch conneds the converter to the for-
wa.rd sun gear; for reverse, the ,rear clvtch connects
the converter TO the reverse sun geor.

BRAKE BAN-DS
Brake bands, operated by hydraulic se-rvos, hold
elemen-ts of the gear set stationary to effect an out-
put speed reduction and a torque increase. In ",lock- Fig. 4·66. Oil caoler connection
up", the -rear band holds the pinion ca'rrier stationary 1 and 2. Connection nipples for oil cooler

4: 26
 VOLVO
Oil 104081

Coolan!

Fig. 4-67. Principle of operation for oil cooler

RE PAI R I NSTRUCTIONS
When carrying out any work on the vehicle, the it up and nme the oH level, see Fig. 4-68. N .B. There
selector lever sh ou Id be in position "P". are different oil leve I marks for a warm or eold gear-
Provided the transmission is operating satisfactorily, box. When the gearbox is warm, after the ear has
the car may be towed in position "N", on condition been driven about 5-7 miles (8-10 km), the upper
that the gearbox is properly adjusted and the fluid mea (3 and 4, Fig. 4-68) applies. The lower area (l and
I'evel is correct. If the transmission is inoperative, the 2) applies when the gearbox is cold. The t,ext on the
propeller shaft should be diseonnecfed before start- dipstiek also mentions this differenee.
ingtowing. If neoessary, top up with oH to the "Max" mark. Do
The controi system of the automatic transmission is not exceed this mark, otherwise the gearbox can
manufactured with the same degree of precision and beeome overheated. The ,d ifference between the "Min"
accurate fits as the injection equipment of a Diesel and "Max" mark is about l pint (0.5 litre). Use an oil
engine. Fluid circulates through the converter, trans- whieh is approved as "Automatic Transmission Fluid,
mission gearbox and controi system. It is therefore Type F".
neeessary to observe the utmost c1eanliness when ear- If topping up with oil i,s required of~en, there must
rying out any work on the transmission. be leakage, whieh should be attended to immediately.

WORK WHICH CAN BE CARRIED OUT

WITHOUT REMOVING THE TRANSMISSION
SUPPLEMENT
CHECKING THE FLUID LEVEL 1=~-3

Normally oil changingi's only ,required when the

gearbox has been reconditioned. However, the oil
4
level shoul,d be checked every 10000 km (6000 miles).
When checking the oil I'evel, the car should be on a
level surfaee. Move the selector to position "P"and
let the engine idle. The fiMing pipe with dipstiek is VOLVO
103243
loeated in front of the bulkhead on the right-hand Fig. 4-68. Checking the oil level
side of the engine. Pull up the dipSJtiek, and wipe it 1. Max. oil leve l, cold gearbox
with nylon doth, paper or ehamois leather. Fluffy 2. Min. oil leve l, cold gearbox
3. Max. oil level, gearbox run warm
rags must not be u'sed. Insert the dipstiek, then pull 4. Min. oil level, gearbox run warm

4: 27
REMOVING AND FITTING THE CONTROl SYSTEM
1. Jack up and place blocks under the v,ehicle. Drain
off the oil into avessel which is absolutely dean .
See Fig. 4-75.
N.B. The oil may be very hot and cause burns
if conract is made with the skin.
2. Release the bolts for the oil sump and rem ove
the sump. Carefully remove the oil pipes (Fig. 4-78).
3. Release the throttle cable from the cam. Remove
the three bolts, see Fig. ' 4-79, which secure the Fig . 4·69. Adjusli ng seleclor conirois
controi system to the gearbox casing. Remove the A=B
controi system stmight downwards so that it rele-
ases from the oil pipes at the front end . rance should be the same In both positions, see
4. Make sure that the oil pipes are in position on Fig.4-69.
the front pump body. Place the controi system 4. Check t hat the pointer for the gear positions
in position and secure it with the three bolts, see points correctly on the scale. If not, a,dju's t the
Fig.4-79. cable sleeve at the indicato r (Fig. 4-123).
5. Fit the throttle coble TO the cam. Mount the o,il 5. Check that the output shaft islooked wi,th the
pipes as shown in Fig. 4-78. Check that the mag - controi lever in positJon "P".
netic element I,ies in the oil sump and fit the ,sump.
Use a new gasket. Coat the threods on the oil ADJUSTING THE THROTTLE CABlE
drain plug with sealing flui,d 277961 and then fit Correct adjustment of this cable is mos,t important
the plug. for satisfactory operation of the transmission. There
6. Lower the vehicle, fill with oi!. a re thre,e different methods. Adjust first in accord-
ance with A, see Fig. 4-70. Method 8 is to be applied
if the transmission is not functioning satisfactorily,
ADJUSTING THE SElECTOR CONTROlS and method C when replacing the cable.
l . Disconnectthe pull rod from the lever on the A. l. Check that engine idling speed is correctly
selector shaft. Set the selector lever to "N". adjusted and that the inner cable and outer
2. Set the levler on the transmission to the central cable are correctly attached.
position. Adjust the length of the pull rod so 2. Screw up the threaded sleeve until it almost lie's
that the pin ean be pushed easily through the against the stop (for vehicles with single ear-
yoke and lever. burettor), and 1/32" (l mm) from the stop for
3. Check the setting by noting the distance to the vehicles wilh twin carburettors, the stop being
selector lever in "N" and "D" positions. The clea- crimped on to the cable.

B c
Fig. 4·70. Adjusling Ihrollle cable

A, Adjusling cable slop

c B. Adjusling wilh lachometer and manometer
e 1. Chock the whee ls and apply the brakes

~~
2, Se led position "D"

,
3. Connect a revolution counter (a)
4. Con ned a pressure gauge (b)

~~~~
c. Measure pressure (P) al 500 r.p.m,

~
d . Measure pressure (P+R) ,at 1000 r.p.m .
R. Should be 1.1-1.4 kp/cm2
(15-20 p.s ,L)"

@ t& C. Adjust the cam in gearbox

~~~~
- c, Accelerator pedal in idling position
~~'o>' ,? : e. Accelerator pedal fully depressed

VOLVO
27981

4: 28
 3. With the accelerator pedal fully depressed, constant radius area of the cam shou ld be the
check that: point <Of contact with the downshift valve.
a . the carburettor lever is at the full open stop. Note: l. The cable is pre-Iubricated with silicon or
b. the line pressure at converter stall speed molybdenum disulphide lubricant -and must
amounts to at least 160 p.s.i. (11 kgJcm 2). not be oiled .
B. If the cable stop has been damaged or moved, 2. Ensure at all times that the outer cable is
the cable must be adjusted as follows; correctly located in the ad juster.
l . Connect a tachometer to the engine and pressure
meter to the transmission as shown in Fig. 4-71 .
2. Chock the wheels ,a nd apply the bm,kes. Start the ADJUSTING THE STARTER INHIBITOR SWITCH
engine and move the lever to "D". Read off the The starter inhibitor switch has two te~minals for the
pressure at 500 and 1000 r.p.m. At 1000 r.p.m. the starter innibitor circuit, the function of which is to
gauge to the transmission as shown in Fig. 4-71. prevent the engine from being storted with the sel,e dor
pressure should be 15-20 p.s.i. (1.1-104 kpJmm 2 )* in any other posili,on than " N" or "P". There m,e also
higher than at 500 r.p.m. If the pressure rise is two termina-Is for the reversing light. It is very impor-
less than 15 p.s.i. (1.1 kgJcm 2 ), the effective length tant that this switch is cor~ectly adjusted, since if the
of the outer cable should be increased by means engine can be ~tarted in any of the driving positions,
of the adjuster. Conversely, if the rise is more the car can eO'sily be set in motion unintentionally and
than 20 p.s.i. (lA kpJcm 2) the effective length of possibly cause an accident. The switch is adjusted as
the outer cable should be decreased. follows :
N.B. On vehicles with an exhaust emis~ion controi l . First check tha-t the seledor controi is corr,e ctly
system, it may be more ' suitable to measure the pres- odjusted. Move the selector to "D".
sure at 700 and 1200 r.p .m. The pressure increa-s e also 2. Slacken the locknut for the switch with the help of
in this case should be 15-20 p.s.i. (U-lA kpjcm 2 ).* the special spanner. Screw out the -switch until it
C If a new cable has to be fitted, the transmission is only held by a couple of threads.
oil pan must be removed. In this event i-t is often 3. Con ned a contral lamp to the reversing light
simpler to adjust the cable by observ:ing the move- terminals--as shown in Fig. 4-72 "A". Screw in
ment of the cam in re lation to acoelerator pedal
movement as follows :
l. With the accelerator pedal fully released and
the carburettor lever at the idling stop, the heel
of the cam should conlad lhe full ,d iameter of
the downshift valve, with all the slack of the
inner cable taken up.
2. With the accelerator pedal fully depressed and
the carburetor lever at the full open stop, the

• AS5-35 EN with effeet from serial

No. 1829: 25-30 p.s .i. (1.8-2.1 kp/em 2).

VOLVO
Fig. 4-72. Adjusting starter inhib itor
400062
A. Bulb eannec!ed to reversing light eantaets
Fig . 4-71. Connecting pressure gauge B. Bulb eannec!ed to starter inhibitor eontads

4: 29
•
 the switch until the lamp goes out. Mark this posi- If the olutch and bands operate satisfactorily with
tion on the housing and switch with o pencil. air pressu.re, faulty operation of the transmission must
4. Connect the con tro I lamp to both the other ter- be due to malfunction of the hydraulic controi system.
minals, Fig. 4-72 "B". Screw in the switch until the The valve bodies assembly must then be dismontled,
lamp lights ·a.gai,n ond then mark .the switch aga in. eleaned, inspected ond re-assembled.
Then screw bock the switch to halfway between
both the marks. Lock with the locknut. Conncect the
leads. FRONT CLUTCH AND GOVERNOR FEED "A"
5. Apply the brakes ond chock the wheels. Check Apply ai'r pressure to the passag·e (5) of the trans-
that the engine can only be std'rted with the seIec- mission case reor wall, see Fig. 4-74. Listen for a
tor ·Iev.er in "N" ör "P". Move the selector lever thump, indicating tha·t the elutch ,is functioning. On the
to "R" and check that the reversing lightlights up bench, also verify by rototing the input shaft with air
when the ligh~ing switch is switch ed on. pressure applied.
If the ex~ension housing hos been removed, rotate
the output shaft so that the governor we.ight will be
ADJUSTING THE REAR BRAKE BAND at the boMom of the assembly. Yerify that the weight
When adjusting this band in the car, a hole hos been movesinwClrds with air pressure appl.ied.
introduced in the body tunnel, whichis accessible ofter
the mats have been moved to one side ond the rubber
removed. Otherwise adj usting i·s carriedout os fol- REAR CLUTCH "B"
lows : Apply air pressur,e to the passage (15) of the trans-
l. Slacken the locknut for t,he adjusting screw. missi,on case web. On the ben'ch, verify by turning
2. Use the special socket SYO 2535 ond con'ned the the input shaft that the elutch is functioning . Keep
torque wrench to the adjusting screw, see Fig. 4-73. air pressure applied for severol seconds to check for
Tighten the screw to 10 IbJt. (1.4 kpm). Back off the leaks. Then I,isten for a thump indicat·ing that the elutch
adjusting screw one turn. is relea-sing when the air pressure is remevecl
3. T'ighten the locknut and fit any pa,rts which have
been removed.
FRONT SERVO "C"
Apply air pressure to the hole immediately adjacent
to the reor retaining bolt. Observe the movement of
AIR PRESSURE CHECKS
the piston pin.
Air pressure checks can be mode on the g,e arbox
assembly to determine whether the dutches ond broke
bands are opera·ting. These checks con be mode with REAR SERVO "D"
the transmission in the car or on the ben ch. In either Apply air pressure to the ho le on the servo body.
even t, drain the Huid ~rom the gearbox ond remove Observe cthe movement of the servo leve·r.
the oil pan as weil os the valve bodies assembly with
oi,1 tubes. The air use,d must be elean ond dry.

V OL VO
105 378

Fig. 4-74. Functioning lesl wilh compressed air

A. Fro nt clutch (S)
B. Rear cl utch (15)
VOLVO
103833 C. Front servo applicalion
Fig. 4-73. Adjusling rear braka band D. Rea r servo

4: 30
 flange. Disconnect the controls from the selector
shaft lever as weil os the reinforcing brocket under
the oil pan.
5. Remove one of the air grilles on the oonverter
cosi ng and unscrew the atfaching bolts for the
converter. With a spann,e r on the camshaft pulley
bolt tum the crankshaft forwards. The spanner is
also used as a counterhol,d.
6. Unscrew the nut for the rear engine mounting ond
remove the cross-member. Disconn,e ct the brockets
for the exhaust pipe and the rear engine mounting.
Remove rthe speedomerter cable from lhe gearbox.
Release the oil ,filler pipe.
7. lower the engine about 20 mm (0.8/1). Observe due
Fig. 4·75. Oil drain plug care with the battery lead. If any tensions arise,
release the lead damp.
8. Disconnect the electric cables from the sta'r ter in-
REMOVING hibitor. Unscrew the screws for the starter inhibi-
GEARBOX WITH CONVERTER tor. Place a jack with fixture SVO 2746 under the
gearbox. See Fi g. 4-76. Unscrew the attaching bolts
l. Ta~e up the oildipstick and remove' the damp for
for the converfer cosi ng. Pull the gearbox back-
the filler pipe. Remove the brocket and the throttle
wards and release the guide pin on the converter
cable from the dashboard and throttle controi
at the same time . lower and rem ove the gearbox.
'r espectively. Disconnect the exhaust pip,e at the
flange . Jack up the car Qnd place blocks under the
front and rea'r axles. DISMANTLING
2. Drain the oil into a dean container, see Fig. 4-75. As a general rule it is advisable to dismantle only
N.B. The oil may be very hot and scald if contacf those components requiring atfention as indicated by
is made with the skin. road-testing or fault-tracing prooedure.
3. Place lifting tool SYO 2727 at the rear end of the Prior to the remova'l of any components, the outside
engine. Hook the I'ifting hook securely round the of the gearbox must be thoroughly washed down with
exhaust pipe. white spirit. A high standard of deanliness is required
N.B. Observe due care so that the speedometer when handling or storing components.
cable or the electric cables are not damaged. When dismantling, the gearbox should be inverted
"f.ighten the nut for the lifting hook until the sling and placed on the bench cradle as shown in Fig. 4-77,
takes the weight off the engine. and special too ls used as shown in the service tool
4. Disconnect the propeller shaft from the gearbox list. Treat the various components with great care,

VOLVO
105379
Fig. 4-76. Fixture for transmission Fig. 4·77. Transmission on bench stand

4: 31
 ;
VOLVO
105 382

Fig. 4·78. OiJ tu bes Fi g. 4-79. Valve bodies assembly

A. Converfer outlet A. Attach i ng screws

B. Fron! servo release
C. Fron! servo apply
D. Rear c1utch
E. Rear servo
8. Unscrew the eight screws which reta in the oil tube
co ll,e ctor.
9. Unscrew the four screws which reta,in the gover-
nor line plate. Note that two screws are under one
particularly light-alloy parts. When the gearbox is to
of the straine'rs.
be completely dismantled, follow the procedure below.
10. Remove the separating plate and ,t hen the check
l. If the converter housing is attached to the gear-
valves for the converter, fast 3-2 and front and
box, remove the six bolts and withdraw the con-
rear pumps, see Fig . 4-81 . Withdraw the manual
verter housing.
controi valve, see "A", Fig . 4-82.
2. Unscrew the "Wedglok" screw for the drive flange
11 . Remove the stops for rthe throtHe valve and the
on the output shaft. Pv!'! out the drive flange and
return spring. Then withdraw the downshift valve,
catch the %" flat washer. Loosen and withdraw
spring and throttle valve, see "B", Fig. 4-82.
the reor housing . Remove the speedometer gear.
12. Remove the dowel pin which retoins the plug for
3. Unscrew the bolts for the oil pan and remove
the modulator va lve. Then rem ove the plug, vdve,
this. Lever out carefully the oil tubes shown in Fig.
plunge'r and spring .
4-78.

THE VALVE BODlES ASSEMBLY

Work on the whole assembly should pr,e ferably be
carried out in a diesel test-room or in a room with
equal standards of cleanliness.
4. Disconnect the downshift vcrlve coble from the
downshift valve cam. Unscrew the thr,e e screws D
which retain the valve bodies assembly to the
gearbox housing, see Fig. 4-79. Lift the valve
bodies assembly straight upso that ihe,leases from E---
the oil tuhes at the front end.
5. Unscrew the two screws for the bracket of the
downshift vallve cam.
6. Remove the two strainers for the front and rear
pump respectively. VOLVO
27968
7. Unscrew from above the screws which reta in the Fig. 4-80. Main components of valve bodies assembly
IJpper valve body. Turn the valve bodiesassembly A. Oil !ube callec!or E. Lower va Ive body
round and uns'crew the other six screws from un- B. Upper va lve body F. Fron! pump s!rainer
C. Governor Ii ne pla!e G. Rear pump s!rainer
derneath. D. Separa!ing pla!e

4: 32
Fig. 4-81. Check valves in lower valve body

A. Rear pump <;heck valva

B. Check valve for fast 3-2
C. Front pump check valve
D. C',"verter autlet check valve
(only R-H drive)

13. Remove the stop for the servo orifice controi valve 15. Remove the SIX screws and end plate from the
and then the spring and valve. upper valve body, see Fig. 4-83. Remove the
14. From the manual vCllve side of the lower valve rollowing parts from the rem end of the body:
body, remov,e the following components: three shift v.alve 2-3, inner spring and plunger together
screws, lowe r body end plate, primary regulator with shift valve 1-2. The spring and plunger for
spring, primary reg·ulator valve sleeve, primary shift valve 1-2 are removed in the other direction .
regvlator vallve, secondary regulator valve spring
and secondary regu,lator valv,e.

'~--D
Fig. 4-82. Lower valve body
A. Manual controi valve
B. Downshift and thrattle va lve
C. Primary regulator valve
D. Secondary regulator valve
E. Servo orifice controi valve
F. Modulator valve

VOLVO -
103 BJ8

4: 33
 ...__-~~--B

Fig. 4-83. Upper valve body

A. 1-2 shift valve and plunger
B. 2-3 shift valve and pl-unger

VOLVO
102640

FRONT AND REAR SERVOS FRONT PUMP ASSEMBL y

16. Remove the two screws which retain the front 20. Remove the oil tubes In the housing . In case of
servo to the body, withdraw the servo and the difficulty pull them out with needle-nose pliers as
strut for the band. shown in Fig. 4-84.
17. Remove the snap ring in the servo with a small 21. Set up the dia I indicator gauge as shown in Fig.
screwdriver. Tlake out the piston and separate 4-85 with plate SVO 2532 and magnetic attachment.
the various parts. Dr,ive out the slott,e d spring pin Place the point of the gauge against the shaft end,
and lever pivot plin if necessary. move the shafts and gears backwards and forwards
18. Unscrew the two screws which re't ain the rear and read of the end float. This should be 0.010-
servo -and withdraw this and the strut. 0.030" (0.25-0.75 mm). Note the amount of play.
19. Unhook the spring. Drive out the pivot pin and 22. Unscr-ew the six bolts which refain the front pump
rem ove the lever. Pull out the piston. to the body. Withdraw the pump and remove the

VOLVO
105383
VOLVO
Fig. 4-84. Removing converter inlet and outlet tubes using 400061
needle-nose pliers Fig. 4-85. Checking end float

4: 34
 VOLVO VOLVO
27665 27970

Fig. 4·86. Removing front pump Fig. 4-88. Withdrawing front clutch assembly

gasket. Push the shaft inwards when withdrawing piston is tight, la y the clutch body with the opening
the pump, see Fig. 4-86. downwards on a bench and hlow out the piston
23. Unscrew the ~ive hexagon boHs and the slotteq with compre.s sed air.
screw. Separate the pump body, gears and other
parts, see Fig. 4-87.

REAR CLUTCH ASSEMBL y

27. Withdraw the rear clutch assembly rI10gether with
FRONT CLUTCH ASSEMBL y the forward sun gear shaft, see Fig. 4-89.
24. Withdraw the front clutch assembly and ,input sh af t 28. Remove the ,t wo oil rings at the front of the shaft.
complete, see Fig. 4-88. lake care of the thrust lhen withdraw the shaft. lake care of the two
wO'She,rs. lake <out the front brake band. needle thrust bearings.
25. Remove the snap ring with a screwdriver. With- 29. Remove the three oil r,ings from the clu1ch body
draw the input shaft. lake out the inner and outer hub.
plates and the clutch hub. 30. Remove the snap 'ring and take out the pressure
26. Remove the snap ring, spring, and piston . If the plate, inner and outer plates.

VOLVO
27669

Fig. 4-87. Converter support separated from front punip

A. Pump odopler ond converter support ossembly
B. Body ond bush ossembly VOLVO
27668
C. Driv; ng geor
D. Driven geor Fig. 4-89. Withdrawing rear clutch and forward sun gear group

4: 35
 --'--- ---------

VOLVO
27963

Fig. 4-92. Withdrawing center support and planet gears

d raw the centre support and planet gears, see Fig.

4-92. lake out the rear brake band. Separate the
center support, one-way elutch and planet gears.
Remove the snap ring and the outer race of the
one-way el utch .
VOLVO
400059
Fig. 4-90. Dismantling rear clutch
GOVERNOR
33. Remove the snap ring, see Fig. 4-93, and withdraw
31. Place special too l SYO 2533 on the elutch as shown the governor. lake wre of the detent ball.
in Fig . 4-90. lighten the wing nut until the snap ring 34. Unscrew the two screws and take off the governor
releases. Remov,e the snap ring and screw back the sleeve. lake off the spring retainer and separate
wing nut. Remove the special tool, then the re- the various parts. Unscrew the screwsand with-
tainer and spring. Withdraw the pisten. If neces- draw the cover plate.
sary blow out the piston with compressed air.

REAR PUMP
CENTER SUPPORT AND PLANET GEARS 35. Unscrew the five hexagon bolts. Use a thin-walled
32. From the ourtsi·de of the ,transmission case remove or ground-diameter socket for the hexagon bolts.
the two centre support screws, see Fig. 4-91. With- Withdraw the pump housing and driven gear.

VOLVO
27959

Fig. 4-91. Center support, retention and passages Fig. 4-93. Withdrawing governor

\
\ 4: 36 l
 Mark the gear on the outside face so that it can permissible limits, it can be taken for granted that the
be re-fitted correctly. thrust washers are not worn.
36. Remove the three Ooil sea-ling rings from the driven Check the gears for wear, seizingor to'o th fractures.
shaft. Mark the driving gear on the ouJside face Also check that the pinions in the planet gear pinion
and then withdraw it. Remove the drive key from carrier run easily on the needle bearings.
the shaft and take out the pump plate. Check the brake bands and discs fOor wear, over-
heating or other damage.

DRIVEN SHAFT
37. Withdraw the driven shaf.t. Remove the thrust
washer. If necessary rem ove the snap ring and ASSEMBLlNG
s,e parate the ring gear from the driven shaft. The utmost c1eanliness must be observed when ?s-
sembling the transmission.
Before assembling, all parts must be carefully was hed
SHAFT, PARKING PAWL, AND LEVERS
in white spi rit.
38. Remove the locking clips with needle-nose pliers. Use new gaskets when assembling. Lubrica1e the parts
Drive out the slotted spring pins ,in the manual with "Automatic Transmission Fluid' Type F".
valve lever shant. Then drive inwards the slotted Tighten all bolts with a torque wrench in accord-
spring pin retaining the pa'rking brake toggle pin. ance with the torqu,e chart in the "Specifications". Use
Sepalrate the parts. The anchor pin for the parking sealing compound 277961 on the tlireads of the inhibi-
pawl (the ,I ower of the two pins as viewed with tor switch, the pressure point plug and the oil drain.
the gearbox inverted) can be withdrawn with a Locking fluid Loctite CV or corresponding is used for
magnet or shaken out by up-ending the gearbox. the flange bolt, and Loctite AV for the nipples for the
39. The throttle cable and other parts in the body are oil cooler connections. Note: Items not described in
removed as necessary. this section are assemb led in ,t he reverse order to
di,s mantling.

TRANSMISSION CASE, SHAFT, PARKING PAWL

INSPECTING AND LEVERS
After c1e'aning, all parts should be thoroughly checked l . The transmission case is inverte,d on the bench
for wear or other damage. cradie.
Check that the white metal bush for the driven shaft 2. Assemble the shaft, parking pawl and lev,e rs in the
and the pins for the parking pawl linkage are firmly reverse order to dismantling. Make sure that the
secured in the case. If they are loose, the case must springs for the levers are correctly fitted, se,e Fig.
be replaced. 4-95. Fitting the detent ball is facilitated by press-
Check the thrust washers and needle bearings for ing down the ba'" using a short length of rt ubing as
wear andany seizing. If the end-f1oat is within the shown in Fig. 4-94.

VOLVO
105384
Fig. 4-94. Localing manual valve lever on delenl ball spring Fig. 4-95. Parking pawl and linkage inslalled

4 : 37
 Fig. 4.96. Location of thrust washers

DRIVEN SHAFT
3. The thrust washer for driven shaft, see Fig. 4-96,
is stu'ck onto the transmission ca se with vaseline.
pump drive key and tit the pump driving gear.
The driven shaft complete with r.ing gear is then
5. Fit the three oil sealing ring's on the shaft, se,e
installed into the transmission case.
Fig. 4-97. Excercise care when doing this as the oil
sealing rings are very fragile. Stand the box onits
REAR PUMP
fron<t end and support under the shaft. Centre the
4. Fit the pump plat,e, ta,king care that its two holes oil rings. The pump body with driven geor is then
I,ine lJP with those in the case. Then insert the
fi1ted.

GOVERNOR
6. Place the governor drive ball in the shaft as shown
in Fig. 4-100. Fit the governor with the cover-plate
~acing <the r,e ar. Fit the snap ring.

Fig. 4·97. I,nstalling driven sh aft oil rings

A. Oil rings Fig. 4-98. Gear train components

4: 38
 . ') " '8

o . ;

.\~

VOLVO
27664
Fig. 4-99. Governor assembly dismanlled

Fig. 4-101. Insrolling rear brake band

REAR BRAKE BAND AND SERVO sealing washers so tha,t the flat surface should face
7. Place the rea'r hrake band in posi,tion In the ca se, inwards. Then tighten the servo screw locating the
see Fig. 4-101. Jhen fit the rear servo assembly. support.
Tighten ·only the rear (short) servo scr,e w since the
long one also locates the centre support.

PLANET GEAR AND CENTER SUPPORT

8. Assemhle the planet gear, one-way clutch and
center support, see Fig. 4-103. Stick the thrust plate
and needle thrust beaoring to the planet cover with
vase,l·i,ne.
9. Turn the fluid passage holes in the center support
upwards and fit the assembled unit into the trans-
mi,ssion case. (Note that the holes point down-
wards when the transmission is turned the right
way up, see Fig. 4-91.)
10. Fit the two center support screws from outside.
Remember that the lock washers ·a lso serve as
VOL VO
103842
Fig. 4-102. Rear servo assembly dismanlled

VO LVO
104 989
Fig. 4-100. Governor and driven shafr
A. Drive ball
B. Governor assembly Fig. 4-103. Insralling cenrer support and planer gears wirh needle
C. Snap ring rhrusr \)earing and plare washer

4: 39
 VOLVO
18011

Fig. 4-106. Rear clutch dismantled

VOLVO 15. Place the front needle thrust bearing on the rear
105 388
Fig. 4-1 04 . Installing front servo and strut sun gear shafrt. Fit the shaft in the rear clutch
assembly. Install the oil sealing rings, see Fig.
4-108.
16. Install the rear needle thrust bearing and fi t the
FRONT BRAKE BAND AND SERVO
clutch in the gearbox as shown in Fig. 4-109.
11. Place the front brake band in posit1ion, see Fig.
4-104. Stick the strut to the servo lever with vase-
line.
Fit the servo. The shorter bolt is fiMed at the front. A
Mak·e sure tha't .the servo strut is correcHy engaged
with the slot in the brake band .
The cam for self-adjustment is fitted later.

REAR CLUTCH
12. Fit the sealing rings for the piston . Use fitting ring
SVO 2534 and fi.t the piston in the dutch ca se, see
Fig. 4-107. VOLVO
28003
13. Fit the spring, spring seat and snap ring using
Fig. 4-107. Installing piston for rear clutch
special tool SVO 2533, which is used when dis-
A. Fitting ring SYO 2534
mantling, see Fig. 4-90.
14. Install the clutch plates. Note tha't the outer plates
are coned and that all the plates should be fitted
with the cone facing in the same diredion . Begin
with an ou.ter plate and then fit inner and outer
plates alterna1tely. Fit the pressure p,l ate and snap
ring.

P-

r
c;-~~
),.1
VOLVO
27973
Fig. 4-108. Forward sun gear components
A. Oil sealing rings, front clutch
B. Forward sun gear assembly
VOLVO
105389 C. Needle thrust washers
Fig. 4-105_ Front servo assembly dismantled D. Oil sea ling ring, gover nor feed

4: 40
 VOlVO
105390

Fig. 4-109. Installing. rear eluteh and forwards sun

gear group
A. Rear dutch
B. Needle Ihrusl bearings
C. Thrusl washer plale

Fig. 4-111. Fittings piston for front eluteh

A. Tube, lenglh 4.3" (110 mm)
FRONT CLUTCH
17. Fit the sealing ring on the piston and the O-ring
in the drum. Place the piston in installation ring
SYO 2900. Press it down level with the lower edge
of the ring. Use press tool SYO 2533 and tube A
as shown in Fig. 4-111. Fit the spring with the
dished side facing rear. Put on the snap ring.
18. Install the dut,oh assembly with ,its two different
thrust washers in the gearbox, see Fig. 4-112. Be
care~ul not to damage the oil seaj,ing rings. For

\
identifying the thrust washers, see Fig. 4-96.
19. F.it the pressure plate, inner and outer plates, and
hub. Fit the thrust washer for the olutch hub and
input shaft into the front clutch, see Fig. 4-113. Fit
the snap ring.
)
VOLVO
105391
Fig. 4-112. Installation sequenee, front c1uteh cylinder
thrust and backing washers

VO LVO
105392
VOLVO
28004 Fig. 4-113. Installation sequenee, front elule/! snap
Fig. 4-110. Front c1uteh dismantled ring, input shaf! and thrus! washer

4: 41
 VOLVO
105393

Fig. 4-114. Installation sequence, front pump assembly

thrust washer and gasket

The f·ront and rear elutches can also be installed in Fig . 4-116. Localian of oil tu bes , front of gearbox
the ge·arbox a's an assembly. In this case they are A. Converter outlet C. Converter inlet
B. Front pump inlet D. Front pump oullet
firSlt assembled individually. The rear clutch is then
stood straoight up, the thrust washe,r for the el utch
hub centred, both the rear thrust washers placed on,
ing with a new gasket and fit the drive flange with
and after this the rear clutch and'gan gear are assemb-
washer and nut.
led with the front clutch.

FRONT PUMP VALVE BODlES ASSEMBLY

20. Fit the O-ring on the pump body, then assemble 23. When assembling, all the component parts which
the pump in the reverse order to dismantling. have been dismantled should be thoroughly
21. Stick on the thrust washer with vaseline and then eleaned and lubricated with oil approved as "Au-
fit the pump with a new gasket 'on the transmission tomatic Transmission Fluid, Type A" prior to reas-
case, see Fig. 4-114. Re-check the end float in sembling in the reverse order to dismantling. Line
accordance with point 21, page 34. up the component parts of the valve bodiesas-
semhly by using two of the Ire~alining bolts. Check
the free movement of all valves in their bores.
EXTENSION HOUSING Check that the strainers are flat so that they make
22. P,lace the speedometer gear correctly on the driven a complete 'seal when screwed down . Tighten ·t he
shaft as shown in Fig . 4-115. Fit the extension hous- screws to the specified torque.

VOLVO
104991
Fig. 4-115. InstalUng speedometer gear
Fig. 4-117. Adjusting front brake band

4: 42
 Fig. 4-120. Oil tube for valve bodies system, vehicle with
R-H drive

Fig . 4-118. Self-adjusting spring bolt cam

24. Fit the oil tubes for ,t he pump and converter on the
front pump, see Fig. 4-116. Do not forget the 0-
VOLVO
ring for the pump inlet tu be. JOl 206

25. Fit the valve bodies assembly onto the gearbox.

Fig. 4-121. Stop for lever
Connect the throttle cable. A= 1/8-5/32" (3-4 mm)

hibitor switch, see "Adjusting the starter inhibitor

switch" on page 29.
MISCELLANEOUS
30. Place the magnetic piece in the oil plan . Fit the oil
26. Place the spacer block SYO 2537 between the bolt
pan with a new gasket.
and cylinder, see Fig. 4-117. Tighten the bolt with
31. On cars which h.Gve six controi positions, the stop
torque wrench SYO 2748 until the ratchet handle
brocket is fitted as shown in Fig. 4-121 . Adjustment
ciicks out This should be at a torque of 10 Ib.in.
is ca~ried olYt 'a s follows:
(11.5 kpjcm).
A. Turn the lever clockwise as ~ar asit will
27. Adjust the location of the spring on the adjusting
go C'P" position) and then four "catches" anti-
screw. It should be 1-2 threads from the lever.
clockwise.
Remove the torque wrench and spacer block. Fit
B. Push the stop braocket forwards so that it comes
the cam. The long end of the spring sticks into the
%_5/32 " (3-4 mm) from the lever see "A" Fig.
cam, see Fig . 4-118.
4-118. Tighten the brocket in this position.
28. Fit the four oil tu bes according to Fig. 4-119. Note
that the oil tube for releasing the front controi
cylinder has a constriction (A, Fig. 4-120) on FITTING
vehicies with a right-hand drive. This end is fitted The converter, converter housing and gearbox ar,e
in the valve bodies system. fitted i.n the reverse order to removing. Connect the
29. Adjust the brake bands, see "Adjusting the rear leads for the starter inhibitor switch and r'e versing
brake band" on page 30. Adjust the starter in- light correotly, see Fig. 4-122.

BLÅ
A BLUE

SVART
BLACK
c

VIT
WHITE

[
RÖD
RED
D

VOLVO
102744

Fig. 4-122. Wiring diagram

VOLVO A. Switch on gearbox for starter C. Starter motor

105396
inhibitor and reversing light D, Cable for reversing light
Fig. 4-119. Retention of front and rear pump strainers B. Starter relay E, Ignition switch

4: 43
SRECTOR CONTROts ASSEMBLlNG AND FITTING
REMOVING AND DISMANTLING The selector controis are fitted in revers e order to
1. Disconnect the controi rod (24, Fig. 4-123) from removal. Lubri,cate the selector controllinks and bear-
the controi lever (16) on the operating rod (10) and ings with Mobilgrease No. 20r similar. Adjust the
from the lever arm (23). Remove the link rod (21). controls according to the instructions given under the
Disconnect and remove the levers. heading "Adjusting the selector controls" page 28.
2. Remove the panel under the dashboard. Dis-
Gon,nect the cable from ,t he gem ,inhibitor and the
REPLACING THE SELECTOR CONTROL INDICATOR
bracket. Take out the combined instrument and
l. Disconnect the battery ea:rth lea,d. Then- rem ove
disconnect the selector from ·it.
the panel under the da'shboard.
3. Remove the upper an·dl ower casing halves over
2. Disconnect the cabl,e kom the gear inhibitor and
the direction indicator switch and steering wheel
the br,a cket. Remove the combined instrument and
lock. Release the bolt in the controi rod and re-
repl'a·ce the indicafor.
move the nut on the ball joint.
3. Fit rthe combined instrument, then the cable at the
4. Remove the screw for the inhibitor plate (2). Pull
gear inhibitor an,d bracket. Adjust the length of
up the controi rod a bit and remove the lock pin
the cable s,leeve so that the pointer points to the
for spring (11). Then pu ll up the controi rod and
correct gear posi,tion. Lock the adjuster sleeve with
remove the remaining parts.
the nut.
4. Fit the panel under the dashboard ond connect
INSPECTlNG the battery earth lead .
Check the various parts, especially for we ar. Replace
worn bushes, I,ink rods, etc.

2 3 9

I " /
!

Fig. 4-123. Selector controls

1. Inhibitor plote
2. Inh·ibitor
3. Selector controi
4. Rubber cover 10
5. Nut
6. Boll shell
7. Selector lever
8. Bush
9. Brocket
10. Controi rod
11. Spring
12. Plostic bush
13. Rubber bush
14. Clomp
15. Boot
16. Lever
17. Boll socket
18. Stop brocket
19. Spocer sleeve
20. Lever on georbox
21. Link rod
22. Lever ottochment
23. Lever orm
24. Controi rod

\
24 23 22 21 20 19 18
VOLVO
105034

4: 44
 FAULT TRACING
ROAD-TESTING the rear wheels, indicating tllat the rear oil pump
(Used together with the faul,t-tracing s,cheme). of the transmission is operating.
It is impor.tant to gain as much informat~on as possible 6a. Stop and restart using full throme acceleration.
as to the precise nature of any fault. If possible, go Check for 1-2 and 2-3 shiffs according to the
out in the car with the customer and get him to demon~ shift speed table in the "Speeifications".
strate the fault. In all eases, the following road-test b. At 25 m.p.h. (40 km.p.h.) in 3rd gear, depress the
procedure should be carried out completely as there aocelerator to full .t hrottle position. Th.e car should
may be more than one fault. downshift to 2nd gear. Repeat at 40 m.p.h. (65
km.p.h.). The car should accelerator in 3rd gear
and should not downshift to 2nd.
c. At 30 m.p.h. (50 km.p.h.) in 3rd gear, depress the
accelerator to the kick-down position. Th,e trans-
TEST NO. mission should downshift to 2nd gear.
1. Check that the starter only opera-fes with the d. At 15 m.p.h. (25 km.p.h.) in 3rd gear, depress the
seleetor in " p" land "N" and that the reversing accelerator to the kick-down position. The trans-
light operates only in "R". mission should downshift to 1st gear.
2. Apply the brakes and, with the engine running at 7a. Stop and restart using forced throttle aoce·leration .
normal i·dling speed, select "N-D", "N-L" and Check for 1-2 and 2-3 snifts according to the
"N-R". Transmissi'on engagement should be felt shift speed table in the "Spe.c ifkations".
in eaeh position seleeted. b. At 40 m.p.h. (65 km.p.h.) in 3rd gear, release the
3. Check the converter staU speed with the trans- accelerator and select "L". Check for 3-2 down-
mission in "L" and "R". Check for slip or clutch shift and engine braking. Check for roll-out 2-1
squawk. downshift at about 5 m.p.h. (8 km.p.h.) and ,engine
Note. Do not stall for longer than 10 seconds or braking.
the transmission wiM overheat. 8. Stop, and wi,th "L" sti ll eng'aged, release brakes
4. With the transmission at normal runni ng tempe'ra- and, using full throttle, acce,lemte ,to 20 m.p.h . (30
ture, select "D". Release ,t he brakes andacoelerate ~m.p.h. ) Check for no slip or oIutch squawk and
with minimum throtNe ope.ning. Check for 1-2 and no upshiHs.
2-3 shifts. Nofe. At minimum th.rottle openings, 9. Stop ·a nd select "R". Release brakes and reverse
the shifts may be difficult to deteet. Confirmation using fuM throttle if possilble. Check for no s,lip or
that the transmission is in 3rd gear may be clutch sqvawk.
obtained by 'seleeting "L", when a 3-2 downshift 10. Stop on the hrakes facing downshiff on a gradi-
should be felt. entand se,leet "P". Re'lease the brales and check
5. At just over 30 m.p.h . (50 km.p.h.), sel,eot "N", that the parking pawl will hold the , car. Re-opply
switch off the ignition and let the car co,ast. At the brakes before ,d isengaging the parking pawl.
30 m.p.h. (50 km.p.h.) switch on the ignition and Repeat with the ear facing uphill. Cheek that the
selleot " D". The eng,ine should then start through selector is trapped by the gate in "P".

I 4: 45
FAULT-TRACING SCHEME
(To be used ,in conjunction with the road-test procedure.)

TEST FAUlT ACTION

1. Starter will no.t operate in "P" or "N" 19

Starter opera1es in all selector positions 20
2. Excessive bump on engagement of /ID", /Il" or /lR" 4,3
3. If. stall speed higher than specified:
{l. wit.h slip an·d squawk in "L" l, 2, 3, 13, 11
b. with sl.ip and squawk in /lR" l, 2, 3, 13, 12
If stall spe.ed lower thanspecified, check engine performance
If stall speed more than 600 ·r.p.m. lower than specified 21
4. No drive in /ID" (if normal in /Il", omit 11 and 13; if no drive in
/ID", /Il" or /lR", add .17) l, 2, 3, 13, 11, 16
Delayed or no 1-2 shift 3, 14, 13, S, 6
Slip on 1-2 shift 2, 3, S, 6,7, 13
Delayed or no 2-3 shift. (If normal in /I R", omit 12). 3,14, 13, S, 6, 12
SI·ip or engine run-up on 2-3 shift 2,3, S, 13, 12
Bumpy gear shifts 3
Drag in /ID 2" and "D 3" 8
Drag on 2-3 shift 5,6
5. Engine will not start through rear wheels 22
6 a. Slip and squawk or jlldder on full throttle take-off ,in /ID" l, 2, 3, 13, 11
loss of performance 'a nd overheating in /ID 3/1 (seized stator) 21
Cont.inue as for test 4 above
b. Transmissi,o n downshiftstoo easily 3
c, d. Transmission will not downshift 3, 13, 14
7 a. As test 6a above l, S, 6, 7, 12
b. No 3-2 downshift or engine braking l, S, 6,.7, 12
No 2-1 downshift or engine braking 8, 9, 10
8. Slip and squawk or judder on take-off in "l" 1,2,3,13,11
TJ1ansmission upshifts l
9. Slip and squawk or judder on take-off in "R" l, 2, 3, 13, 12
Slip but no judder on take-off in /lR" (if engine brak.ing)
availahle in /Il l", omit 8, 9, 10) 1,2,3,8,9,10
Drag in "R" 5
No drive in "R" (if engine braking available in "l l", omit
8,9, 10) 1,2,3,8,13,9, lO, 12
10. No park- l, 15
Mis- Screech or whine, increasing with engine speed 17
cell- Grinding o,r grat,ing n·oise from gearbox 18
aneous Knocking noise from torque converter area 23
At high speeds in "D 3", transmission downshifts to /ID 2" and
immediately back to /ID 3" 12

4: 46
ACTION The stall speed me.a ns the speed e btained at fvll
1. Check manu-al linkage odjustment. threttle en .theengine wi th the I.ock-up engaged but
2. Check fluid leve\. wit,h the ear statienary. Check that the transmissien
3. Check adjustment of downshift valve cable ha,s the cerreot running tempe-rature an,d tnat the fluid
using line pressure gauge ond tachemeter. level is cerred befere the stall speed test. The test
4. Redllce engine idling speed. must net take place lenger than ,ten seconds, otherwise
s. Check frent band adjustment the transmi'ssien will overheat.
6. Check frent servo seals and tubes for leakage. Favlt-traoing en the cenverter is earried out as fe l-
7. Check frent band fer wear. lews :
8. Check rear band adjustment. 1. If the general performanee ef the v,ehicle is belew
9. Che-ck rear servo seal and fit ef tubes. standard, check llhe cenvenfer stall speed with an
10. Check rear band for wear. accurate tachemeter by applying maximum pres-
11. Exarnine frentdutchand seais, also front sun sure en the feotbrake pedal, seleding "Leok-up"
gear shaft sea,ling rings. Verify that cup plug and ful,ly depressing the aceelemter. If the sta'"
indriven snatt is net leaking or di.sl'e dged. speed is up te 300 r.p.m. be,lew that specified, the
12. Exarnine rear dutch, check valve, and seak engine is net developing ills ful·1 peweor.
Check fit ef t ubes. 2. Inability te start on steep gradients comb ined
13. Strip valve bodies ond dean . with poer acceleration from rest indicates that
~4. Strip governer valve and dean . the cenverter stater Qne-way dukh is slipping or
lS. Exarnine pa-rking pawl, gear and interna-I that the stator suppert is fractured. This cendition
linkage. perrnits the stalt or te rotate in an epposite direc-
16. Examine ene-way dutch. tien te the turbine and terqlle multiplicatien cannet
17. Strip and examine frent pump and drive eceur. Che,ek the stall speed and, if it is more than
fingers. 600 r.p.m. below that specified, the cenverter
18. Strip and examine gear train. a'ssembly must be repl,a ced.
19. Adjust starter inhibitor switch inwards. 3. Be-Iew sllandard aceele-r ationin 3rd gear abeve
20. Adjust starter inhibiter switch outwards. 30 m.p.h. (SO km.p.h.) cembined wi~h a substantially
21 . Repl,a ce -ferque cenverfer. reduced maximum speed, indicates that the stater
22. Check rear pl/lmp dr,ive pin. one-way duteh has leeked in the engaged eondi-
23. Examine terque cenverter -drive plate fer tien. The stater will then net ro.talle with the turbine
cracks or frocture . and impeller, therefore the fluid f1ywheel phase
ef the cenverter performanc~ cannet eccur. This
conditien wif,f alse be indicated by excessive ever-
heating ef the transmission, although the stall
FAULT-TRACING ON THE CONVERTER speed will remain as specified. In this case the
The -CQnverter heusing is welded tegether and can cenverter assembly must be replaced.
therefere nQt be repaired but must .be rep'laced in 4. Stal,1 speed which is higher than that specified,
the event of defeds. There is nO' ,drain plug since indieates that the cenverter is not receiv,ing its
fluid changes do not eccur and fluid filling is den e required fluid supply or that sl,ip is occurring In
threugh the transmissien. the dutches of the automotic·transmission .

4 : 47
 GROUP 45

PROPELLER SHAFT

TOOlS
SYO 2846 Special socket for propeller shaft bolts

DE SCRI PTI ON

VOL VO
104 186

1 2 3 4 5 6 7 8
Fig . 4-124. Propeller shaft with support bearing
1. Flange on gearbox 5. Intermediate universal joint
2. Front universal joint 6. Rear propeller shaft
3. Front sectian of propeller shaft 7. Rear universal joint
4. Support bearing 8. Flange on rear axle

The propeller shaft is of the di\'ided, tubul·ar type,

see Fig. 4-124. The rear end of the front section of the
propeMe'r shaH is in the form of a splined sleeve. In
this there is a splined shaft which also fonms one of
the yokes on the intermediafe universal joint. The
rear end of the front sedion of the propeHer shaH
is carried in a ball be'a ring. The ball bearing is con- 8
tained in a rubber bearing housing, which is attached
9
to the propeller shaft tunneli with a ,oove·r, see Fig.
4-125. The propeller shaft is fitted with three universal
joints. Each joint consists of a spide'r with four ground
11
trunnions carried in flange yokes by means of needl,e
bea,rings. 12
VOLVO
1041 87
Fig. 4-125. Support bearing
1. Front section 5. Rubber housing 9. Rubber cover
of propeller shaft 6. Dust cover 10. Washer
2. Floar iunnel 7. Nut 11. Suspension spring
3. Dust cover 8. Rear sectian 12. Cover
4. Bo II beari ng of propeller shaft

4: 48
 REPAIR INSTRUCTIONS
REPLACING THE SUPPORTBEARING DISMANTLING
1. Jack up the vehicle. Slocken the propeller shaft DISMANTLING THE PROPELLER SHAFT
from 1he rear axle flange. Bend back the lock 1. Bend baok the lock washer and unscrew 'the nut
washer and unscrew the nut at the sliding joint. fOor the support bearing . Remove the rem section
Pull out the propeller shaft to the rear. of the propeller shaft. Pull off the support bear-
2. Loosen the cover for the support bearing. Pull off Ing.
the support beming complete. 2. Remove the support bearing from the housing .
3. Press the old bearing out of the rubber housing .
[iit the new bearing.
4. Fit the support bearing and the other parts in DISMANTLING THE UNIVERSAL JOINTS

the reverse order to removal. If the splined joint 1. Remove the snap rings securing the needle bear-
appears dry, ,Iubfi.cate it with grease mixed with ings in the yokes, see Fig. 4-127.
molybdenum disulphide. 2. Secure the shaft in a vice so that the universal
joint comes as near as possible to the vice jaws.
REMOVING Remember that the propeller shaft is tub ular and
can easily be deformed.
Jaå up the vehicle. SIaeken the propeller shaft from
3. With a hammer and metal punch drive the spider
the gearbox and re,a r axle fl anges. The bolts can be
as far as it will go in one diredion. The needle
loosened by an air impact wrench and special socket
bearing will then come about half way out.
SYO 2846, see Fig. 4-126. Loosen the cover for the
4. Then drive the spi der as far as it will go in the
support bearing and take down the prope ll er shaft
opposite direction, see Fig. 4-128.
complete.

Fig . 4-128. Removing the spider, I

VO LVO
Fig. 4-126. Removing the bolts 103227

VO LVO
101779
Fig. 4-127. Removing the snap ring Fig . 4-129. Removing the spider, "

4: 49
 5. Drive out one of the needle bearings with a thin
metal punch. Remove the spider, see Fig . 4-129.
Drive out the other needle bea~ing.

INSPECTING
It i,s extremely important t,o ensure thar .the propeller
\
shaft is straight.Since even minor domage on a pro-
peller shaft can oause vibration, the inspecl1ion must
be very thorough. The shaft should be set up between
centers and checked along its entire length with an
indicator gauge while it is rotating. If it is out-of-true
more than 0.25 mm {O.OlO"), the shaft must be replaced.
N.B. No atfempt should be made to straighten a Fig. 4-130. Fitting the spi der
damaged propeller shaft - discard and replace with
a new one.
Examine the support bea,ring by pressing the bearing 2. I,nsert the spider in the flange yoke. Push the spi-
races ag'ainsteach other by hand and ,t uming them der over in one diredion so far that the needle
in opposite directions. The bearing should run easily bearing can be fitted on to the trunnion, se Fig.
without binding at a,ny point. Ifit ,does not, scrap the 4-130. Then press the needle bearing in so far that
hearing and replace it with a new one. the snap ring can be fitted. Use a drift having a
Check needle bea'rings and spiders. Worn o,r ,domaged diameter sl,ightly less than that of the needle bear-
parts shou,ld be replaced. ing sleeve.
3. Fit the other needle bearing and snap ring as
above. The fitting of the spider in the other yoke
ASSEMBLlNG should also be carried out in the same way as
ASSEMBLlNG THE UNIVERSAL JOINTS described in operation 2.

1. When fitting the old needle bearings, check that

they are filled with grease and that the rubber
seals are not damaged. New bearings should be FITTING
half-filled with grease. Fitting is in reverse order to 'removal.

4: 50
 GROUP 46

REAR AXLE
TOO LS
The followjng too ls are used for repak work on th e re a r axle

I Q
~
ram 1845 2261 2284 2393 2394 2404 2483
01
2595

2597 2599 2600 2709

! .~
2806 2837 2838

2844 2845 4030

2841 2842
2839
~.
~ -: ~:~.

2840 t(8F

~ o 1
I .
m I
2843
(!j
VOL VO
1033 95

Fig. 4·131. Spe cial raols for rhe re ar axle

SYO 1801 Standard handle 18X200 mm SYO 2601 Holder for expander 1001 SYO 2394 (fitted on tool)
SYO 1845 Press taol for fitting flange SYO 2709 Puller for dri ve shaft
SYO 2261 Puller for flange SYO 2714 Fixture for rear a xle, used on garage jack for re·
SYO 2284 Retainer for dial indicaror for final drive adjustment moving and fitting rear a x le, see Fig . 4·165
SYO 2393 Measuring tool for pinian adjustmenl SYO 2806 Tool for fitting oil seal at flon ge
SYO 2394 Expander 1001 used for removing and filling differential SYO 2837 Counlerhold fo r flang e
SYO 2404 Tool for fitting fra nI pin ian bearing. Used 0150 w hen SYO 2838 Press 1001 for removing and fitting bearing and lock
checki ng toolh mesh ring on dri ve shafl
SYO 2483 Puller for differential carrier bearings SYO 2839 Ring for fitting bearing and lock ring on drive shafl.
SYQ 2520 Sland, see Fig . 4· 132 Used logeIher w ilh SYO 2838
SYO 2522 Fixlure fo r rear a x le (used laget her w ith stand SYO SYO 2840 Adjusting ring for pinian
2520 for work on the final dri ve) SYO 2841 Box spanner for adjusting ring SYO 2840
SYO 2595 Adjusting rings for differe nlial SYO 2842 Sleeve for fitting inner ring , rear pinian bearing
SYO 2597 Brake for crOWn w heel, used w he n checking looth SYO 2843 Drifl for removing outer ring, rear pinian bearing
mesh SYO 2844 Puller for rear pinian bearing
SYO 2599 Drift for removing ouler ring, fronl pin ian bearing SYO 2845 Press 1001 for fitting outer ring , pinian bearing
SYO 2600 Measuring fi xture for adjusling rings SYO 4030 Puller for oil seal at flange

4: 51
 ·.

VOLVO
400049
Fig. 4-132. Stand and fixture fo r rear axle

DESCRI PTION
The rear aXlle is cmried in two support arms. The selves in the differential. carrier consist of two bevel
supports arms are provided with a couple of robust pinions on a trunnion and two side gears in which
bushes and are attached to the body. The rear axle drive shafts are carried by me,ans of internai splines.
housing is attached to the suppo~t arms with levers. The differential g,e ars are journalled so that they can
In order to take up the rear axle torque, there are rotate and permit .the drive shafts to rotate at dif-
two torque rods attached to the drive shaft tubular fe,rent speeds when the ear is being driven round
covers and to the body. A track bar prevents the body bends. There is a thrust was her under each of the
and rear axle from moving sideways in relation to differential gears.
each other. The d~sign of the rear axle is shown in The drive pinion is wrried in taper roller bearings.
Illustration 4 E. The axial location of the drive pini'on relative to the
The final drive is of the hypoid type, that is to say, crown wheelis adjusted by means of shims under the
the drive pinion lies below the centre of the crown oute,r race of the rear pinion bearings. Application of
whe,el. It consists of the drive pinion, crown wheel the pinion bearings is by means of shims under the
and differential gears. The gear backlash and differ- front pini'on bearing inner ring. The outer end of each
entialcmrier bearing tensi'on are adjusted by means drive shaft is journalled in a taper roller bearing.
of shims inside the differential carrier bearings. Bearing cleOlfance is not adjustable but ,is determined
The differential wrrier and the crown wheel are jour- by the construction of the bearing, see Fig. 4-136.
nalle1d in the final drive housing by means of two There are oil seals on both sides of the drive shaft
taper roller bearings. The crown wheel is bolted to bearings.
the differential carrier. The differential gears them-

4: 52
 REPAIR INSTRUCTIONS
WORK WHICH CAN BE CARRIED OUT 5. Fi,1I the space between the seal lips on the new
WITH THE REAR AXLE INSJALLED oil with g'rease. Then place it on the drive shaft.
REPLACING BEARINGS AND Fit the beaping and lock ring. Turn the bearing
DRIVE SHAFT OIL SEALS correctly, see Fig. 4-136.
N.B. Always use a new lock ring.
l. Jack up the vehicle and prop up under the rear
Place fitt,ing ring SYO 2839 against the bearing
axle. Remove the wheels.
and the lock ring. Close the tool arms and lock
2. Disconnect the brake pipe from the brake caHpeL
them round the fitting ring, see Fig. 4-135. Press on
SIaeken the holts for the brake disc and remove
the bearing and lock ring by screwingin the
the disc.
spindie.
3. SIaeken the bolts for the thrust washer. These are
6. Grease the beaJ1ing. Then fit the drive shaft.
slackened through the holes in the drive shaft
Tighten the bolts for the thrust washer to a tor-
flange . Pu ll out the drive shaft with puller SYO
que of 5 kpm (36 Ib.ft.). Fit the brake disc and
2709, see Fig. 4-133.
hrake caliper. Connect the brake line. Yen t and
4. Secure press tool SYO 2838 in a vice. Secure the
adjust the brakes, see Part 5.
drive shaft to the spindle plate . Screw in the
7. Fiton ~he wheels and wheel nuts. Lower the ve-
spind le s'o that the tool arms can be placed
hicle. Tiighten the wheel nuts.
against the bearing, see Fig. 4-134. Screw out the
spi.ndle and press off the bearing and lock ring.
Remove the oil seal.

VOLVO
10178 1 VOLVO
103176
Fig . 4-133. Removing the drive sh aft
Fig. 4-135. Fitting the drive shaft bearing

VOLVO
VOLVO 103376
103175
Fig. 4-134. Removing the drive shaft bearing Fig . 4-136. Drive shaft journalling

4: 53
 2806

VOLVO
103 031

Fig. 4-137. Counterhold for flange Fig . 4-139. Filling the oil seal
1. Oil seol 2. Spring eoil wi lh greose eooling

REPlACING THE PIN lON Oll SEAl

l . Disconnect the rear section of the propeller shaft
from the flang'e on the pinion. Cheå for looseness
of the pinian in its bearings. If there is laoseness,
this must be ,r emedied before a new oil s,e a,1 can
be fitted . Se'e theinstructions under the heading
"Assembling".
2. Remove the nut for the flang'e . Use for ~his pur-
pose tool SYO 2837, see Fig. 4-137. Pull the flange
off with puller SYO 2261, see Fig. 4-138. Pull out
the old oil sea,l with puJ,Jer SYO 4030.
3. Fit the new oil seal with tool SYO 2806. When
fitting the oil seal, lubrieate the sea I lips with
grease. At .the same time apply a ,Iaye,r of grease
to the spring eoil. See Fig. 4-139. This last-men-
tioned measure is made to prevent the spring eoil
from jumping out during fitting.
Fig. 4-140. Filling the flange
4. Press on the flange with the help of press tool
1. Press 1001 SYO 1845
SYO 1845, see Fig. 4-140. Fit the washer and nut.

If-- .
t

VO LVO
2;:038
Fig. 4-138. Removing the flange Fig. 4-141. Locating the axle prop

4: 54
 Tighten the nut to a torque of 28-30 kpm (200- facing inwards to the fixture support, when tnb
220 Ib.ft.). pinion is pointing downwards. Remove the brake
5. Connect the propeller shaft section. pipes.
2. Release the bolts for the hrake backing plates
REMOVING THE REAR AXLE and brake sho.e retainers. They are slackened
l. Place chocks in front of the frontwheels. Slacken through the hales in the drive shaft fl anges. Pull
out the drive shafts with puller SYO 2709, zee
the rear whee,1 nuts. Ra·ise the rear end of the
vehicle and place an axle prop under in front of Fig.4-133.
the rear jack attachments, see Fig. 4-14l. Note that 3. Remove th~ inspection cover.
4. If the final ,d rive is being reconditioned because
the prop must not be placed at a point further
than the dash line indicated in the figure . Take of noise, the mesh pattern should be checked
hefore dismantling takes place, as this might assist
off the rear wheels.
in locating the fault. Before carrying this out,
2. Repl·aca the Ilifting plate on the jack with fixture
clean the t,e eth so that no misleading mesh pat-
SYO 2714 (compare with Fig. 4-165) and raise the
tern is abta:i,ned.
rear axle sl-ightly. Slacken the upper attaching
5. Check the alignment markings on the cap and
bolts for the shock absorbers. D,isconnoct th,e
carrier, see Fig. 4-142. If there are no markings, or
parking brake wires from the levers and brackets
if they are ,difficult te see, mark ene side with
on the brake backing plates. Use for this purpose
a spring fixture, see Part 5. a punch . Remove the ca ps.
6. Fit teol SYO 2394 in theholesin the drive pinien
3. Disconnect the propeller shaft section from the
carrier as shewn in Fig. 4-143. Fit the teel with
flang.e on the pinion. Remove the brake pipe
retainers SYO 2601 . Tensien the toel until it fi.fs
union from the rearaxle casing.
exactly ·in the heles in the carrier. Then tensien
4. Loosen the front a,litaching bolts fo'r the support
the bolt a further 3-3V2 turns. Lift eut the differ-
orms about l turn. Unscrew the 'rear bolts for the
enl"ial carrier with crewn wheel. T0011 SYO 2337
torque rods. Loosen the track har from the hracket
can be used fer this purpese.
on the rear axle casing. Remove thelower attach-
7. Tum the final drive and let the eil run eut inte a
i·ng bolts for the springs.
centa,iner. Use tool SYO 2837 as a ceunterheld
5. Lower the ja.ck until the support arms 'release from
fer this purpose, see Fig. 4-137. Pull eff the flange
the spring. Slacken the balts securing the rear
with puller SYO 2261, see Fig. 4-138. Press out the
axle casing to the support a~ms. Lower the jack
and pull .t he Irear axle forwa:rds. pinien.
8. DriVe eut the frent pinion bea:ring, the washer
and the e iii seal with standard handle SYO 1801
DliSMANrrLlNG THE RIEAR AXLE
and drift 2599.
l. Place the rear axle in fixture SYO 2522. The rear 9. If necessary, drive eut .t he 'rear bearing euter ring
axle is placed with the underside of the drive eut ef pesitien, see Fig. 4-144. Use standard handle
SYO 1801 and drift SYO 2843.
10. Clean the gasket. File eff all burr on the surface
on which the indicater retainer SYO 2284 is te
slide.

Fig. 4-142. Alignment marking on cap and carrier Fig. 4-143. Expanding the drive pinion carrier

4: 55
 1
l
Fig. 4·144. Removing the rear pinion bearing race
1. Removing drift SYO 2843

3
11. If necessary, pull off the rear bearing from the
pin ian with puller SVO 2844, see Fig. 4-145. The
puller is fitted in the following way (see Fig. 4-146):
Move the puller down over the rollers and press
down the lock ring . Then pull up the puller with VOLVO
102436
the balt until the rollers lie flush with the edge of
Fig . 4-146. Puller filled
the inner race and the edge on the puller. Tap
l. Puller is pressed down over the rollers
out the lock ring with a hammer. 2. Rollers are pulled up
8. Lock ring knocked securely inta position

DISMANTLING THE DIFFERENTIAL

l. Release the ring gear balts and remove the crown
wheel.
2. Drive out the lock pin, see Fig. 4-147, and then the
shaft for the differential gears. Take out the
differential gea'rs and the thrust washers.
3. Pull off the differential carrier bearings with puller
SVO 2483, see Fig. 4-148. Take care of the shims.

INSPECTING THEREAIR AXLE

First clean all the parts thoroughly. Gheck the bear-
ing ,r aces and bea'rings. The races, rollers or roller
reta in ers must not be scmtched or damaged. All

VOLVO
25527
Fig. 4-145. Removing the rear pinian bearing
1. Puller SYO 2844 Fig. 4·147. Removing the lock pin

4: 56
 VOLVO
102 371
Fig. 4·148. Remaving the differential carrier bearings
1. Puller SYO 2483

lll18
Fig. 4-149. Fitting the differential gear

damaged hearings and bearing races should be re- Check that the bra.ckets for the support arms and
placed. tra.ck rod m,e intad.
Note that both parts of theouter ring ror lhe drive Inspect the drive shafts. Drive shafts which are warped
shaft bemings q.r·e stuck together with new bearings. or damaged in any other way should be replaced
This adhesion may l'Oosen aftelr driving for some time, with new ones.
but it does notinHuence .~he usahillity of the bearing. Examine the oil sea,ls and replace them if they are
Check both ,the pinion driv·e and crown wheel care- damag'ed or worn.
fully for damag,e to the teeth. The most damage is Check the rear axl,e casing for era eks. Check that the
seizi'ng gear reeth. This is caused by incorred running- brackets for the support arms and track rod are not
in, wrong oil,in~ufficient tooth Hank or faulty tooth damaged.
contact. If the cause of the seizing ,is not remedie d
at an ea'rly stage, the enti're gear whee,1 can be
damaged.
ASSEMBLlNG
The differ·e ntial gears should also beexamined for ASSEMBLlNG THE DIFFERENTIAL
damage to the teeth. They should be ~itted in a dean l. Place thediHerential ~ide gears toge~her with the
and .dry 'c ondition ,in the differential carrier together thrust washersin the differen~ial carrier. Then
with the shaft and thrust washers. Play should then "roll" in both the side pinions simultaneousl,y with
be che.cked by means of marking blue behind both the dis hed thrust washers, see ' Fig. 4-149.
the differential side gears. If the playexceeds 0.06 mm 2. Drive in the shaft. Check the differentiol. If ther,e
(0.0024"), when the gears have been rotated to maxi - is any play, fit new dished thrust washers, see
mum play, replace with thicker washers. These are Fig . 4-149.
available in sizes 0.78 mm, 0.86 mm and 0.94 mm (0.031, 3. Fit the crown wheel. Make sure thaI the contact
0.034 and 0.038"). surfaces are dean and without any burr. Tighten
Ched< 0150 to see whe,t her the cylindrical part of the the bolts to a torque of 6.5-9.0 kpm (47-65
Hang'e which goes into the oil seal .is worn orscrat- IbJt.) .
ched. If this is the case, 'replace the flange together
wi~h the eil seal.
Thepinion nut is provided with a sl,it for locking. In FITTING THE PINlON
time this slit Iloses its lock'ingeffediveness. For this l. Clean the marking surface on the pinion with ex-
reason, the .nut should be repla·oed if ithas been tremely fine emery doth . Fit the adjust.ing ring
removed acouple of times. The washer under the nut SYO 2840 and tool SYO 2841 on the pinion, see
should also be replaced if it has hecome deformed. Fig. 4-150. Place the pinion in the carrier, see Fig.
Check the oil seols and ,replace them if they are 4-152, and secure the adjusting ring by screwing
damaged or worn. in the lock screw.
Make sure th at thepe are no cracks in the rear casing. 2. The pinion should have a certain nominal measure-

4: 57
 $V02840 SVD 2841

VOLVO
103264
Fig. 4; 150. Adjusling ring and 1001 for pinian localion

ment (A, Fig. 4-151) to the centre line of the crown

wheel. Due to tol'e rances in the manufacturing,
ther,e me deviations from The nominal measure- Fig. 4·152. Localing Ihe measuring 10015
ment. This ,is indicated on the g'round surfaces on
the pinion with a f,igure provided with a plus or
minus sign. If there is a plus sign in front of the To check the ~ocation of the pInJon, use a dia I
~igure, the nominal measurement should be in- indicator, indi'c ator retainer SYO 2284 and a
creased, and if the sign is minus, the nominal measuring tool SYO 2393, which consists of two
measurement should be decreased . The figure in- parts: a pinion gauge and an a,djusting jig.
dicated on the pinion shows the deviation In Chec~ing is as follows:
thousandths of an inch. Plaoe the pin'ion gauge on the ground surface of
the pinion and the adjusting tig in the differential
bearing positions as shown in Fig . 4-152. Place the
Conversion table, inches to millimetres
indi'cato, retaine'r on the drive pinion carri,er and
inches millimetres zero-set the gauge against the adiusting jig,
0.001 0.025 see Fig . 4-153. Then move the indicato r retainer
0.002 0.051 over so that the indicator comesagainst the pinion
0.003 0.076 gauge, see Fig. 4-154. If the pinion is marked O,
0.004 0.102 the adjusting iig and pinion gauge should be at
0.005 0.127 the same height; if ,t he pinion is marked - , the
0.006 0.152 pinion gauge should be higher than the adiusting
0.007 0.178 i,ig; and if ,it 'is marked +, the pinion gauge should
0.008 0.203 be lower than the adiusting jig with wrrect setting.
0.009 0.229 The setting is adiusted by turning the cam on the
pinion until the gauge dial shows .the correct
value according to the marking . Then lock the

Fig. 4.151. Pinion localion

A. Nominal measurement Fig . 4·153. Zero.zelling Ihe indicalor

4: 58
 24536
Fig. 4-154. Measuring the pinion location
Fig. 4-156. Measuring the shim

adjusting ring with the lock serew. ~emove the

measuring gauge and pinion . 4. Press the rear bearing on the pJnlon with sleeve
3. Plaoe the rem pinion hearing eomplet-e with the SVO 2842, see Fig . 4-157. Fit the measured shims
ou'te'r ring in measuring fixture SVO 2600. Put on and press in both the outer rings of the beaorings
the plate, spring and nut. Turn the nut with the with tool SVO 2845, see Fig. 4-158.
flat side faeing upwards. The plate, and thereby 5. Insert the pinion in the easing and fit on three 0.75
the bearing, ,is tumed fOTwards and baekwards mm (0.03") thick shims and the front pinion bearing.
several ~imes so that the rollers take up the eOf- Fot tool SVO 2404 and press tool SVO 1845 on the
reet position . Pla'e e the adjusting ring in the front end of the pinion and pull in the pinion, see
measuring fixture as shown in Fig. 4-155. Use re- Fig . 4-159. Apply the nut tightener until it must
ta'i ner SVO 2284 and dial indieator, plaoe the press the pinion forwalrds so thot it does not strike
measuring poi,nt of the indieator opposite the aga,inst the bea'ring positions.
adjusting ring and ze'ro-set the indieator. Then 6. Repla,e e press 1001 SVO 1845 with a washer and
set the pointer of the indieator to the outer ring nut. Tighten the nut to a torque of 28-30 kpm
of the bearing. The dial indieator now shows (200-220 Ib.lit.). Fit on th~ pinion gauge and the
dir,e etly the thiekness the shims should have.
Measure the shims for theeorrect thiekness with
a micrometer, see Fig. 4-156. N.B. It is almost im-
possible to obtain a shim with exaetly the eorreet
thickness. However, they must not be 0.03 mm
(0.0012" ) thicker than the measured value, but up
to 0.08 mm (0.0032") thinner.

SyO 2284

Fig . 4-155. Determining the shim thickness Fig. 4-157. Fitting the rear pinion bearing
l. Adiusting ring 2. Dial indicator 3. Bearing, complete l. Fitting sleeve SYO 2842

4: 59
 ~
SVO 1845

svo

Fig . 4-158. Fifling the bearing rings

l. Press 100 1 SYO 2845
VOLVO
24534
Fig. 4-159. Fifling the pinion

dial indiwtor retainer. Pull down l1he pinion whi,le 0.008") is obtained. Tighten the lock screws in the
turning ,itforwards and ba·c kwar,d s at the same adjusting rings.
~ime .Zero-se,t theindicator. Then press the pinion 2. Fit on brake tool SYO 2597 as shown in Fig . 4-16l.
upwa-rds, tuming i-t at rthe same time forwards and Apply ma'rking blu,e to several teeth at thre'e points
backwards. Read off the dearance. on the crown whe.el. This can serve as a ,c he'ck on
7. Remove the pinion. Remove the shims corre~pond ­ the aown wheel for possible warping . Rotate the
ing to the measured clearance + 0.07 mm (0.003"), pintion 10-12 turns in both directions and check
Re-fit the pinion. the mesh marking pO'ttern. With correct tooth
8. Then ·c heck the pi,nion bearing fi,t wi,~h the torque mesh, the mesh marking pa'Hern shou,ld be hori-
gauge. The torque gauge should show 6--11 kpcm zontal in the middle of the tooth but somewhat
(5.20-9.55 Ib.in.) for used bearingsand 11-23 nearer to the ,t oe than the heel. -The patterns on
kpcm (9.55-20 Ib.in .) for new bearings when the the coast side and drive side should coincide
pinion mtates. too far towards the toe on the coast side, see
Oftenan alterartion in the thickness of the shims not coincide, the pinion location must be ad just,e d
,is required because of ,t he rto lerances which must
be present.
9. Check the locating of the pini,on with the dia l
indicator, rerta·i ner SYO 2284 and measuring too l
SYO 2393, see dso operation 2.

FITTING THE DIFFERENTIAL

1. Lubri,w t'e :the inside of the adjusting rings SYO
2595 and put them on the differential carrier. The
ring with the black-oxidized adjusrting ,ring should
be placed on the crown wheel side. Also lubricate
the bearing location in theoarrier. Place the
differentia l wrri'e r and the adjusNng 'ri ngs in the
final drive housing, see Fig. 4-160. Use the dial
indicator and adjust ,in the rings so that the cor-
Fig . 4-160. Adjusting rings for differential
reet tooth flank clearance 0.13-0.20 mm (0.005- l. Adjusli ng rings SYO 2595

4: 60
 Fig. 4·161. Brake fool for differential VOLVO
24269
Fig. 4-163. Faulty tooth contacl

before assembling is continu'e d. If the porterns lie Rotart,e the plate ~orwards and ba·ckwa'rds several
too far towards the heel on the drive side and times. Put on the dialindicator and retainer SYO
too· far towards the toe on the coast side, see 2284. Zero-set the indicator to the ac~justing ring
Fig . 4-163, the pinion should be moved inwards. If and then pl.ace the measuring point faoing the
the me'sh pa#erns lie too far towards the toe on bearing, see Fig. 4-155. Read off the indicator. With
the drive side and too far towards the heel on a micrometer meO'sure the shims, the total thick-
the coast side, see Fig. 4-164, the pinion should ness of which oorresponds to the read-off va,lue
be moved outwards. Note rthat the potterns will + 0.07 mm (0.003"). Place the shims tagether with
I.ie somewha't nearer the ,t oe when the adjusting the measured bearing to the one side. Repeat the
rings are fitted than when the bearings are in - ahove prooedure with the other be.aring.
staHed. N.B. Make sure which side rthe respedive be'a ring
3. When the correct tooth flank clearance and mesh and shims are rfro be fitted on .
putt.ern a're obrtained, remove the differ.e ntial and 4. Fit the shims on the differential carrier and press
adjusNng ring. Then place the cenrtre washer on on the bearings.
the meawring fixture. Fit abearing into the 5. Fit tool SYO 2394 on the drive pinian carnier, se·e
measuring fixture, allso the plate, spring and nut. Fig. 4-143. Expand the tool until the pins are
Fil' the nut with the Hut side fucing downwards. exactly f lush against the hole edges in the wrrier

Toe

Coast side Drive side

VOLVO
lDI9l, E
Heel VOLVO
24272
Fig. 4-162. Correcl tooth contacl Fig. 4-164. Faulty tooth contacl

4 : 61
 to prevent the spring COliI from jumping out of
posiofion durin g the fitting .
Then press on the flang·e with the help of tool
SYO 1845, see Fig. 4-140. Fit the washer and nut.
Tighten the nut to a torque of 28-30 kpm (200-
220 IbJt.).
2. F,it the inspect.ion coverand gasket.
3. Fit the drive shafts. Tighten the bolts fo r the thrust
washers to a torque of 5 kpm {36 IbJt.). Grease
the bea'ring.
4. Then fit the brake discs and brake cal,i per. Fiinally
M the brake pipes.

FITTI NG THE REAR AXLE

Fig. 4·165. Fixlure for rear axle
l . Place ,t he rear axle on fixture SYO 2714, which IS
mounted on a garage jack, see Fig . 4·165. Move
the rear ,axle in under the vehicle and fit on the
bolts for the support ar ms and torque rods.
and then tighten the screws a further 3-51f2 turns.
Fi,t the differential and outer rings. Remove tool 2. Raise the jaoek un,~il the trad< bar atta'c hment on
the rear a>ele is on the same level with the attach-
SYO 2394. Fitthe cap and fighten the bolts to a
ment on t.he body. Fi,t the tra.ck rod .
torque of 5.0-7.0 kpm (36-50 Ib.ft.).
6. Check the tooth flank clearanoe and the mesh 3. Fi,t the attaching bolts for the spring's. Tight·e n the
patfern. nuts forr the torque rods and suppo'rt arms.
4. Fit the bracket, screw union and brake hoses. Fit
the universali joint to the f/ange.
ASSEMBLlNG THE REAR AXlE 5. Fit the upper bolts for the shock absorbers. Fit
l. ~emove spanner SYO 2404. Fit the oil slinger and the han,d brake wire in the brackerJ1s and at the
oi·1 seal. The oil sea'l is fiUed with to,ol SYO 2806, levers. Adjust the handbrake and bleed the brakes,
see Fig . 4-139. see Fiig. P,a rt 5.
When fitNng the oil seal, sm ear the sea,1 lips with 6. Fiit on the wheels and wheel ",uts. Lower the ve·
grease. N the same rflime apply a lay,er of grease hide. T,ighten ~he wheel nuts to a final torque of
to the spring coil. Thi,s la'st-ment·ioned measure is 10-14 kpm (70-100 IbJt.).

4: 62
Engagement of "R", "D" or "L" A B C D E F a b c d e T g h m n p q N O P Q R S T U v W X Y Z
Bumpy ... . .. . . ..... . 2 l 5 3 4 6 7
Delayed ... . . ..... . ..... . ......... . 2 3 4 7 6 5 13 8 9 10 11 12
None . . ................ . . . .... . ........ . 2 3 4 5 6 7 8 9 10
5
Starting from rest
None forward ................ . . . . .... . 3 2 4
None reverse .... . ... . ...... . ... . 2 765 3 4 9 8
Seizure reverse 2,
No neutral 3 2
Upshifts
No 1-2 .... .. .. . .... 2 8 9 10 673 4 5
No 2-3 .... .. ...... . 8 9 10 672 3 4 5
Above normal sh if t speeds . 8 9 10 273 456
Below normal shift speeds ......... . .. . 5 6 2 3 4
Upshift quaiity
Slip on 1-2 .. ... . ..... . .... . ... .. . ... . 2 3 4 8 9 10 6 7 5
Slip on 2-3 ..... . 2 3 4 9 10 11 7 8 5 6
Rough on 1-2 l 2 10 3 456 9 7 8
Rough on 2-3 ... l 2 6 3 4 5
Seizure on 1-2 5 6 2 3 4
Seizure on 2-3 2 3 4
Downshifts
No 2-3 .... . ........ . .. . . . . . .. . . l 3 2 4
No 3-2 ......... .. .. . ... . . . .. . .. . .. . l 3 2 4 5
Involuntary high speed 3-2 . .. . .. .. . . . . . . . 2 3
Above normal shift speeds ..... . ......... . 5 6 423
Below normal sh ift speeds ..... . .. . .. .. .. . 5 6 4 2 783
Downshift quaiity
Slip on 2-1 .......... . . ....... . .
Slip on 3-2 . ........... . ..... . ......... . 6 7 8 4 5 3 9 2
Rough on 2-1 .... .. . . . . . . .. . ....... . 3 2
Rough on 3-2 ..... . .... . ... . .... .... . 5 3 4 2 678
Line pressure
Low, id ling . ..... . ...... . ..... . ... . .... . 2 3 6 8 5 4 7 9
High, idling .. . ........ . . . ... . ......... . . . l 2 3 5 4
Low at stall 2 6 8 7 3 549 10
High at stall .. 4 l 2 3
Stall speed
More than 600 r.p.m. below nominal speed l
Over 2500 .. . ................... .. . . .... . 2 3 4 5 6 7 8 9 10 11 12 13

No push start 2 6 5 8 9 10 11 3 7 12 4
Overheating 2 3 4

The numbers indicate the recommended sequence of fault investigation

FAULT INVESTIGATlON KEY

Preliminary adjustment faults
A. Fluid level incorrect. p. 2-3 shift valve plunger sticking.
B. Downshift valve cable incorrectly assembled or adjusted. q. Converter "out" check valve missing or sticking.
C. Manual linkage incorrectly assembled or adjusted. s. Pump check valve missing or sticking.
D. Incorrect engine idling speed.
E. Incorrect front brake band adjustment. Mechanical faults
F. Incorrect rear brake band adjustment. N. Front clutch slipping due to worn plates or faulty parts.
O. Front clutch seized or plates distorted.
Hydraulic controi faults P. Rear clutch s lipping due to worn plates or faulty check valve in piston.
a. Oil tubes missing or not installed correctly. Q. Rear clutch seized or plates distorted.
b. Sealing rings missing or broken. R. Front band slipping due to faulty servo, broken or worn brake band.
c. Valve body assembly screws missing or incorrectly tightened. S. Rear brake band slipping due to faulty servo, broken or worn brake band.
d. Primary regulator valve sticking . T. One-way clutch slipping or incorrectly fitted.
e. Secondary regulator va lve sticking. U. One-way clutch seized.
f. Throttle valve sticking. V. Input shaft broken.
g. Modulator valve sticking. W. Front pump drive fingers on converter hub broken.
h. Governor valve sticking, leaking or incorrectly fitted. X. Front pump worn.
I. Orifice controi valve sticking. Y. Rear pump worn or drive key broken.
m. 1-2 shift valve sticking. Z. Converter blading and/or one-way clutch fails.
n. 1-2 shift valve sticking.

QUICK-RE-FERENCE FAULT-TIMCING CHART FOR AUTOMATIC TRANSMISSION

(The numbers indicate the recommended sequence of fault investigation)
 19 ---~-~d-b~
18
17
16 -----'~'-
15

1. Crankshaft
2. Clutch plate shaft
(input shaft, gearbax)
3. Support bearing in crankshalt
4. Circlip
5. Clu!ch plate
6. Flywheel
7. Flywheel casing
8. CI utch cover
9. Retainer
10. Thrust plate
11. Support rings
12. Pressure spring
13. Release bearing
14. Clutch wire
15. Washer
16. Rubber bush
17. Washer
18. Nut
19. Rubber stop
20. Stop bracket
21 . Pedal shaft
22. Clutch pedal
23. Adjusting nuts
24. Cover, gearbox
25. Lever and release shaft , -- 24
26. Release fork
27. Return spring '----- 25
28. Washer
' - - - - - 26
27
28

VOLVO
103222

Illustration 4-A. Clutch and clutch controls

 1. Cluteh easing
2. Engaging ring
3. Interlock ball
4. Spring
5. Seleetor rai l, revers e geer
6. Selector rail for 1st and 2nd gears
7. Selecfor rail for 3rd and 4th gears
8. Flange 30
9. Spring
10. Selector fork
11. Gear wheel, 3rd speed
12. Gear wheel, 2nd speed
.. 31

13. Needle bearing

32
14. Spring
15. Synehronizing hub, 1st-2nd gears
16. Interlock ball
17. Sliding plate
18. Flange 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 192021 22 2324 252627 28 29
19. Seleetor fork, 1st and 2nd gears
20. Gearbox eover
21. Synchron izi ng eone I
22. Flange ~--36
23 . Bush
24. Thrust washer
25. Ball bearing
26. Selector fork, re verse gear
27. Flange ---38
28. Shaft
29. Bush
30. Gear lever knob
31. Gear lever, upper secfion
32. Rubber bush
33. Rubber bush
34. Gear lever, lower secfion
35. Washer
36. Cover
37. Spring
38. Protective easing
39. Oil seal
40. Mainshaft
41. Speedometer drive
42. Rear eover
43. Speedometer pinion
44. Sh ift lever
45. Gear wheel, l st gear
46. Needle bearing
47. Reverse gear
48. Bush
49. Slide register
50. Engaging sleeve and gear wheel
for reverse geor
51. Circlip
52. Reverse gear shaft
53. Needle bearing .
54. Gear wheel
55. Gearbox housi ng
56. Synehronizing hub
57. Engaging sleeve
58. Circlip
59. Synehronizing con e
60. Needle bearing
61. Drain plug
62. Gear wheel
63. Countershaft
64. Ball bearing I I I I l I i I i I
65. Ball bearing 67 66 65 64 63 62 61 6059 58 57 5655 54 53 52 51 5049 48 47 4645 44 43 42 41 40 39 VOLVO
lOJ 172
66. Oil seal
67. Cover
68 . Input shaft

Illustration 4-8. Gearbox

 9 10 11

6 7 b60~
12 I
Y amC
13 15
17
18

l. Nul 56. Washer

2. Lock washer 57. O-ring
3. Bridge piece 58. Cyl i nder
5. Breather 59. O-ring
6. Front casing 60. Plug
7. Gasket 61. Spring
8. Brake nng. 62. Ball
9. O-rin g 63. Non-retur b
10. O-ring 64. O-ri ng n ody
11. Sea l 65. Pump body
33
12. Gasket 66.
67 WPump p Iung,er
13. Solenoid · asher (2)
14. Bolt 68. Fine filter
15. Thrust bearin . 69. Seal
16. Spri ng' g reta Iner
70. Plug
17. Ball be . 71. Data plate
18 ' anng 75
· C"clip 72. Screw
19. Circlip 73.
74 Planet gear and .
· Sungear carrfer
20. Circlip
21. Stud 75. Clutch slid '
76. Pre-filter Ing member
22. Piston sea l
23. Piston 77. Gasket
24. Conn ec t'mg rod
25 78. Magnet
26' ~on-return ball 79. Base plate
I 80. Bolt
27.· Plug,
on-return
va ve spring
81 . Resilient w h
84. Bush as er
28. Key
29. Resilient rin :~. Th:ust washer
30. Circlip g · Od throw
31 . Eccentric 87. Circlip er
32. Piston pin 88. Uni-dire .
89. Stud cflonal clufch
33. Gasket - ~
36. Stud 90. Resilient wa h ~8L
37 O nice
38' T nczzle
91 . Nul s er
~80
· Sea I 95.
96 Speed
O . ometer pinion
39. Plug · -nng
40 .. O-ring 97. Bush
41. End piece 99. Bolt
42. Piston 100. Retainer
43. Washe r 101 . Oil seal
44. Spring 102. Stud
45. Retainer 106 · S peedometer d .. 88
geer nVlng
46. Spring
47. Screw 110 O utpul shaft 89
~
111'
48. Screw 112 · Ball be anng
.
49. Holder · Spacer
SO. Spring 113. Rear c .
114. Ball aSl~g

~~~2
51. O-ring 115 . bearlOg
52. Plug · Od seal
53. Nut 116. Flange
54. Piston 117. Washer
55. Spring 118. Nut

111~
113 0 - 96
102

101 , 91

100---(ji
l;--99 VO LVO
103120

Illustration 4-C. Overdrive

 2 5 6 7 8

l. Oil seal
2. Front pump
3. O-ring
4. Pump body
5. Gasket
6. Thrust washer
7. Snap ring
8. Input shaft
9. Thrust washer
10. Hub
Il . Disc kit
12. Snap ring
13. Spring
14. Ring
15. Piston ring (rubbe r)
16. Pistan and reed
17. Rubber ring
18. Front clutch cylinder
19. Front servo
20. Servo strut
21. Contad pin
22. Brake band
23. Thrust washer
9
----------
- ----

24. Thrust washer

25. Snap ring
26. Spring seat
27. Spring
28. Snap ring
29. Disc kit
30. Piston ring
31. Piston
32. Front drum
33. Oil ring
34. Rubber ring
35. Needle bearing
36. Key
37. Reverse sun gear
38. Needle thrust plate
39. Oil rings
40. Forward sun gear
41. Oil ring
42. Centre bearing
43. Servo strut
44. Brake band
45. Needle thrust bearing
46. Thrust plate
47. Snap ring
48. Free wheel
49. Brace
SO. Planetary gear
51. Thrust plate
52. Gear
53. Snap ring
54. Driven shaft
55. Washer
56. Oil ring
~----- .
57. Seal ring I
58. Gearbox housing I
59. Rear servo
60. Stop shaft
I
61. Nipple
I
62. Key I
63. Pump plate I
64. Oil pump, rea r I
65 . Ball I
66. Centrifugal governor
67. Snap ring
68. Valve housing
69. Spring
70. Reta i ner
71. Speedometer gear
72 Flange

VOLVO
105035

Illustration 4-0. Automatic transmission BW 35

 2 3 4 5 6 7 8 9 10 11 12

1. Tubular shaft
2. Diffe rential carrier bearing
3. Bearing cap
4. Shims
5. Differential carrier
6. Thrust washer
7. Differential side gear
8. leck pin
9. Differential pinien
10. Crewn wheel
11. Shaft
12. Thrust washer
14. Flange
13. Rear axle casing
15. Dust cever plate
16. Oil slinger
17. Oil seal
18. Shims
19. Frent pinien bearing
20 . Pinien
21. Rea r pinien bearing
22. Shims

22 21 20 19 18 17 16 15 14 13 VOLVO
102 845

Illustration 4-E. Final drive

 Part 5

BRAKES
 (ONTENTS
Group 50. General
Toals . ...... .. . . 5:1
Description ... 5 :2
Repair Instructions 5:3
Cleaning .. 5 :3
Brake fluid 5 :3
Fault tracing 5:3
Servicing . . 5 :6

Group 51. Wheel Brake Units

Description ... . .. . 5 :7
Repair Instructions .... .. ........... .. . . . ... .. . 5 : 10
Replacing the brake pads 5 : 10
Reconditioning the wheel brake units 5 : 12
Brake disc .. . . 5 : 16

Group 52. Hydraulic Footbrake System

Description ... 5 : 17
Repair Instructions 5 : 20
Master cylinder 5 : 20
Warning valve 5 : 23
Brake valve 5 : 23
Brake lines 5: 24
Bleeding the hydraulic system 5: 25
Adjusting the brake light switch 5: 27
Brake pedal . .... . . ..... . 5: 27

Group 54. Auxiliary Brake System

Description .. ... ... ... ....... . 5: 29
Repair Instructions .... .. ..... . ... . 5: 31
Replacing the air cleaner and damper ... 5 : 31
Replacing the check va!ve .. 5 : 32
Replacing the servo cylinder .. . .. ... .. . . 5 : 32

Group 55. Parking brake

Description ... . . . ..... . 5: 33
Repair Instructions ... . . 5 : 34
Adjusting the parking brake 5: 34
Replacing th~ cable ...... .. . 5: 35
Replacing the parking brake lever or ratchet parts 5: 36
Rear wheel brake unit (parking brake component) . .... . . . 5: 36
 GROUP 50

GENERAL
rOOlS
The following special tools are used for repair work
on the brake system .

The testing device (Fig. 5-2) is used, for example, to

trace faults in the brake system.
SYO 2742
Removal of the pistons in the front brake caliper is
made easier with the help of wooden inserts accord-
o ing to Fig. 5-3.
SYO 2809 A hose connection (see 2, Fig. 5-4) is required for
removing the pistons in the rear brake calipers.
A bleede,r unit of the type shown in Figi.. 5-5 is used
for bl'eeding the system. A connection cove,r (s·e e 1,
Fig . 5-4) is also required for connecting the unit to
the brake fluid container.
VOLVO
Fig . 5-1. Special 1001. 103033

SYO 2740 Bleeder 1001

SYO 2742 Holder for cable spring
SVO 2809 Tool for pressing in and checking pistons

VOLVO
Fig . 5·4. Cannections 103177

l. Connection
(Can be oblained fro m Volvo Service De pt.j
2. Conne ction for brake caliper
Fig. 5-2. Testing device SYO 2741 YS\'~?
l. Nipple plug 4. Hose
2. Connection nipple 5. Bleeder device
3. Enlarging nipple 6. Pressu re gauge

95

f - - - - - -- - - - 210 - - - -_ _ _ _ _-1 Yd1~W

Fig. 5-3. Wooden insert for front brake calipers Fig. S-S. Bleeder unit

5:1
 DESCR I PTION
The 164 is fitted with two brake systems which are circuit takes care of the upper cylinders of the front
independent of each other. One of these, the foot- wheel brake units and the left rear wheel. With such i
bra ke system, is co ntrolled by a brake pedal and an arrangement, braking effect is ensured, should
o pe rates on all four whee ls through a hydra ul ic one of the brake lines fail.
system. The other brake system, the parking, brake, The servo brake cylinder (S) is directly influenced by
functions by means of a brake lever and operates both the brake pedal, and wi th vac uu m assistance from
the rear wheels mechanically. the induction manifold of the engine less pedal
Fig . S-6 shows the arrangement of the footbrake pressure is required for braking. The function of the
system which has d isc brakes all round. brake valves (10 and 11 ) is to assist in providing a
The hydraulic part has two separate circuits. The su itable distribution of braking power between the
master cylinder (l ) is of the tandem-type and each front and rear wheel brakes.
fro nt wheel brake unit (13) has two pairs of cylinders Concerni ng a more detai led description of the units
entirely separa ted from each another. One of the making up the footbrak e and the pa.rki ng brake
circuits serves the lower cylinders of the front wheel systems, see the re,spective Groups in question.
brake units and the right rear wheel, while the other

Vccuum _ Primcry circui t Primary ci rcuit, - Secondary circuit, . Secondary circuit,

pressu re cbove reduced pressure press ure above reduced pressu re
34 kp/cm 2 34 kp/cm 2
(484 p.s .i.) (484 p.s. i.)

Fig. 5-6. Brake system

1. Tandem master cyli nder 9. Brake disc with drum 15. Warning swilch
2. Brake fluid container 10. Brake va lve, 16. Warning va lve
3. Vacuum line secondary circui t 17. 6·b ranch un ion,
4. Check valve 11. Brake valve, (doubl e 3-branch union)
5. Servo brQ)<e cylinder primary circuit 18. Brake p ipe
6. Brake switch 12. Brake pedal 19. Cover plate
7. Warning lamp 13. Front brake ca liper
8. Rear bra ke ca li per 14. Bra ke d isc

5:2
----------------------------

REPAI R I NSTRUCTIONS
CLEANING filled, likewise with all work concerning connections,
The components of the hydraulic brake system should etc. the greatest cleanliness should be , observed in
be cleaned in clean brake fluid or denatured alcohol, order to prevent dirt from getting intö the system.
which does not contain benzene (benzol). On ly clean, unused brake fluid should be filled.
Of the existing kinds of denatured alcohol being sold Brake fluid which is expelled during, for example,
generally only methylated spi rit is free from benzene. bleeding, may not be put back into the system.
Brake fluid is an excellent but expensive cleaning After use over a long period, it is normal that even
agent. From most viewpoints, methylated spi rit is first-class brake fluid gradually deteriorates through
therefqre the most suitable. the absorption of moisture and small impurities. Thus,
Petrol, white spirit, trichlorethylene or alcohol with deteriorated brake fluid can be recognized by the
benzene must not be used for cleaning as, like the fact that, compared with new brake fluid, it is darker
slightest trace of mineraloil, they attack the rubber or has changed its colour, is relatively odourless and
seals and cause them to swell out. For this reason, watery, i.e. when felt between the fingers it lacks the
hands should be washed with soap and water before normal feeling of a light lubricating film. Such brake
the internai parts are touched. The mechanic working fluid should be replaced by new fluid, and this should
with the hydraulic components should preferably be also be done when the master cylinder and wheel
provided with rubber gloves. brake units are being overhauled.
Final rinsing should take place in a cleaning agent
free from impurities after which the parts can be
dried in the open air. To precipitate the drying and FAULT TRACING
complete the cleaning process, filtered, compressed The following fault tracing procedure can be used,
air free from moisture can be used . It is of the utmost for example, after the discovery, following upon some
importance that no alcoholic residue is left in the kind of brake testing, that the capacity of the foot-
system when filled with brake fluid . Traces of alcohol brake sy~tem is not what it should be. Fault tracing
in the brake fluid reduces its boiling point and can can also be carried out with a view to preventing
result in the formation of vapour which can affect faults arising.
brake functioning. l . Check that the level of the brake fluid reaches
After being cleaned and dried, the parts should be up to the "Max" mark on the container. Top up,
moistened with brake fluid, assembred and then the if necessary. See under the heading "Brake Fluid".
comprete unit filled with brake fluid as soon as 2. Remove both the inside venting nipples at one
possible in order to prevent corrosion attacks from of the front brake calipers and connect up the
mo-isfure in the air. This applies to parts which should testing device SYO 2741 shown in Fig. 5-2.
be fitted immediately in the vehicle. To counteract 3. Depress the brake pedal several times to even out
corrosion on brake parts which are stored, or for any any partiai vacuum in the servo brake cylinder
other reason are not covered by brake fluid, the and in this way disconnect it. Check that when free
plungers, cylinders and sea Is should be coated with a the brake pedal is about level with the clutch
thin layer of lubricant called brake paste intended for pedal.
this purpose. Under no conditions whatsoever must 4. Apply and re lease the footbrake while reading
other types of grease or rustproofing oil be used. off the pressure gauges of the testing device. The
pressure in both the circuits should be observed.
At 100 kp/cm,2 (1422 p.s.i.), there must not be a
BRAKE FLUID diffe'rence In pressure of more than 3 kp/cm 2
Only first-class brake fluid, which is guaranteed by a (42.7 p.s. i.).
well-known manufacturer to fulfil the requirements 5. With the help of a pedal jack apply the foot-
according to the standard SAE 70 R 3, should be used brake to a hydraulic brake pressure of about
for the brake sys,tem. Brake fluid with the later desig- 100 kp/cm2 (1422 p.s.i.). Check the l.ines and
nation SA,E 70 R 3 (J70B) or SAE J1703 can also be parts for damage and leakage. The pressure
used. Fluids which only fuHil the requirements accord- should remain unchanged for at least 15 seconds.
ing to SAE 70 R l, for example HD-qual,ity and 6. Remove the pedal jack. Depress the brake pedal
FS-VV-H 910 A, should not be used. Mixing of brake and maintain this pressure. Start the engine. Here
fluids produced by d ifferent firms should be avoided. a noticeable lowering of the pedal should be felt
When the container of the master cylinder is being when the servo cylinder starts to operate.

5:3
 7. Stop the engine after it has run a; least l minute. units. Apply the footbrake with the pedal jack
With the help of the pedal jack apply a hydraulic to the incoming pressure according to the table
pressure of 25 kp/cm2 (356 p.s.i. ). Wait a couple below. Read off the incoming pressure on the
of minutes. The hydraulic pressure should not drap pressure gauge for the front wheel brake unit.
more than 5 kp/cm,2 (71 p.s.i.). Read off the outgoing pressure on the gauge
8. Check the warning valve. Connect a hose to one which is connected to the rear wheel brake unit.
of the venting nipples of the testing devi~e and From the point of view of leakage, the brake
open the device. Switch on the ignition switch and valve is not defective if the pressure remams
check that the warning lamp lights when the park- unaitered for at least 15 seconds.
ing brake is applied.
Release the parking brake. With a pedal jack
apply the footbrake slowly. When the warning Incoming. pressure 30 50 100

lamp lights, check the pressure on the pressure

kp/cm2 (p.s.i.) I (427)
I (711 )
I (1422)
gauge. The lamp should light at a pressure dif-
Outgo ing pressure 30 I(512-
36--42 I 62- 69

fere·nce of 5-15 kp/cm 2 (71-213 p.s.. i.) be,t ween

kp/cm~ (p.s.i.)
I (427) 597) (882- 981)

the circuits.
After the test, shut off the bleede-r nipple and 10. Check the other brake valve in the same way by
remove the pedal jack. Disconnect the electric connecting it to right rear wheel brake unit and
cable and unscrew the warning valve switch so the inner, lower nipple of the front wheel brake
that the warning valve returns to its normal posi- unit.
tion. Screw in the electric switch to a tightening 11. Jack up the vehicle so that the whee ls rotate
torque of 1.4-2.0 kpm (10-14 Ib.ft.). Connect the freely. App ly and re lease the brake during which
electric cable. a check is made to see if the wheels can be
9. Check the brake va lve of the secondary circuit rota ted . The whee ls shou ld be free fo r half a se-
by connecting the testing devices to the venting cond after th e pedal has been re leased. The test
nipple on the left rear wheel brake unit and tö should be carried out with and without apartial
the upper nipple on one of the front wheel brake vacuum in the servo brake cylinder.

FAULT TRACING SCHEME

Test
opera- Fault Cause Remedy
tian I I I
3
I Pedal too low or too high I Faulty brake pedal or carpet
I Adjust
4 Fading pressure Damaged brake line Replace the damaged lin e
Blocked hose Replace hose
Difference between circuits Leakage in one of the circuits See points 5
greater than 3 kp/cm2
Faulty master cylinder Recondition master cylinder
(42.7 p.s.i.)

5 The pressure drops Externai leakage Tighten connectians and replace

line or recondition leaki ng part
Leaking brake va lve Recondi tion or replace b rake
va lve
Leaking seal in w heel unit cy- Recond iti o n wheel uni t cylinder
linder
Leaking sea l in master cylinder Recondition master cylinder

6 The pedal does not go down Leaking vacuum line Rep lace vacuum line
Blocked air filter or leaking seal Rep lace fil ter or seal
for front pressure p lunger in
servo cylinder.
Faulty servo cylinder Replace servo cylinder
completely

5:4
 Test
opera- Fault Cause Remedy
tion I I
7 The pressure drops more than Leaking check valve Remove and blow clean the
5 kp/cm 2 (71 p.s.i.) valve and replace the seal ring.
If insufficient, replace check
valve
Leaking seal for front pressure Remove master cylinder and re-
plunger in servo cylinder place seal
Internai fault in servo cylinder Replace servo cylinder comple-
tely

8 The parking brake warning Wrongly adjusted switch Adjust the switch
lamp does not light Faulty electrical parts Replace faulty parts
Footbrake warning lam p does Faulty switch Replace switch
not light
Warning lamp does not go out Pistons seize Replace warning valve
when pistons have returned to
normal position
Warning when pressure differ- Faulty warning valve Repla::e valve
ence is other than 5-15 kp/cm 2
(71-213 p.s.i.)

9-10 Faulty outg,o ing pressure Leaking valve Recondition or replace brake
valve
Faultily set valve Adjust if reconditioned valve
tested, see page 5 : 19

11 A circuit fades Blocked equalizing hole in Recondition the master cylinder

master cylinder
The rear wheel brakes fade Parking brake cabl.e chafes Replace the cable
Faulty adjusted parking brake Adjust the parking brake
Faulty brake valve Recondition or replace brake
valve
A wheel brake fades Damaged brake line Replace line
Blocked hose Replace hose
Worn sealing ring Recondition wheel brake unit

5:5
 SERVICI NG
From the point of view of traffic safety, the condition (1/8"). Under no circumstances must the linings be
of the brakes is an extremely irilportant factor. It is worn down below 1.5 mm (1/16"), For replacement of
essential, the refo re, that any work carried out on the pads, see pages 5 : 10 and 5 : 11.
the system should be done by qualified mechanics
with the greatest care, likewise that a regular check
is made according to the instructions given below. FUNCTION CHECK
In addition to the regular check on the brakes
CHECKING THIE BRAKE FLUID LEVEL carried out by the driver as result of the driving
done, the brakes should be checked eve ry 10000 km
When fi"ing the tank with fuel, check to make sure
(6000 miles) by a workshop mechanic. The footbrake
that the fluel level in the master cylinder container is
should also be checked then to make sure that it func-
not below the "Min" mark. This can be done without
tions satisfactorilYi if necessary, check with the help
removing the cap. Every 10000 km (6000 miles) top-
of proper testing equipment (see "Fault Tracing") . A
up, if necessary, to the "Max" container mark.
check should also be made that there is no leakage
A first-dass brake fluid which meets the require-
and that the brake lines are not exposed to such
ments according to SAE 70 R 3 should be used for
damagie that leakagle can be expeded. The parking
toppingl-up. Brake fluid with the later designation
brake should provide full braking power at the 3rd-
SAE 70 R 3 (J7QB) or SAE J1703 can also be used. Be-
4th ratchet segment. If it does not do so, adjust the
fore remova l, 'delan the cap of the container and
parking brake alccording to the instructions given on
obse.rve max'imum deanliness when filling with fluid.
page 5: 34.
Avoid spi",ing the brake fluid onto the painfwork as
this can damagle it. Check to make sure that the vent-
hole in the cap is not blocked. OVERHAUL
Every third year or 60000 km (36000 miles) the brake
CHECKING THE BRAKE PADS system seals and air filter for the servo brake cylin-
Every 10000 km (6000 miles) check the wear on the der shoul,d be replaced. Where driving conditions
linings. The brake pads should be replaced when the are for the mostly diusfy, the air filte,r should be re-
linings are worn down to a thickness of about 3 mm placed more often.

5:6
 GROUP 51

WHEEL BRAKE UNITS

DESCRI PTION
CONSTRUCTION OF THE FRONT 6
WHEEL BRAKE UNITS 7
Fig. 5-7 shows how the brake components are located 5
___- - 8
at the front wheels. The disc (3) is of cast iron and is
attached to the wheel hub with which it rotates. The
cover plate (4) protects the disc from dirt.
9
Mounted on the stub axle is the front wheel caliper O
(2) which houses the wheel unit cylinders and brake
pads. The front wheel brake caliper consists of a
housing in two halves (6 and 14, Fig. 5-8) bolted to- 3
gether and located on either side of the brake disc.
Each half contains two cylinders and pistons. The 2
upper 'cylinder is completely separated from the
lower one, but both upper and lower cylinder are
each connected through channels to the corresponding
cylinder in the other half. The function of the sealing
rings (l) is partly to prevent brake fluid from oozing
out and partly to return the pistons to the rest position
Fig. 5·8. Fran! wheel brake c"liper
after braking. Rubber dust covers (3) prevent dirt from
1. Sealing ring 8. Bol!
entering. Each sealing ring has a square section and
2. Piston 9. Retaining clip
presses against the piston from the slightly oblique 3. Rubber dust cover 10. Brake pad
4. Retaining ring 11. lower bleeder nipple
groove in the housing . The brake pads (10) are pro-
5. Channe l 12. Damping spring
vided with bonded facings and are held in position 6. Outer half 13. Retaining pin
by means of retaining pins (13). 7. Upper bleeder nipple 14. Inner half

CONSTRUCTION OF REAR WHEEt UNITS

(Footbrake component)
Fig. 5-9 shows the location of the brake components
on the rear wheels. The brake disc (2) is of ca st iron
and is fixed to the drive shaft with which it rotates.
The cover plate (3) prevents dirt from reaching the
disc.
The rear wheel brake caliper is mounted to the rear
axle casing with the help of a retainer. It houses the
wheel unit cylinders and brake pads. It consists of a
housing divided in two halves (9 and 14, Fig. 5-10)
bolted together and located on either side of the
brake disc. Each half contains a piston and a cylin-
der linked by means of a channel in the housing .
The caliper is provided wfth an A.S.B. (anti-shake
back) device. The function of the A.S.B. device is to
keep the pistons and the b rake pads at the correct
Fig. 5·7. Brake campanen!s, fra n! wheel
distance from the brake disc when there is consider-
1. Hub 3. Brake disc
2. Fron! brake caliper 4. Cover plate
ab le movement of the disc occasioned by lateral cast

5:7
 a pin (2) which is pressed into the caliper. The spring
moves on the pin with a certain amount of friction .
The sealing rings (l) have a square section and press
against the piston from the slightly oblique groove
in the housing. The function of the sealing rings is
part,ly 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 pads (13) are provided with
bonded facings and are held in position by means of
retaining pins (16).

VOLVO
ID) 860

Fig . 5-9. Brake componenls, rear wheel FUNrCTION

l . Drive shafl 3. Cover plale HYDRAULIC
2. Brake disc 4. Rear brake coli per
The lower cylinders of the front wheel brake units
and the right rear wheel brake unit are connected
through brake lines to the primary chamber of the
(due to the axial play of the drive shafts when driv-
master cylinder, see Fig . 5-11 . In the same way the
ing round bends or on rough ground). The A.S.B. de-
upper cylinders of the front wheel brake units and the
vice prevents a reduction in the pedal travei (that is,
left rear wheel brake unit are connected to the
the distance from the pedal position at full brake opp-
master cylinder through the secondary chamber.
lication to the floor plate). The A.S.B. device consists
of the following (see Fig. 5-10): A spring (3), a washer
(4) which holds the spring securely on the piston, also

Fig. S-lO. Rear brake coli per

l. Sealing ring 10. Bleeder nipple

-
2. Pin 11 . Boll
3. Spring 12. Retaining clip
4. Washer 13. Brake pad
5. Pislon 14. Inner half Secondary circuit, Primary circuit,
pressureless pressureless VOLVO
6. Rubber dust cover 15. Damping spring 102897
7. Relaining ring 16. Relain ing pin
8. Channel 17. Spacer Fig. 5-11. Rest position
9. Ouler half l. Warning lamp

5:8
- -- -- -- ---------~

A warning valve is located between the master cylin- sufficient to move the pistons back to a certain ex-
der and the brake lines for both the circuits. The tent, see Fig . 5-11 . The return movement forms the
valve is connected to the same warning lamp which clearance between the brake linings and the brake
indicates when the handbrake is applied. The lamp disc. This means that, in the rest position, the brake
will light during brake application if there is too linings are always at a certain distance from the
larg,e a pressure difference (about 10 kp/cm 2 = 142 brake disc regardless of wear, so that the wheel
p.s.i.) betwe,enthe two brake circuits. brakes are self-adjusting .
When the pressure in the master cylinder rises as a Should leakage occur in one of the circuits, fu ll
re,sult of brake application, the pjstons are displaced braking effect is still obtained on both the front
and press the lining pads against the rotating friction wheels and one rear wheel if pedal pressure is in-
surface of the brake disc, see Fig. 5-12. The pressure creased. Fig . 5-13 shows how this operates when
appl~ ed, and thus the brake effect, varies in propor- leakage occurs in the secondary circuit. When there
tion to the foot effort applied to the pedal. When is a pressure difference in the brake circuits of about
the pistons are displaced, the sealing rings are ten- 10 kp/cm2 (142 p.s.i.), the warning valve piston is
sioned laterally. They remain in this state as long pressed over to the side with less pressure and the
as the footbrake is applied. When the brake pedal warning lam p lights. The warning lamp will remain
is released, the pistons are relieved of hydraulic lighted until the leakage in the circuit concerned is
pressure. Since there is no residua I hydraulic pressure repaired.
in the system line, the tension in the sealing rings is

_ Second a ry ci rc ui t, _ Pri mary circuit, _ Secondary _ Pri.mary cir- _ Primary ci r-

press ure above press ure obove clrcu lf, cult, pressure cvit, red uce d
_ 34 kp/c m' (484 p.s.i.) , 34 kp/cm' (484 p.s. i. ) pressure less above 34 kp/ pressu re
Seco nda ry ci rcui t, Prim ary circui t, cm' (484 p.s.i.)
reduced pressure red uced pressure
Fig . 5-12. Brake application Fig. 5-13. Bra ke application, Jeakage in secondary circuit

5:9
 2 3 4
B A B

VOLVO
102901

Rest position Brake applicatian

Fig. 5-14. Function of A.S.B. device

Fig . 5-15. Brake caliper with A.S.B. device

1. Washer 2. Spring 3. Pin 4. Sealing ring
A.S.B. OEVICE (REAR BRAKE CALlPERS)
When the brake is released, see Fig . 5-14, there is
a clearance A between the brake pad and the disc moved backwards by the sealing ring (4) so that
and al50 a clearance B between the washer and the clearances A and B are restored.
spring. With brake application, see the figure, the If the lateral movement of the brake disc (when
piston (and thus also the brake pad) is pressed driving on rough ground or round bends) should
against the brake disc and this removes the clearance, now be greater than distance A, the piston is moved
A. If distance A is now greater than distance B, this backwards into the cylinder. Owing to the friction
means that the washer (l, Fig. 5-15) is pulling the between the spring and the pin in the A.S.B. device,
spring (2) with it in the direction of the brake disc. the lateral movement of the piston will not be greater
When the brake pedal is released, the piston is than that of the disc.

REPAIR INSTRUCTION S
REPLACING THE BRAKE PADS brake unit should be reconditioned. To provide
space for the new brake pads, the pistons mus!
The brake pads should be replaced when about 3 mm
be pressed into the cylinders. It should be noted that
(1/8") of the lining thickness remains. On no account
the brake fluid I'e vel in the master cylinder will then
must the linings be worn down to below 1.5 mm
rise and the brake fluid may possibly spurt out.
(l/W').
Take care not to damage the disc or piston when
The function and I,ife,timre of the lining's will bene,fjt if
pressing in the pistons. Tool SYO 2809, Fig . 5-17,
lengthy and he.fty braking is avoide,d in the beginning.
can be used.

Front wheel brake units

l . Remove the hub caps 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. Remove the hairpin-shaped locking clips for the
guide pins. Pull out one of the lock pins whi le
holding the damper springs in place. Remove the
springs and the other lock pin . Draw out the
pads and spacers, see Fig. 5-16.
4. Carefully clean out the cavity in which the pads
fit. If any of the rubber dust covers are damaged,
they should be replaced . If dirt has penetrated
into the cylinder due to a damaged cover, the Fig. 5-16. Removing the brake pa ds and spacers

5: 10
5. Fit the new pads. Fit one of the retaining pins
in position, then the damping springs and finally
the other retaining pin. Fix the pins with the re-
taining clips. Check that the pads are movable .
6. After the requisite brake pads have been re -
placed, depress the brake pedal several times to
check if the movement is normal. Generally the
system does not require bleeding after rep lacing
the brake pads.
7.Fit the wheels after the contact surfaces between
wheel and brake disc have been cleaned of sand,
etc. Tighten the nuts so much that the wheel can-
not be moved. Lower the vehicle and secure the
wheel nuts. Tighten every second nut a little at
a time until all are finally tightened to a torque
I/OlVQ
·04 )3\
of 10--14 kpm (70-100 Ih.ft.). Fit the hub caps. Fig. S-18. Fitting the brake pads and spacers

Rea·r wheel brake units

1. Remove the hub caps and siaeken the wheel nuts.
2. Jack up the rear end and prop blocks under the
rear axle. Remove the wheels.
3. Remove the hairpin-shaped retaining clips for the
5. Press the pistons into the caliper with tool SVO
guide pins, see Fig. 5-10. Pull out one of the
2809. When pressing in, check the function of the
retaining pins while keeping the damping springs
pistons in the A.S.B. device, see Fig. 5-17. The
in position. Remove the springs and then the other
pressing-in force should be 20-80 kpcm (17-70
retaining pin. Pull out the pads and the spacers,
Ib.in.). If force greater than this is required, the
according to Fig. 5-16.
caliper should be reconditioned. Note that when
4. Carefully clean the cavity occupied by the pads.
pressing in the pistons, the brake fluid level in
If any of the rubber covers is damaged, replace
the brake fluid container will rise possibly caus-
it. If dirt has penetrated into the cylinder due to
ing the fluid to spurt out.
a damaged cover, recondition the brake unit.
6. Fit the new pads, and the spacers, see Fig. 5-18.
F.il one of the rertoining pins in position and instarll
the damrping spring.s and the other re.taining pin ..
Fix the pjns with retaining dips. Cheå that ther pads
are movable.
7. After the requisite brake pads have been replaced,
depress the brake pedal several times to check
that the movement is normal. Generally the
system does not require bleeding af ter replacing
the brake pads.
8. Fit the whee ls after the con tact surfaces between
wheel and brake disc have been cleaned of dirt,
etc. Tighten the nuts so much that the wheel can-
not be moved. Lower the vehicle and tighten the
wheel nuts. Tighten every second nut a little at a
time until all are ti'g htened to a final torque of
10-14 kpm (70-100 Ib.ft.). Fit the hub caps.

RECONonlONING
THE WHEEL B~AKE UNnS
When working with the hydraulic system, observe the
instructions under "Cleaning" and "Brake fluid",
vOLVO
102985
Fig. S-17. Pushing in the piston Group 50.

5 : 11
 VOLVO
101666
Fig. 5·19. Fitting the front brake hoses
1. Connection for the 5. Clip
primary circuit 6. Connection for lower
2. Connection for the wheel unit cylinder
secondary circuit 7. Connection for upper wheel
3. Upper brake hose unit cylinder
4. lower brake hose

Fig . 5·21. Removing the front wheel brake caliper

Front brake calipers b ra cket. Place the protective casing on the brake
REMOVING lines to prevent unnecessa ry leakage. Discon·
1. Remove the hub caps and slacken the wheel nuts nect the connection (6) for the upper hose from
slightly. Temporarily plug the vent·hole in the brake the brake.
fluid container cap to reduce possible leakage. 4. Unscrew the attaching bolts (S and 7, Fig. S·20)
2. Jack up the front end and prop blocks unde r the and remove the brake caliper, see Fig. S·21.
front jack attachments. The linkage arms should
be off·loaded so that the brake hoses can be
fitted in the correct position . Unscrew the wheel DISMANTLING
nuts and lift off the wheels. 1. Remove the hairpin·sooped retaining clips for the
3. Remave the clip (S, Fig. S·19). Disconnect. the con· retaining pins. Pull out one of the retaining pins
nection (2) and the lower hose (4) from the while holding the damping springs in position.
Remove the springs and the other retaining pin.
Pull out the pads, compare Fig. S·16.
2. Remove the retaining rings for the rubber dust
covers. Place a piece of wood, similar in shape
to that shown in Fig. S·3, between the pistons
and press them out against the wood with the
help of compressed air, see Fig. S·22. The pistons
can then be easily removed. Lever off the rubber
4
dust covers.
3. Remove the sealing rings with the help of a blunt
5 tooL Be careful not to damage the edge of the
grooves. Unscrew the bleeder nipples and also
the brake li nes.
6 N.B.: Both halves of the brake caliper sh ou Id not be
separated. The reason for this is that the assembling
7 requires test pressure equipment and special fluid
for the bolts.

VOLVO
101867
Fig. 5·20. Front wheel brake unit fitted
INSPECTING
l. Front wheel brake caliper 5. Attaching bolt
2. lower bleeder nipple 6. Connection for upper Before inspecting clean all the parts according to the
3. Upper bleeder nipple wheel unit cylinder instructions given under "Cleaning", Group SO. Make
4. Connection for lower 7. Attaching bol!
wheel unit cy linder sure that the channels are clean .

5: 12
 the hairpin-shaped retain ing clips. Check that the
pads are movable.
6.Fit the bleeder nipples and also the brake lines.

FITTING
l. Place the caliper in position. Check that the con-
tact surfaces of the retainer are clean and not
damagled. Check the location of the brake, caliper
in relation to the brake disc. Axial deviation is
checke,d by me.asuring with a feele'r g,uage on both
.. sides of the d isc the distance between disc and
VOLVO
101871
caliper support nib. The difference in me,a sureme,nt
Fig. 5-22. Removing the pistans is miax. 0.25 mm '(0.010").. The caJiper should be
1. Wooden disc
paralle'l with the disc. lhisis checked b)l measur-
ing the dis.tanice to the uppe,r and lower support
The sealing rings and rubber dust covers should be
nibs on the celliper. The I'o cation of the brake
replaced whenever reconditioning takes place. If any
cal,ipe,r earn be adjusted with shims, which are
of the cylinders are scored or scratched, or damaged
availabl,e in thicknesses of 0.2 and 0.4 mm (0.,008
in any way, the complete cylinder housing should be
and 0.016"). Fit the attaching bolts after they have
replaced. Inspect the other parts and replace any
been coate,d with a coupla of drops of Lock-tite,
that are damaged or worn .
type AV. Ch,e ck that the brake disc rota tes easily
Check also the brake disc, see under "Brake Disc".
in the brake pads.
2. Fit the hoses and their connection as weil as the
ASSEMBLlNG guide clip as shown in Fig. 5-19. It is important
l . Coat the working surfaces of the pistons and that the hoses are fitted in the correct way, that
cylinders with brake fluid. is, without being tensioned and with the linkage
2. Fit new sealing rings in the cylinders, see Fig. arms unioaded. Remove the plug for the vent-
5-23. hole in the brake fluid container cover.
3. Fit the plungers with the large end diameter 3. Fit on the wheel after the contact surfaces have
facing inwards. Make sure that the plungers are been cleaned OC dirt, and then tighten the nuts
fitted in straight and are not scratched. sufficiently so that the wheel can not be displaced
4. Fit the rubber covers on the plunger and housing. on the hub. Lower the vehicle and tighten the
Fit the lock rings, compare Fig. 5-28. wheel nuts. Tighten every other nut a little at a
5. Fit the brake pads. Place one of the retaining time until all are finally tightened to a torque of
pins in position and fit the damping springs and 10-14 kpm (70-100 Ib.ft.). Fit the hub cap.
then the other retaining pin. Secure the pins with 4. Bleed the fitted brake caliper, see Group 52.

Fig. 5-23. Filling the sealing ring Fig. 5-24_ Front brake caliper assembled

5 : 13
 3. Disconnect the brake line (2,Fig. 5-25) at the con-
nection to the caliper and fit a protective cover on
the brake line. Remove the attaching bolts (l and 3,
Fig. 5-25). Remove the brake caliper, see Fig . 5-26.

DISMANTLING
1. Remove the hairpin-shaped retainning clips for the
retaining pins. Pull out one of the retaining pins
while keeping the damping springs in position .
Remove the sp ri ngs and then the other retaining
pin . Pull out the pads and the spacers, see Fig.
5-18.
2. Remove the dust cover retaining tings and the
dust covers. Place t he caliper in a vice as shown
in Fig. 5-27. Fit tool SYO 2809 and press one of
Fig. 5-25. Rear wheel brake unit fitted
the pistons down to the boHom. Fit a suitab le
1. Allaching balt 4. Rear wheel brake caliper
2. Brake line 5. Bleeder nipple venting connection, see Fig. 5-4, in the caliper.
3. Attaching balt Place a hose piece in the caliper and force out
the other piston. The pressure required may go
up to about 7 kp/cm2 (100 p.s.i.). Remove the
piston.
3. Fit the tool as shown in Fig. 5-28 with a suitable
Rear wheel brake shoes rubber sealing A for the free cylinder. Press out
REMOVING the piston . Remove the piston and the tool.
l. Remove the hub caps ond slacken the wheel nuts 4. Remove the sealing rings with help of a blunt
slightly. Temporarily block the vent-hole in the tool. Take care not to damage the ed ges of the
brake fluid container cap to reduce possible lea- grooves. Screw out the venting nipple.
kage. N.B. Both halves of the brake caliper should not be
2. Jack up the front end and prop blocks under the separated. The reason for this is, that assembling of
rear ax-le. Remove the wheels. Re leia se ~he parking these halves requires pressure testing equipment and
brake. special fluid for the screws.

Fig . 5-26. Removing the rear wheel I>rake caliper Fig . 5-27. Removing the piston

5: 14
 ASSEMBLlNG
l . Coat the working surfaces of the pistons with
brake fluid.
2. Fit the new sealing rings In the cylinder, see
Fig. 5-23.
3. Fit one of the pistons in the caliper. Make sure
that the piston does not come at a slant and is
scored or that it damages 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
kpcm (17-70 Ib.in .). If the force required is other-
wise, the piston must be replaced.
4. Fit and test the other piston in the same way as
Fig . 5·28. Removing the piston above. Place the rubber dust covers on the piston
A=Rubber sea l and housing. Fit the retaining pins.
5. Fit the brake pads and the spacers,. Place one of
the retaining pins in position and fit the damp·
ing springs and then the other reta ining pin . Fit
INSPECTlNG
the hairpin-shaped retaining clips. Check that the
Before inspecting, clean the parts according to the pads are movable.
inskuctions gliven under "Cle,aning" Group 50. Pay 6. Fit the bleeder nipple.
particular attention to the cleaning of the channels.
Check the pistons and pins in the caliper with a
view to the AS.B.-device. If the pins in the caliper FITTING
are worn, the entire caliper must be replaced . Sealing l. PI'ace the wliper in position. Check that the contact
rings and rubber dust covers should be replaced surfaces of the retainer are dean and not damag-
when reconditioning. If there are any scratches or ed. Check the lowtion of the brake wliper in
suchlike in any of the cylinders, change the entire relat,ion to the brake disc. Axial, de'viation is cheiCk-
cylinder housing complete. Inspect the other parts and ed by measuring with a fee·ler guage on both sides
replace those that are damaged and worn. of the disc the distance between disc and caliper

VOLVO
103 121
Fig. 5·29. Checking the A.S.B.·device Fig. 5·30. Rear wheel brake caliper assembled

5: 15
 101875
Fig. 5·31. Checking the run·out

VOlVO
101876
Fig. 5·32. Removing the brake disc

support nib. The difference in measurement is max. brakes at the outer edge of the disc and is measured,
0.25 mm (0.010").. The caliper should be paralIei for example, according to Fig. 5-3l. Check first that
with the disc. This is checked by me·asuring the the wheel bearings are correctly adjusted and that
distance to the upper and lower support nibs on the disc fits securelyan the hub. The thickness is
the caliper. The location of the brake caJipe,r can measured with, for example, amicrometer. It should
be adjusted with shims, which are available in not vary more thCln 0.03 mm (0.0012") when the disc is
thicknesses of 0.6-1 .8 mm (0.024--0.071 "). Coat the rotated one turn, since this can cause avibrating
attaching bolts with a couple of drops of Lock-tite, brake pedal.
type AV, and then fit them. If a fault is discovered during the above-mentioned
2. Connect the brake I'ine, see Fig,. 5-25. inspection, t~e brake disc should be replaced. When
3. Gean the wheel contact surfaces and disc beJore doing this, the brake caliper should first be removed .
fitting on the wheel. Tighten the wheel nuts so Then unscrew the lock balts and lift off the brake
mu ch that the wheel cannot be, mcved. Lower the disc, see Figs. 5-32 and 5-85. Top on the inside of the
vehicle and tig,hten the wheel nuts finally. Tighten disc with several light blows from a plastic hammer
each othe,r nut a little at a time, until a ll are finally or similar tool. When fitting, check that the contact
tightened or a torque of 10-14 kpm (70.--:.100 Ib.ft.). surface is clean .
Fit the hub cap. If, for any reason, a new brake disc is not available,
4. Bleed the fitted brake calipe r, see Group 52. the old one can be reconditioned by fine turning.
Here accurate aligning of the disc is required and
machining should be carried out on both sides. Af ter
BRAKE DISC the machining, the thickness of the disc must not be
The brake disc should be examined with regard to less than 13.14 mm r(0.517") for the front wheel brake·s
the frictian surface, run ·out thickness. and 8.4 mm '(0.331 ") for the rear whee,1 brake's. The sur·
Small marks on the friction surface or linings are of face irregularity should be max. 3 fL measured on an
minor importance, but radial scratehes reduce the arbitrary diameter and max . 5 fL measured radially.
braking effect and increase wear on the linings. The After the reconditioning, the disc must not have a run-
run- out must n.ot exce·e d 0.1 mm {0.004") for the front out of more than 0.1 mrm(0.004") and its thickness must
wheel brake5 and 0.15 mm (0.,006"), for the rear wheel not very more than 0.03 mm (0.0012").

5: 16
 GROUP 52

HYDRAU LIC FOOTB RAKE SYSTEM

DESC RI PT ION

MASTER CYLINDER
The maste r cylinder is of the ta ndem type. Its con -
struction is shown in Fig. 5-33 a nd its functi on is as
follows :

- - Secondary ci r-
cuit, pressureless
Se.c anda ry circuif,
high pressore

Fig. 5-35. Norma/

Primary circuit
pressureless
Primary ci rcui t,
high pressure

brak ~ app/ication
t

VOL VO
1031 84

When the system is a t rest (Fig. 5-34), the pistons are

kept pressed back by ~h e force of the springs. When
the pistons are in this position, the connections be-
tween the b ra ke flu id conta iner and w heel brake un its
are open . At th e moment braki ng take s place, the
primary piston (to the right) is pressed in by the
Fig . 5·33. Maste r cylinde r p iston rod. Th is closes the connection between the
1. Equalizing hale 17. Stop screw container and the wheel brake unit and the pressure
2. Overflow hale 18. Seal in front of the piston rises. The p ressure influences the
3. Washe r 19. Pisfon seal
4. Piston sea I 20. Connection for seconda ry piston so tha t it a lso is moved to the left.
5. Washer primary circuit The same over-pressure arises in front of both pistons
6. Piston seal 21 . Piston seal
7. Washer 22 .. Secondary pisfon (Fig. 5-35), the brake fluid is forced out into the
8. Circlip 23. Washer respective brake line and all the wheel brakes are
9. Primary piston 24 . Piston seal
10. Washer 25. Connecfion for applied, providing the system is functioning properly.
11 . Piston seal secondary circuit If a leakage has occurred in the secondary circuit
12. Washer 26. Cyl i nder
13. Thrust washer 27 . Spring no hydraul ic counterpressure builds up in front of the
14. Spring 28 . Thrust washer seconda ry piston . Instead, this pisten is moved in-
15. Screw 29. Washer
16. Spring retainer wards when the brakes are applied until it is stopped
by the end of the cylinder (Fig . 5-36).

Secondary cir- _ Primary circuif,

Secondary cir- Primary circuit,
cuit, pressureless pressureless cuit pressureless pressureless
_ Primary circuit, V OLVO
103 185
Fig . 5-34. Rest pa sition high pressure
and 2. Connecfion for brake fluid container
Fig. 5-36. Brake appl ication with leakage in
the se conda ry ci rcuit

5 : 17
 - - Secondary cir·
cu if , pressureless
Secondary circuit,
high pressure

Fig. 5·37.
Prima ry circuit,
pressureless

Brake appli cati an wi th leaka ge in

the primary ci rcuit
VOLVO
103186

Fig . 5-39_ No rma l position

The hydraulic pressure between the pistons can then
rise and apply the brakes in the primary circuit If
leakage occurs in the primary circuit, the primary
circuits exceeds about 10 kp(cm 2 (142 p.s.i,). The valve
piston is moved and the brakes are applied until the
construction is shown in Fig. 5-38 and it operates as
primary piston makes contact w ith the secondary
follows :
piston. Both pistons are then p ressed inwards, the
If there is no fault in the circuits and the brakes are
pressure in front of the secondary plunger rises and
applied, the hydraulic pressure on the pistons is
the brakes in the secondary circuit are applied (Fig.
largely the same on both sides (Fig. 5-39). But should,
5-37).
for example, the pressure in the secondary circuit be
somewhat higher than in the primary circuit, this will
WA,RNING VALVE try to displace the pistons to the right in the figure.
This lifts the thrust washer (11) and the pressure of the
A warning valve is connected between the brake
spring (9) counteracts the displacement.
lines from the master cylinder and the six-branch union
It is only when the pressure in the secondary circuit
for both brake circuits. Its function is to warn the driver
first exceeds that in the primary circuit by about
when the pressure difference between the two brake
10 kpm(cnY (142 p.s.i.) that the pistons are pushed
so far to the right that the quide pin (4) can be pres-
sed downwards. When this hoppens, the switch
washer (2) reaches the housing (3) and current is cut
in (Fig . 5·40). The guide pin is prevented from return-
ing to its normal position until the fault has been
rectified ond the warning switch (3) removed.

11 10 9 8 7
VOLVO
102454

Fig. 5-38. Warning valve

1. Electrical connection 8. Sealing washer
2. Switch washer 9. Sprir,g
3. Switch housi ng 10. Connection, frant
4. Guide pin wheel brakes
5. Connec1ion, rear 11 . Thrust washer
wheel brakes 12. O.ring
6. Connection, master 13. Piston
cy linder 14. Housing
7. End piece Fig . 5-40. Warning position

5: 18
 BRAKE VALVE
A brake valve is connected to each of the rear wheel
brake lines, see Fig. 5-6. When the ingoing brake
pressure exceeds 34 kp/cm2 (484 p.s.i.) a reduction
takes place in the valve. The more powerful the
pedal pressure, the greater will be the reduction and
thereby the larger the difference between the hydraulic
pressure in the front wheel and rear wheel cylinders.
This results in a suitable distribution of braking force
between both pairs of wheels. The construction of the
brake valve is shown IS Fig. 5-41 and its function is
o VOLVO
101 883

the following. Pressure below 34 kp/cm 2 (484 p.s.i.)

When the footbrakes are applied, the pressure from
Fig. 5-42. Brake opplicatian
the master cylinder is transmitted via the connection
(7, Fig. 5-41). The pressure then proceeds through the
. cylinder (6), the counterbore, past the valves (17) and
In cylinder (6) moves the piston to the left so that
(4) to cylinder (3) and then on through connection
the valve rad comes up against its stop and opens
(19) to the rear wheel cylinders, see Fig . 5-42. The
the valve this causing the pressure in cylinder (3) to
hydraulic pressure per unit surface is equal on the
increase. Due to the larger pressure surface in this
different parts of the piston (21), but since its pres-
cylinder, the piston is moved to the right again and
sure surface is larger in cylinder (3) than in cylinder
the valve closes. In this way, the piston assumes a
(6), the force developed will move the piston to the
position of balance and the outgoing pressure from
right of the figure . However, this is counteracted by
the brake valve will be lower than the ingoing
the pressure from the springs (10).
pressure, see Fig. 5-42. The difference in these pres-
When I1he hydraulic pre,ssure approaches 34 kp/cm 2
sures is determined by the different areas and spring
(484 p.s.i.) the spring pressure is overcome and the
tension.
piston (21) is moved to the right. By means of pres-
When the brake pedal is released, the pressure in the
sure from the smaller spring (5), the valve (4) shuts
cylinder (6) falls. The piston (21) is moved to the
off the connection between the two cylinders and
right by spring (10). When the pressure on the right-
forms two separate systems, one for the front wheels
hand side of the valve (4) falls so much that the
and one for the rear wheels.
hydraulic pressure on the left-hand side enables the
With continued increase in pressure in the master
valves to be actuated, the connection between both
cylinder and front wheel cylinders, the hydraulic force
the cylinders is opened again. As the pressure falls,
spring (10) presses the left piston back to its original
position where the valve is held in the open position
by mechanical means, see Fig. 5-41 . The equalizing
valve (17) is fitted with controi channels which ensure
an even flow of pressure through the valve.

Fig. 5-41. Brake valve, consfruction

l. Plug 12. Adjusling screw
2. O· ring 13. LocknuI
3. Cylinder 14. Spring housing
4. Valve 15. Relainer
5. Va lve spring 16. Screw
6. Cylinder 17. Equalizing valve
VOLVO

- -
7. Con nection lo 18. O-ring !O1 884

masler cylinder 19. Conneclion lo rear

8. Pislon gaskel wheel brake cylinders
9. Brackel 20. Housing Reduced pressure Pressure below 34 kp/cm 2
(484 p.s .i.)
10. Spring 21. Pislon
11. Relainer 22. Valve housing Fig. 5-43. Reducing action

5: 19
 REPA IR INSTRUCTIONS

c. C

Fig. 5·44. Removing the master cylinder

, , 3

Fig . 5·46. Container parts

5 VOlVO
103189

1. Filler cap 4. Container

2. Strainer 5. Rubber seal
3. Rubber sea l

MA5lER CYLlNOER 2. Remove the lines from the moster cyllinder and fit
plastic plugs as the lines are disconnected.
With regard to repair work on the hydraulic system,
3. Remove the two attaching nuts for the master
the instructions given under "Cleaning" and "Brake
cylinder and lift the cylinder forwards, see Fig.
Fluid", Group 50, should be observed. When the mas-
5-44. Empty out the brake fluid .
ter cylinder is removed, the brake peda l should not
be depre,s sed because the r.e sulting abnlo rmal position
for the parts of the servo cylinder can cause damage.
DISMANTLING
1. Fix the flange of the master cylinder firmly in a
REMOVING vice, see Fig . 5-45.
1. Place a cover over the mudguard and rags under 2. Place both hands under the container and pull it
the master cylinder in order to avoid possible up from the rubber sea Is. Remove the filler cap
damage to the paintwork should the brake fluid and strainer from the container and also the
spill over. rubber seals from the cylinder, see Fig. 5-46.

Fig. 5·45. Removing the container Fig. 5·47. Removing the stop screw

5 : 20
 VOLVO
\05008
Fig. 5-49. Secondary pisten

1. Spri ng 5. Washer
2. Thrust washer 6. Piston
3. Back-up ring 7. Piston seal
4. Piston seal 8. Pislon seal

ASSEMBLlNG
l. Fit the brass washer (S, Fig,. 5-49) and the piston
seal (4) on the secondary piston (6).. Check to make
Fig. 5-48. Master cylinder dismantled
sure that the seals are turnedr correctly, see Fig.
1. Cy linder hous ing 4. Secondary piston
5. Circl ip
5-49.
2. Slop screw
3. Pri mary piston 6. Sea ling ring 2. Coat brake fluid on the cylinder and dip the
piston and seals in brake fluid before fitting. Fit
the back-up ring (3), the thrust washer (2) and the
spring (l) on the secondory piston and fit the piston
as shownin Fig. S-SO. Be care.ful when inse.rting' the
seals. in the cylinder.
3. Unscrew the stop screw (Fig. 5-47). Remove the
3. Fit the washer (9, Fig. 5-51)" the piston seal (10), the
circlip from the primary piston with the help of
plastic washer (11), the piston seal (12), and the
circlip pliers. Remove the pistons.
washer (13) on the primary piston. Check that the
seals are facing correctly, see Fig. 5-51.
4, Dip the piston and the seals in brake fluid and
INSPECTING fit the piston in the cylinder, see Fig. 5-52. Press
Before inspecting, clean all the parts according to the in the piston and fit the circlip (S, Fig. 5-48).
instructions given under "Cleaning", Group 50_ Exa- 5. Check that the hole for the stop screw is c/ear
mi ne the inside of the cylinder carefully. If there are and fit the screw (2, Fig. 5-48) with a new sea ling
any scores or scratches, the cylinder should be re- washer. The tigMening torque is 0.0-0.8 kpm (3.6-
placed. Rust formation and similar damage can as a 5.7 Ib.ft.).
rule be e limi nated by honing. the cylinder. The pro- 6. Check the movement of the pistons and make
ced ure for this varies with different makes of too Is sure that the through -flow ho les are clear. The
so that no general description can be given. Follow,
therefore, the instructions of the manufacturer. Clean
the cylinder carefully after honing and check that
the holes are clea r.
If wear on the cylinder or secondary piston is sus-
pected, the diameter should be measured with a
micrometer or indicator. The cylinder bore must not
excee.d 23.92 mm (0.942") and the diame,t er of the
piston may not be less than 23.66 mm (0.931"). Each
time reconditioning is carried out, replace the primary
piston (3, Fig. 5-48) and the seconda ry piston (4, Fig.
5-48) comp lete as weil as the stop screw (2) with
washer and circlip (S), also the sea ling ring (6). More-
over, the rubber seals (Fig. 5-46) fo r the container
should be replaced. Fig. S-50. Fitting the secondary pisten

5: 21
 2
I
\
3 5 6 7
i II
8
I/W//
9101112 13 14
I ,

1Å -,~_ _--=-==1
( I

VOLVO
105009

Fig. 5·51. Primary Piston

l. Sleeve 8. Piston
2. Spring 9, Washer
3. Screw 10. Piston seo l
4, Thrust was her 11. Plostic washer
5. Back up ring 12. Piston sea I
6. Piston sea l 13. Washer
7. Washer 14. Circlip VOLVO
103194

Fig. 5·53. Checking the equalizing hole

1. 0.7 mm (22 s.w.g .) soft wire
A=Clearonce between washer and seal

equalizing hole is checked by pressing the pistons washers together with the attaching nuts. The
in about 1.0 mm (0.04") and by inserNngi a soft tightening torque for the nuts is 1.2-1.5 kpm
copper wire, diameter 0.7 mm (22 s.w.g.), down (8.7-10.8 Ib.ft.).
through the hole as shown in Fig . 5-53. If the 2. Connect up the lines, see Fig . 5-54. Depress the
equalizing hole is not clear, the master cylinder pedal and tighten the nuts for the lines when fluid
is generally wrongly assembled . free from air force s its way out.
7. Fit the rubber seals (3 and 5, Fig. 5-46). Fit the 3. Bleed the entire brake system.
brake fluid container, see Fig. 5-45. Fill the con-
tainer with brake fluid and vent the cylinder.
Place plastic plugs in the cylinder. Check to make
sure that the vent-hole in the cap (l) is open
and fit the strainer (2) and cap in position.

FITTlNG
l. Place the sealing ring (6, Fig. 5-49) on the master
cylinder. Fit the cylinder in position and then the

Fi g . 5·54. Maste r cylinder fitted

l. Nut 5. Warn ing volve
2. Brake fluid container 6. Elec . contae!
3. Maste r cylinder 7. Broke pipe, secondary
VOLVO 4. Broke pipe , prima ry circuit
103193
Fig. 5-52. Fitting the primary piston circuit

5: 22
 Fig. 5-57. Brake valves fifted
1. Adjus! ing screw 6. Braeket
2. Lef! brake va lve 7. Attaching screw
Fig. 5-55. Removing Ihe elec. conlacl (secondary circui!) 8. Right brake va ive
3. Screw (assembling) 9. Fram the master cyl inder
4. Brake hose to lef! primary circui1
rear wheel la. From the master cylinder
WARNrING VALVE 5. Brake hose lo right secondary circuit
rear wheel
NORMALlZING THE PISTONS / ... ~

1. DiscOnnect the electric cable and screw out the

warning switch (Fig. 5-55) so that the pistons
return to normal position.
2. Repair and bleed the fau lty hydmu lic circu it.
BRAKE VALVE
3. Screw in the warning switch and tighten it to a
REMOVING
torque of 1.4-2.0 kpm (10-14 Ib.H.). Conned the
Unscrew and plug the brake pipe connection (lO, Fig.
electric cabl,e.
5-57). Slacken the brake hose (4) a max. 1/4 turn at
the valve. Remove the attaching screw and unscrew
REPLACING THE WARNING VALVE
the valve from the brake hose, see Fig. 5-58.
l. Disconnect all connections. Remove the attaching
nut and then the valve.
2. Insta ll the new valve in reverse order to removal.
RECONDITIONING
Fig. 5-56 shows the various connections.
l . Separate the spring housing from the hydraulic
3. Bleed the brake system.
part by removing the four screws (16, Fig. 5-41 ).
Shake out the springls and conta,iner. The adjusting
screw must not be removed.

Fig. 5-56. Warning valve fitted

1. Primary circui t, fro nl whee ls
2. Mas!er cy li nder primary circui!
3. Master cy li nder seco ndary circ ui !
4. Secondary circ ui t, front whee ls VOLVO
101897
5. Secondary circui!, rear wheels
6. Primery circu i1, rear whee ls Fig . 5-58. Removing Ihe brake valve

5 :23
 14 9 11 10 15

-~
INSTALLlNG
Screw the brake valve on to the brake hose, see Fig.
5-58. Place the valve 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. BLeied the brake system.

ADJUSTING
The adjusting screw (12, Fig. 5-41) is not intended for

Ifi\ 9"
adjusting in the normal meaning of the word. Its
function is to balance the variations in the manu-
facturing . The carefully checked adjustment made at
8 21 18 22 2 1
VOLVO
102 460
the initial assembling is generally sufficient for the
Fig. 5·59. The brake valve dismantled
entire life't ime of the va·lve. For this reason, the
1. Plug 14. Spring housing
adjusting screw must not be touched.
2. O·ring 15. Reta i ner
8. Piston seal 18. O-ring If, after reconditioning, it has been establisf;ed with
9. Bracket 20. Hausing the help of testing according to "Fault Tracing", para-
10. Spring 21. Piston
11. Retainer 22. Valve housing graph 9, Group 50" that the outgoing pressure lies
outside the limit values, an adjustr.lent can be made
with the adjusting screw. Turning the screw clock·
wise increases the outgoing pressure. Lock the screw
finally after turning. The tightening torque for the
locknut is 2..5-3.5 kpm (8-25 Ib.ft.). The adjuslme.nl
may only be carried out after reconditioning.
2. Screw out the plug (l) and press out the plunger
complete, see Fig . 5-59.
BRAKE LINES
3. Clean the hydraulic part, see under the heading
"C leaning", Group 50. CLEANING
4. Inspect the parts. If the cylinder surfaces are The brake lines can be cleaned by flushing them with
scratched or damaged by rust, the valve should brake fluid or spi rit and then by blowing them clean
be replaced complete. However, if the cylinder with moisture-free filtered compressed air. The pur-
surfaces are not damaged, replace only thE: piston
complete. When doing so, check that the seal is
facing in the direction shown in the Fig. 5·60. 5 6
5. Fit the piston (21) complete after having coated
it with a brake fluid or a light layer of brake
paste. Screw in the plug (l) together with the seal-
ing ring (2). The tightening torque is 10-12 kgm
(70-85 Ib.ft. ).
6. Place the retainer (11) in the housing (14) and
turn it according to Fig . 5·41 . Place the retainer
(15) in the spring (lO) and insert it in position in
the housing. Now fit the housing on the hydraulic
part with help of screws, washers and nuts.

3 2
Fig. 5·61. 6·branch union
1. Secondary circuit from wa rning valve
2. Secondary circuit, right front wheel
VOLVO 3. Primary circuit, right front wheel
101899
4. Primary circuit wa rning valve
5. Primary circuit, lef! front w heel
Fig. 5·60. Piston sea I 6. Secondary circuit, lef! front wheel

5: 24
pose of this is to remove all brake fluid and dirt As soon as any part of the system has been removed,
particles and should be carried out in connection w ith blieeding must be carrie d out. Air can also enter the
the co mplete recönditioning of the hydraulic syste m system if there is too small a quantity of brake fluid
and a new fitting. in the container. If, for example, only a wheel brake
When complete reconditioning is being carrie d out, unit has been re moved, it is usually sufficient just to
the brake service unit (see Group 50) can suitably be bleed this. If, on the othe,r hand, the master cyl,inder
connected to the master cylinder and then the system or its lines have been removed, the entire brake
emptied ~hrough ~he bleede,r nipp les. The system system mus,t be bled.
should therefore be flushed with spi rit, after which When bleeding or other similar work in being carried
it should be blown clean with compressed air. When out, no brake fluid must be permitted to get on to
such a reconditioning has been carried out, the com- friction surfaces or linings. Do not spill any fluid on
ponents of the hydraulic system should be taken out the paintwork as this may damage it. If the vehicle is
and checked to ensure that any dirt and flushing fluid to be place'd on bilocks during the bleeding', the rear
have been effectively removed. end should be somewhat higher than the front end.
N.B. With regard to requirements concerning the When filling with oil observe the follow ing: The
cleaning agent, see the general instructions, Group 50. brake fluid must meet the re quirements according to
Do not fill up with brake fluid which has been drain- SAE 70 R 3. Brake fluid with the, later des,ignation
ed from the system. SAE 70 R 3 (J lOB) or SAE J1703 can also be' used. Brake
oil which has been bled out of the system must under
REPLACING THE BRAKE LINES no circumstances be put back into the bleeder unit or
the container.
If leakage occurs, or if the brake lines have been
exposed to such externai damage that leakage or
constriction can result, the damaged lines sho uld be BLEEDING WITH THE BLEEDER UNIT
replaced according to the instructions given below. l. Check to make sure there is full return on the
If the replacement concerns the front brake hoses, it brake pedal and thClt nelither mats nor suchlike
should be carried out with the front wheels unioaded. prevent full trave! (about 152 mm=6") from being
1. To prevent unnecessary spilling of brake fluid, utilized during the bleeding . Depress the brake
the existing fille r cap on the master cylinder pedal several times to even out any underpre1ssure
container should be temporarily replaced with in the servo cy linder and in this way disconnect it.
one w ithout a vent-ho le. 2. Remove the el,edric switch from the waming valve.
2. Clean round the connections and remove the 3. Clean round the cap on the bmke flu,id conta'iner.
damaged brake line. If necessary fill the container with brake fluid up
3. Take a completely new brake line, blow it clean to the "Max." mark.
internally with moisture-free filtered compressed
air and fit it. Make sure that the brake line lies in
such a position that it does not chafe while driv-
ing . Particularly important points are where the
pipes pass the steering rod, where they must not
come nearer than 10 mm (3/8"). If a pipe is not
bent correctly, it should be adjusted manually
before being fitted .
Bending a pipe already connected often results
in deformation at the connections. The front brake
hoses must only be fitted according to Fig . 5-19
and always with the linkage arms unioaded. Do
not forget the clips.
4. Bleed the brake system according to the instruc-
tions g,iven below. Fit the filler cap with vent-hole
in the cont'a iner.

BLEEDING THE HYD,RAULJC SYSTEM

A sign that there is ai r in the system is that the
brake pedal can be depressed without any appreci-
Fig. 5·62. Pedal traveI
ab le resistance, or if it feels spongy. A=approx. 152 mm (6")

5: 25
 Fig. 5.63. Connecting the bleede r unit

VOLVO
103265
Fig. 5·65. Bleeding the front wheel brake unit

4. Fit on the container a cap specially used when W hen b lee,ding remove the protective cap and fit
ble.eding, see Fig.. 5-63. Confl.ect the bleeder unit the bl eeder tool SYO 2740. See Figs. 5-65 and 5-66.
according to the instructions of the manufacturer. Le t the o th er end of the hose hang down into a
The working pressure is 2 kp(cm f (28.4 p.s.i.). The co llecting vessel. Open the bleeder nipple and
type of ble:ede.r unit which may be used is show in ha ve som eo ne careful ly depress the brake pedal.
Fig.. 5-5. Close the nipp le when brake fl uid free from air
5. Bleeding should take place in the order shown in bub b les fl ows o ut. Make sure there is no leakage
Fig. 5-64. Nate tha,t the bleeder nipple should be between the nipple and th e tool, as this can give
opened max. half a turn in order to prevent air ri se to mis leading res ul ts.
from sneaking in via the threads of the nipple.

VOLVO VOLVO
101 902
103199
Fig. 5-64. Bleeding diagram Fig. 5·66. Bleeding the left rear wheel brake unit

5 : 26
6. Repeat the bleeding so tha t bo th circuits are bled nipple. The lower end of the hose should be
at least twice. Refit the protective caps on the extended by means of a glass or plastic tube. Also
nipples. requi red is a g la ss bottle filled with so much
7. Remove the hose to the brake fluid container and brake fluid that the opening of th e pipe can be
release air to the unit. Remove the cap on the kept under the surface in order to prevent air
container: Blow clean the vent-hale in the standard from being sucked into the system. To turn the
cap and refit this on the container. nipple use a 5/16" ring spann er. New brake fluid
8. Fit the warning switch and tighten it to a torque must be avai la b le so that the co ntainer can be
of 1.4-2.0 kpm (10-15 Ib.ft.). Connect the el.ectric gradually filled. The leve l must not go below the
cable. Che~k ihat the warning lamp lights only "Min." mark since this wou ld allow air to penet-
when the parking bmke is opp lied. rate into the system via the container.
5. Bleeding, shou ld be carried out in the o l· der sho wn
in Fig. 5-64 and as follows:
MECHA NICAL BLEEDIN G Remove the masking cap and fit the ring spanner
1. Check to make sure there is full return on the and plaS>tic hose on to the bleeder nipp le. A I,I.ow
brake pedol and that neither mats nor suchlike the opening of the pipe to hang down below the
prevent full tra~el (about 152 mm=6") from. being surface of th e fluid in the glass bottle, see Fig.
utilized during the venting. Depress the brake 5-67. Open the b leeder nipp le at the most half a
peda,1 se,v e,wl times to even out any underprelisure turn . Slowly press the brake pedal down to the
in the servo cylinder and in this way disconnect it. bottom. When the pedal reaches the bottom,
2. Remove the electric switch from the warning va lve. pause a little and then quickly release the pedal.
3. Clean round the cap on the brake fluid container. Repeat this p rocedure until brake fluid free from
Blow clean the vent-hale in the cap. If neces- air bubbles flows out. Then press the pedal to the
sary, fill the container with brake fluid up to the bottom and close the bleeder nipple.
"Max." mark. To prevent air forcing its way in 6. Repeat the bleedingl so that both the circuits are
through the brake fluid container, the oil level in b led aj' le ast twice. Re-fit the protedive, caps on
the container must not go below the "Min." mark. the nipples.
4. Required for the bleeding is a plastic hose which 7. Fill the container w ith brake fluid up to the "Max."
can be presse,d on to and sea led round the bleeder ma rk.
8. Fit the warn ing switch and tighten it to a torque
of 1.4-2.0 kpm (10--15 Ib.ft.) . Connect the electric
cab le. Check that the warning lam p lights only
w hen the handbrake is applied.

ADJUSTIING THE BRAKE LIGHT SWITCH

Check the distance from the brass hub on the brake
light swi tch to the brake pedal, see Fig . 5-68, when
the brake pedal is released. The distance should be
4±2 mm (0.16-0.08"). To adjust, slocken the screw fo r
the brocket (12, Fig . 5-69). Remember to tighten the
screw after adjustment.

REPLACING THE BRAKE PEDAL

l . Remove the panel under the dashboard .
2. Remove the b rocket (12, Fig. 5-69) for the brake
light switch (11). Remove the split pin and bolt
(13). Unhook the return spring (10) and the spring
(16). Unscrew the nut for the bolt (7) and pull out
the bolt.
3. Lift out the pedal (18).
4. Fit the new pedal bushes (9) and lubricate the
VOLVO
103266
Fig . 5-67. Bleeding the front wheel brakes bearing sleeves (8) with a light layer of ball-

S: 27
 10
g
8
7

11
12
6 - -r ---mffZ---,i4
5 - ---+-fflf---;;::r 13
14
4
15
16
17
18
VOLVO
103210
3
2 VOLVO
105010

Fig . 5·68. Adjusting the brake light switch

A=2-6 mm (1/8")

bearing grease. Fit the sleeve and the return

spring.
Fig . 5-69. Drake pedal suspension components
5. Place the pedal in position and fit the bolt (7) and
L Bolt 10. Return spring
nut. Hook on the springs. Fit the split pin bolt (13) 2. Bearing sleeve 11. Brake light switch
ond spHt pin. 3. Bush 12. Brocket
4. Nut 13. Split pin bolt
6. Fit the brocket (12) and adjust the brake light 5. Thrust rod 14. Link
switch (11), see under UAdjusting the brake light 6. Split pin bolt 15. Split pin bolt
7. Bolt 16. Spring
switch" . 8. Bearing sleeve 17. Link arm
7. Re-install the panel. 9. Bush 18. Brake pedal

REPLACING THE BUSHES IN THE BRAKE

6. Press in the new bushes (3 and 9) and lubricate
PBDAL AN'D LEVER
them with a light laye r of ball-bearing grease.
l . Remove the panel under the dashboard. Fit the bearing sleeves (2 and 8) and the return
2. Remove the brocket (12, Fig. 5-69) for the brake spring (10).
light switch. Remove the split pins and bolts (6- 7. Place the lever (16) in position and fit the screw
13).. Unhook the return spring! (lO) and the spring (l) and the nut. Fit the split pin bolt (6) and the
(16). Unscrew the nuts for the screws (1-7) and split pin.
remove the screws. 8. Place the pedol' (18) in pos.ition and fit the saew
3. Lift out the pedal (17) and the lever (16). (7) and the nut. Hook on the return spring. Fit the
4. Press out the bearing sleeves (1-8) and the bush- split pin bolt (13) and the split pin.
es (3-9). 9. Fit the brocket (12) and adjust the brake contact
5. elean the parts. If the bearing sleeves are worn, (11), see under UAdjusting the brake light switch".
replace them. 10. Re-install the panel.

5. : 28
 - - - - - -- - - -- - -

GROUP 54

AUXI LIARY BRAKE SYSTEM

DESCRI PTION

VOLV O
103 201

Fig. 5·70. Se rvo cylinde r

l. Vacuum inlet 9. Rear vacuum chamber 17. Retainer 25. Valve piston 33. Valve spring
2. Sea Ii ng ri ng 10. Retaine r 18. Filter 26. Stop washer 34. Return spring
3. Front vacuum chamber 11. Diaphragm 19. Silencer 27. W asher 35. Rubber cover
4. Front thrust rod 12. Guide housing 20. Sealing ring 28. Guide housing 36. Washer
5. Retainer 13. Valve piston sea t 21. eyl i nder 29. Valve guide 37. Rear thrust rod
6. Diaphragm 14. Sealing ring 22 . Return spring 30. End
7. Sealing ring 15. Seal 23. End 31. Val ve plate
8. Guide sleeve 16. Guide 24. Reaction disc 32. Attaching screw

SERVO CYLI NDER

This is a mechanical tandem-type servo device located
between the brake pedal and the master cylinder, see
Fig. 5-6. Due to the servo cylinder, which is assisted
by vacuum from the engine induction manifoid, less
pedal p ressure is requi red when braki ng. The co n-
struction as weil as the designation and location of
the parts are shown in Fig. 5-70. The servo cylinder
funcrions as follows.
When the system is at rest, the parts of the servo
cylinder are in the position shown in Fig . 5-71. The
thrust rod spring holds the thrust rod and th.e valve
piston flexibly connected to it pressed to the right.
Movement is limited by the stop plate. In this posi-
tion, the valve plunger keeps the valve lifted from
Max. partiai vacuum _ Atmospheric pressure
the seat in the guide housing, and this closes the air VO LVO
103202
channel and opens the vacuum channel. Thus an Fi g . 5-71. Rest position

5 : 29
 •

the piston reaching the valve shutting off the air

supply. The pressure behind the diaphragm remains
constant and is thus unable to overcome the hydrau-
lic counterpressure in the master cylinder. The mov-
able parts of the servo cylinder, the refo re, remain in
this position, and constant braking is obtained as long
as the same pressure is maintained on the brake
pedal.
If pressure on the pedal is increased, the pressure
of the valve piston on the reaction disc centre will
be greater, this causing a certain displacement for-
wards of the piston. When this happens, the valve
leaves the seat of the piston, more air can flow
in and greater brake application is obtained until the
new equalizing position is attained.
_ Afmospheric
Max. partiol If the pressure on the pedal is reduced, the reaction
vacuum pressure
VOLVO
103203
disc centre can be thrust out still further, and this
Fig. 5-72. Full brake applicalion
causes the valve piston to lift the valve from the
seat in the guide housing. The spaces on both sides
of the diaphragm are thereby connected with each
other, equal pressure arises, the guide housing is
equivalent vacuum exists on both sides of the dia· moved backwards by the spring pressure and there
phragm which, together with the guide housing, is is a reduction in the brake application. This proce-
held pressed to the right end position of the dia- dure also reduces the contraction of the reaction disc
phragm spring. periphery, so that the valve piston can return to
When the brake pedal is depressed, the rear thrust the position shown in Fig. 5-73 and the new equaliz-
rod and valve piston are moved to the left (for- ing position is reached. If the brake pedal is released
wards). The valve spring causes the valve plate to ful/y, al/ the parts of the servo cylinder are returned
move also until it reaches the seat in the guide to the rest position and the brakes are released.
housing. This closes the connection between the front Should any fault occur with the vacuum supply, brake
and rear side of the diaphragm. When the piston application can still take place due to the fact that
continues moving, its movements are transferred via the servo cylinder functions as an extended thrust rod.
the reaction disc and front thrust rod to the master As no servo effect is then obtained, greater pressure
cylinder. When the seat of the valve piston leaves the on the pedal is of course required.
plate, the connection between the rear side and the
centre of the valve section is opened. Air from atmos-
pheric pressure can then flow in behind the dia-
phragm. When there is partiai vacuum on the front
side of the diaphragm, it is moved, and also the
guide housing, forwards. In this way, the force app-
lied to the front thrust rod is increased. The parts of
the servo cylinder are in the position shown in Fig.
5-72 when the pedal pressure provides maximum
servo effect.
If the pedal pressure is less than that mentioned
above, the same procedure takes place in the be-
ginning. During brake application, the hydraulic
pressure in the master cylinder increases and a lso the
counterpressure on the front thrust rod. The pressure
of the guide housing is transmitted to the thrust rod
through the outer part of the reaction disc. Because
the disc is made of rubber, its periphery contracts
while its centre tends to expand, see Fig . 5-73. This
Max . partiol _ Partio l _ Atmospheric
causes the guide housing to be moved further for- vacuum vacuum pressure YS~l
wards than the valve piston and results in the seat of Fig. 5-73. Parlial brake applicalion

5 : ::;0
 l
CHECK VALVE
The check valve (Fig. 5-74) is placed on the line be-
tween the engine intake manifold and the servo brake
cylinder. Its purpose is to prevent air from flowing
back to the servo brake cylinder. The va lve only
opens when there is alarger degree of va cuum at
connedion l than at connection 2. Fig. 5-74. Check valve
l . Connection for inta ke 2. Co nn ectio n fo r servo
manifold cylind e r

REPAIR INSTRUCTIONS
REPLACING AIR CLEANER AND DAMPER FITTING
FOR SERVO CYlINO'ER 1. Fit the cleaner and the silencer. The slots on the
REMOVING cleaner and damper shou ld be displaced 180 0

l . Remove the panel under the dashboard . from each other.

2. Remove the fusing for the brake light. 2. Fit the protective washer and the rubber cover.
3. Remove the bracket (12, Fig. 5-69) for the brake Check to make sure that the cover is pressed
light switch. down properly at the inner edge of the protec-
4. Remove the split pins and the split pin bolts (6 tive was her.
and 13). 3. Fit the split pin bolts.
5. Lift up the brake pedal. Remove the rubber cover 4. Fit the bracket (12, Fig. 5-69), and adjust the brake
(35, Fig. 5-70). light switch (11 ), see under "Adjusting the brake
6. Remove the protective washer, see Fig . 5-75, from light switch" on page 5 : 27.
the cylinder. 5. Fit the panel under the dashboard and the fusing.
7. Remove the damper (l, Fig . 5-76) and the air
cleaner (2).

YS~3' Fig. 5-76. Replacing Ihe deaner and damper

Fig. 5-75. Remaving the washer 1. Damper 2. Air decner

S: 31
 REPLACING THE S,ERVO CYLINDER
REMOVING
l . Remove the master cylinder, see page 5 : 20.
Disconnect the vacuum hose from the servo cy-
linder.
2. Disconnect the lin k arm (16, Fig . 5-69) from the
brake pedal. Remove the bracket with clutch pe-
dal stop from the cowl.
3. Remove the 4 nuts securing the servo cylinder to
the cowl.
4. Pull the servo cylinder forwards and d isconnect
the fork from the link arm.

FITTl N G
Fig . 5·77. The check valve filled
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 link arm .
Push in the servo cylinder so that the attaching
bolts come into position .
2. Place the resilient washers under the attaching
REP1A,CING THE CHECK VALVE nuts. Secure the cylinder.
Remove the check valve, see Fig. 5-77, from the 3. Fit the bracket for the clutch pedal. Secure the
vacuum hose . Ensure that the new check valve func· link arm to the brake pedal.
tions properly. Fit the valve so that the arrows on 4. Fit the vacuum hose. The connection for the
the valve housing point away from the servo cylinder. vacuum hose should face downwards.
The vacuum hose connection should face downwards . 5. Bleed the entire brake system.

•'f I ."

\ 5: 32
 GROUP 55

PARKI N G BRAKE
DESCRI PT ION
The construction of the parking brake is shown in Fig. they are held pressed by the spring (14), which also
5-78. The parking brake lever is mounted on the floar locks the small serrated wheel of the adjusting screw.
on the outside of the driving seat. The movement of Due to this type of suspension, the brake shoes are
the lever is transmitted via the shaft (4), lever and self-centring and both the shoes are partly self-apply-
pull rad (5) to the pulley (6). From here the movement ing (Duo-Servo). The brake drum is fitted on the drive
is transmitted through the cable (7) to the rear wheel shaft and so designed that it also serves as a brake
brake units. At each rear wheel, the movements of the disc for the footbrake.
cable influence the lever (16), which is carried in a When the pa,rking braka is applied, the lever and rad
movable rad (17) on the brake shoes. The lower press the shoes against the brake drum. When the
ends of the brake shoes are held pressed against the wheels or drive shaft attempt to turn the drum, the
anchor balt (18) by the lower spring . The upper ends shoes accompany the rotation because of the fri ctian
are jointed through the adjusting devices (15) to which between lining and drum. Due to the "floating" sus-

VOLVO
104326
Fig. 5·78. Parking brake
l. Inside support at!achment 12. Brake drum 22. Pawl
2. Rubber cover 13. Brake shoe 23. Ratchel segmenl
3. Lever (seca ndary shae) 24. Rivel
4. Shaff 14. Return spring 25. OuIside support allachment
5. Pull rad 15. Adjusling device 26. Warning valve swilch
6. Pulley 16. Lever 27. Push rad
7. Cable 17. Movable rad 28. Parking brake
8. Rubber cover 18. Anchor boll 29. Spring
9. Front at!achmenl 19. Relurn spring 30. Pus h bullon
10. Cable sleeve 20. Rear altachmenl
11 . Altachmenl 21. Rubber cable guide

5: 33
pens ion of the shoes, the primary shoe is thus pressed
upwards and the secondary shoe downwards unt il the
-
lowe r en d moves towards the anchor bolt, see Fig.
S-79.
Due to the fact that the turnin g ce nt re of the se -
condary shoe lies in the a nc ho r bolt and th a t of the
primary shoe in the adjusting device, the fri ction be-
tween the drum and the linings w ill assist in bra ke
application . Also contributing to this is the retarding
effect on the secondary shoe because of the primary
shoe 's endeavour to accompan y the d irectio n of rota-
tion of the drum.
Fig. 5-79. Duo-servo principle

REPAIR INSTRUCTIONS
ADJUSTlNG THE PARKING B~KE nect the cable to the lever and remove lhe holder
SYO 2742.
The parking, brake should give full effect at the third-
S. Repeat the adjusting procedure with the othei
fourth notch . If it does not do so, adjustment should
rear w heel.
be carrie d out. Here the wheel brake units are first
6. Apply the parking brake lever and check that full
adjusted and, if necessary, the cable .
braking effect is obtained on the 3rd-4th notch .
l. Apply the parking brake, remove ~he hub caps of
If the pairking brake can be applied sIiiII further, the
the rear wh-ee,ls and loosen the whe,e l nuts.
2. Jack up the rear end, prop blocks under the rear
axle, remove the nuts and take off the wheels.
Release the parking brake.
3. Check that the brake pads are not stuck to the
brake disc. To prevent the lever when adjusting
from influencing the shoes and thus give misled-
ing results, the spring tension acting on the lever
shou ld be reduced. This can be done by fitting
holder SYO 2742 (Fig . 8-83) or by disconnecting
the cable from the lever.
4. Set the drum so that its hole coincides with the
serrations on the adjusting screw and apply the
shoes by moving the screwdriver handle upwards,
see Fig. S-80. When the drum can be rotated
easily, discontinue applying the shoes. Then turn
the adjusting screw back 4-S serrations. Check
that shoes do not "drag" by rotating the drum
in its normal direction of rotation. Yery little
dragging may be permitted. If, however, the
dragging is more pronounced, the adjusting screw VOLVO
103213
should be released a further 2-3 serrations. Con- Fig. 5·80. Adjusting the ha ndbra ke, rear wheel

5 : 34
 VOLVO
10 2996
Fig. 5-82. Brake componenls, righl-hand sleered vehicle

l, Locknut 4. Clevis
VO LVO
1032 J4 2, Adjusting nut 5. Sleeve
Fig. 5-81. Adjusting device cable 3. Spring 6. Locknut

l. Bolt 6. Locknut
2. Pull rod 7. Pulley
3. Locknut 8. Bolt
4. Spring 9. Whee l
5. Adjusting nut 10. Cable 5. Place holder SYO 2742 so that the return spri ng
is held in position according to Fig. 5-83. Bend up
the lock and remove the lock pin so that the
cable releases from the lever.
6. Remove the return spring with was hers. Loosen
cable should be tensioned . This is done by loosen-
the nut for the rear attachment of the cable
ing the locknut,s and screwing in the pulley or the
sleeve. Lift the cab le forwards after having loosen-
clevis on ~he pull red. After adjust,ing" tighten the
ed both sides of the attachments.
locknuts. Check that there is approximately the
same braking effect on both rear wheels.
IN STALLING
7. Mount the wheels after having cleaned any dirt
from the contact surfaces, and tighten the wheel l, Adjust the brake shoes of the rear wheels. Check
nuts sufficiently so that the whee l cannot move. that the brake pads do not stick to the brake disc
Lower the vehicle and tighten the nuts. Tighten and adjust the drum so that its hole coincides
every other nut a little at a time until all are with the serrations of the adjusting screw. Place
tightened to a torque of 10-14 kpm (70-100 a screwdriver between the serrations of the adjust-
Ib.ft.). Fit the hub caps.

REPLACINiG THE CA,BLE

REMOVING
l. Apply the parking brake, remove the hub caps of
the rem wheel.s 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.
Rel'e ase the parking brake.
3. Remove the puller (7, Fig. 5-81) or the devis (4,
Fig,. 5-82). Remove the whee,1 from the cable_
4. Remove the rubber cover (8, Fig . 5-78) for the
front attachment of the cable sleeve and the nut Fig . 5-83. Filling the spring 1001

as weil as the attachment for the rubber sus- l. Cable altachment 7. Lock pin
2. Was her 8. Holder SYO 2742
pension ring on the frame member. Remove the 3. Return spring 9, Nul
cable from the other side of the attachment in the 4. Washer 10. Lock washer
5, Lever 11 . Cable sleeve
same way. 6. Rubber cover

5: 35 •
 Fig . 5·84. Inne r shaft suppart
I. Spring washer 6. Rubber cover Fig. 5·85. Remavin g the brake drum
2. Atfachment boll 7. Floor
3. Flat washer 8. Support pin
4. Shaft 9. Bush
. 5. Inner support atfachment 10. lever
4. Remove the rubber covers, the ratchet segment
and the bearing'. Pull the parking brak e lever with
shaft and lever forwards.
ing screw and apply the shoes by moving the 5. Unscrew the button (3D, Fig. 5-78) and remove the
screwdriver handle upwards, see Fig . 5-80. When spring (29) fro m the parking b ra ke I,e ver. Remove
the drum can be turned easily, discontinue apply- the rivet (24) and take out, the push rod (27) and
ing the shoes. Then turn the adjusting screw 4-5 the pawl (22).
serrations back. 6. Fit the new parts in the reverse order, see Fig.
2. Fit on new rubber cable guides for the cable 5-78. Make sure that the rivet is firmly fixed but
suspension . Place the cable in position in the rear does not obstruct the movement of the pawl.
attachment and tighten the nut. Fit the washers Lubricate the bushes with a thin coat of ball bear-
and return spring . Compress the spring with the ing grease. Do not forget to lock the pull rod
help of the holder tool, see Fig. 5-83. Oil the lock and make sure that the rubber covers seal weil.
pin and fit it together with the cable on the lever.
Fit the attachment and rubber cable guide on
~EAR WHEEL BRAK,E UNIT
the frame member.
( PA'~KING BRAKE COMPONENT)
3. Fit the cable in the same way as above on the
DISMANTLING
othe r side of the vehide.
4. Place the cable sleeve in position in the front 1. Appl,y the parkin.g brake, remove the hub caps of
attachments and fit rubber covers. the rear whee,/s and loosen the wheel nuts.
5. Lubricate and fit the wheel and pulley or the devis 2. Jack up the rea r end, prop blocks under the rear
on the pull rod. Adjust so that ~he parking brake axle, remove the nuts and take off the wheels.
glives full effect a,t the 3rd-4th notch. Re,l eas,e the pa<rking brake.
6. Fit the ' wheels, see operation under UAdjusting the 3. Screw loose the brake line (2, Fig . 5-25) from the
parking brake" ;' , rear brake caliper and plug the connection. Brake
fluid must not spill onto the disc or brake pads.
Remove the attaching bolts (1 and 3, Fig. 5-25).
REPlAGING THE PARKING BRAKE LEVER Lift out the caliper, see Fig . 5-26.
OiR RATCHET PA,~TS 4. Remove the attaching bolts for the brake drum
1. Jack up the rea r end and prop blocks under the and lift off the drum, see Fig . 5-85.
rear a xle. 5. Unhook the lower return spring . Lift the shoes
2. Remove the split pin and stretch the cable so that forwards, see Fig . 5-86.
the pull rod (5, Fig. 5-78) can be removed from
the lever. INSPECTING
3. Loosen th e three attachments for the frame of the First check that there is no oil leakage. If there is oil
seat slide rails and lift the whole seat forwards. leakage, replace the sealing ring, see Group 46. Clean

S: 36
 VOLVO
103 267
Fig. 5·86. Fitting the brake shoes Fig. 5·87. Brake parts
l. Anchor bolt 4. Link
2. Locknut 5. Lever
3. Was her 6, Brake shoe retainer

all the pa rts e xcept the brake linings. Check that the 7. Check that the brake pads move freely from the
lever joint does not chafe and replace parts which brake disc and adjust the parking brake, see opera-
are damaged or worn . tion 4-6 under "Adjusting the parking brake".
If the brake linings are oily or worn down to the 8. Bleed the fitted brake caliper, see Group 52.
rivets, replace the shoes completely. The brake drum 9. Fit the wheel, see operation 7 under "Ad justing
should be replaced if its friction surface is concave, the parking prake.
or if its out-round e.xceeds 0.2 mm (0.008"). Rust spats
can, however, be polished off. Wipe the contact sur-
faces on the backing plate.

ASSEMBLlNG
l. If new linings or drums are to be fitted, siaeken
the pulley (7, Fig. 5·81) or the devis (4, Fig. 5-82)
to remove tension in the cab le_
2. Coa,t the 6 g,uide lips on the backingi plate as weil
as the lever joint and adljus,t.ing screw with heat-
resistant glraphite grease intended for this purpose.
3. Check that the lever and anohor baH parts are
correctf.y fitted, see Fig,. 5-87. Fit the bmke shoes,
see Fig. 5·86. The shorter sle,e ve on the adjusting
dev ice should be turned forwards on the right-
hand side and backwards on the left-hand side,
see Figl. 5-89.
4. Hook on the return spring.
5. Fit the brake drum with attaching balts. 103217
6, Place the brake caliper in posit,ion. Fit any shims Fig. 5.88. Parking brake
and the atta,c hing balts (l and 3, Fig,. 5·25) after 1. Front brake shoe 4. Upper relurn spring
sme,aring the balts w ith a coup le of drops of Lock- (primary shoe) 5. Adiusling device
2. Relainer fo r brake shoe 6. Rear brake shoe
tite, type AV. 3. Lower return spring (secondary shoe)

S: 37
·.
 Part 6

FRONT END
AND
STEERING GEAR
 (ONTENTS
Group 60. General
Tools . ...... .... ... .. ... .... ......... ..... . . . ... . . ... .. . . . 6: l

·. Wheel Alignment ........ . .......... . .......... . . . . . . . . . . . .

Wheel angles .. . .. . . .... . ................ .. . . . . . .. . .. . .
Procedure before w heel adjusting ........... . ...... . ... . .
6:
6 :
6:
3
3
4
Measuring wheel angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 : 4
Adjusting wheel angles ... .. . . . .. ..... . . . . . ... ... . . . ... .. 6 : 5
Caste r .. ... ........... ..... ........ . .......... . . . . .. .. 6: 5
Camber .. .. . .. . ...... ... . . .... . .. . ..... . . . ... . . . . .. ... 6: 5
Toe-out .. ... .... ...... ..... . ... ... .. ..... .... . . . . ..... 6: 5
Steering limits . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6: 7

Group 62. Front End

Description .. . .. ..... .... . ...... . . . ... ... . .. . .. . ... . . . . .. . 6:8
Repair Instructions . .. . ..... . . ..... . ..... .. .. .... .... . .. . .. . 6: 10
General .. . .... .. . . . ...... .. . . .. ... . ... . . .. . ... .-. . . . ... . 6 : 10
Front end, complete ..... .. . .. . . ... . . .. .. .. . . . ... . ....... . 6: 10
Stub axle .. . . ........ .. . .. .... . . .. . ..... . ...... . .... . .. . 6 : 10
Upper bal'l joint . .. ...... . . ... .... .... ... . .... .. . .. .... .. . 6: 12
lower ball joint ... . ... . . ... .. . . .. .. .. . . . . ... ... .. .... . .. . 6: 13
Upper wishbone .. . . . . . .. .. .... .. .. . ... . . . . . . .. ... . .. . . . . 6: 14
lower wishbone .. . .. . ..... ..... . .. . . .. .. ... . . . ...... ... . 6 : 14

Group 64. . Steering Gear

Description ... . ........ . . ... ..... .. ... . .. .. . .... .. .. ... . . . 6: 16
Mechanical steering .... .. . ........... . .... .. ... ... . . .. . . 6: 16
Servo steering ................ . .. . . .. .... . . ..... . 6 : 18
Repair Instructions ...... . .. .. .. .. . . . .. . .. . . . ... .. .. . . ... . . . 6: 23
Replacing the steering wheel . . ... . .. .. .... . .. .. ... . ..... . 6: 23
Replacing bearing in !iteering 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 carried out with servo steering in vehicle . .... . . . . . 6: 29
Fill ing with oil and bleeding . . .... . . . . . . ...... .... ... . 6: 29
Checking the oil level ... .. ..... .. ...... . .... ... . .... . 6: 29
Draining the oil ...... . ..... . . .... ..... .... .. . . . .... . 6: 29
Filling with oil and bleeding ... . . . ..... .. . . .. . ..... .. . 6: 29
Inspecting the servo steering ......... . ... .... . ... . . . . 6 : 30
Checking the hydraulic function ... .............. . . . 6: 30
Checking the mechanical function ..... . . .. .... . . .. . 6 : 30
Replacing sealing ring for controi spindle . .. . ...... . . . 6: 31
Replacing the steering box .. . .. .. ...... . .... ...... . . . . . 6: 31
Replacing the servo pump ... . . . ...... . . ... ........... . . 6: 32
Replacing the o il filter . ..... ... . ....... .. ... . ...... ... . 6 : 32

\
 G'ROUP 60

GENERAL
TOOlS

; i
J

1801
~ 2294 2699
O O
2700 2701. 2703
~
2704
~
2904

~
2905

2711 2713
~
2715 2722
@
2723

@)
2724
@
2725
~ 2726
~'
2734
@
2735
O)
2736
tö
284-9
Y§§\,'3'~

Fig. 6-1. Tools for work on the front axle

SYO 1801 Standard hand le 18x200 SYO 2724 Drift, far fifling outer ring, outer front wheel bea r ing ,
SYO 2294 Press tool, for removing the ball joints, tie·rod end for removing outer ring, inner front wheel bearing
SYO 2699 Press tool, for remov ing and fifling ball joints and rubber SYO 2725 Drift, for removing outer ring, outer front wheel bearing
bushes, wishbones SYO 2726 Puller, front wheel hub
SYO 2700 Sleeve, for fifling ball joint, lawer wishbone SYO 2734 Drift, for removing relay arm bush
SYO 2701 Sleeve, for removing and filling boll joint, upper wish· SYO 2735 Drift, for fiWng relay arm bush
bone, ond bus hes in lower wishbone, inel. fifling ball SYO 2736 Counterhold, for removing re lay arm bush
jaint, lower wishbone SYO 2849 Puller, for pitman arm
SYO 2703 Drift, for fi fli ng ball joint, lower wis hbon e SYO 2520 Stand fo r fixture for reeo ndi tion ing }
SYO 2704 Drift, for fifling ball joint, upper wishbone the front a xle Fig. 6·2
SYO 2711 Steering wheel puller SYO 2560 Fixture fo r front axle
SYO 2713 Spanner (%") for upper wishbone shaH bolt, wheel SYO 2904 Drift, for removi ng and fifling bush in lower wishbone
adjustment (diagonal tyres)
SYO 2715 DriH, fo r removing and fifling grease cap in hub SYO 2905 Drift, for removing and fifling bush in lower wishbone
SYO 2722 Puller, inner ring, inner front wheel bearing (radial tyres)
SYO 2723 Drift, for fifling outer ring, inner front wheel bearing
and oil seal in hub

6:1
 2860
-i
2863

~
2865 2866

VOLVO
103126
Fig. 6-4. Tools for work on the servo steering

Fig . 6-2. Stand and fixlure 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 nipple for SYO 2g64

~
1.801
O
2716
~'1
2719 2720
cg
2850 2721

VOLVO
103175

Fig . 6-3 . Tools for work on the mechanical steering gear

SYO 1801 Standard handle 18X200

SYO 2716 Drift, far fil1ing bush , pilrnon arm shafl
SYO 2719 Sleeve, for fil1ing oil seal, pitman arm shaft
SYO 2720 Removal 1001 for pitman arm shaft bush
SYO 2721 Rearner for pitman arm shaft bush
SYO 2850 Pilot for rearner 2721

6:2
 WHEEL ALlGNMENT

WHEEl ANGLES VERTICAL LINE

For the vehicle to have good steering properties and

a minimum of tyre wear, the front w heels must have
certa in pre-determined settings, generally known as
the wheel angles. The wh eel angles refer to the
easter, camber, kin g pin inclination, toe -out and toe-in.

CASTER
Caster generally refers to the longitudinal inclination
(forwards or backwards) of the king pin. As this ve-
hicle does not have a king p in, the easter consists of
the angle between a vertical line and a line through
the centre of the ball joints (Fig. 6-5).
Caster has the effect of causing the wheels to run
straight forwards thereby facilitating the steering.

CAMBER
Camber is the inclinatiön of the wheel itself outwards
or inwards. It is positive if the wheel is inclined out- Fig. 6-6. Camber and king pin incJination
wards (see C, Fig . 6-6) and negative if the wheel in- A = VerlicJe line C = Comber D = King pin inclinotion
clines inwards. Faulty camber causes uneven tyre
wear.

KING PIN INCLlNATION

King pin inclination means the inclination of the king
pin inwards. Since th is ear does not have a king pin,
the inclination is represented by an angle made be-
tween a verticle line and a line th rough the centre
of the ball joints (D, Fig. 6-6).
King pin inclination causes the centre lines of the ball
joints and the wheel to approach each other towards
the road surface. This makes the wheel easier to turn .
The inclination also assists the tendency of the wheel
to run straight forwards since the ear is lifted very
slightly when the wheels are turned.

TOE-OUT
When driving round a bend, the wheels roll at dif-
ferent radii. For the m to have the s'ame pivoting
centre, and consequently minimum tyre wear, the front
VOLVO
104572
wheels must be turned to different extents. This re-
Fig. 6-5. Caster
lationship is determined by the shape of the steering
A = Vert icl e line
B = Coster rad and steering arms, see Fig. 6-7.

6: 3
 A
as to how measuring shou ld be carried out except in
the ca se of the steering geometry. The measu ring
principle is that camber is measured directly with the
wheels pointing straight forwards. Caster and kin pin
inclination cannot be measured directly. Instead, the
angular alteration wh ich occurs when the wh eel is
turned from 2Qo outwards to 2Qo inwards is measured
on the ijlstrument.
Most types of mode rn wheel alignment measuring In-

struments require that the wheels are locked with, for

B
example, the help of a pedal jack.
Fig. 6·7. Toe·out ond toe·in When measuring the wheel an gles, follow the instruc-
tions applicable to the measu ring instrume nts con-
cerned.

TOE·IN
The difference in the distances (A and B, Fig. 6-7) be-
tween the wheels measured at hub height at the front
and rear of the tyres is known as toe-in. The purpose
of toe-in is to reduce tyre wear.
CHECKING THE KING PIN INCLlNATlON
The king pin inclination, which on this vehicle IS
represented by the inclination of the centre line of the
ball joints, should be 7S at a camber of QO . This
cannot be adj usted and is difficult to measure exactly
due to the tension and resilience in the parts, so that
the angle read off on the instruments will not be
PROCBDURJE BEFORJE WHEEL A'DJUS,TING exact king pi n inclination but can serve as a guide.
Wheel angles can be influenced by the factors listed
below. Therefore, before measuring and adjusting any
faults shou ld be remedied.
1. Check tyre p ressu re and wear.
2. Play in front wheel bearings.
3. Play in bal'l joints or wishbone attachments.
4. Broken springs.
CHECKING THE TOE·OUT
5. Abnormal (temporary) equipmen~ or loading .
Other factors whiCh can influen ce the steering during l. Place the veh icle front wheels on turntables and
driving without being revealed when measuring the make sure that the wheels point straight forwards.
wheel angles a re : Before the ear is placed on them, the turntables
1. Wheel out-of-true more than 2.5 mm (Q.l"). must be set to zero and locked.
2. Poor shock absorbers. 2. Turn the wheels to the left until the right wheel
3. Faulty steering box adjustment. has turned 2Qo inwards. The scale on the left turn-
4. Play in intermediate arm journalling or steering table should then read 22.5±1 0 .

rod pa rts. 3. Check the position of the right wheel in the same
manner by turning the wheels to the right until
the left wheel has turned 2Qo inwards, when the
right turntable scale should give the same reading
as previously indicated on the left. Both measure-
ments should thus lie within the above-mentioned
tolerances, otherwise it means that ~he steering
gear or front end is distorfed.
MEASURING THE WHEEL ANGLE'S 4. There are no adjusting possibilities, but if the toe-
The wheel angles are measured with special measur- out is incorrect, the steering arms and steering
in g instruments of which there are many different rods should be checked. Replace any pa rts that
types. No general description can, therefore, be given are damaged.

6:4
ADJUSTING THE WHBEL ANiGL'ES
N.B. The front wheel angles are always adjusted In

the following order :

1. Caster
2. Camber
3. Toe-in
To save tim e and labour, easter and eamber should be
adjusted at the same time, see under "Adjusting the
eamber".

VOLVO
101980
Fig . 6·8. Adjusting the easter and eamber
A=Shims
CASTER
The easter for eaeh wheel should be with in a toleranee
range of 0° to + l 0, that is, min. 0° and max. 1°
positive. The differenee between both sides should,
however, not exeeed l/2°.
To adjust, sl'aeken the special bolts at the upper wish-
bone shaft with tool SYO 2713 (Fig. 6-6). Use one end other for the rear bolt. Then either inerease or reduee
of the tool for the front bolt and the other for the rear the number of shims equally for both bolts. More
bolt. After the bolts have been slackened several turns, positive eamber is obtained by removing shims, and
the requisite number of shims can be either removed negative eamber by increasing the number of shims.
or added, whiehever is the ease. Positive easter is The shim thiekness required for a eertain alteration in
obtained by either adding shims to the rear bolt or angle is shown in the diagram in Fig . 8. Shims are
removing shims at the front bolt. stocked in thieknesses of 0.15-D.5-1.0-3.0 and 6.0 mm
The diagram in Fig. 8 shows the shim thieknesses re- (0.006-0.020-O.039-O.12 and 0.24"). The eamber is
quired for a eertain alteration in angle. Shims are altered by removing or adding an equal number of
stocked in thieknesses of 0.15-D.5-1.0-3.0 and 6.0 shims at both the bolts.
mm (0.006-O.020-O.039-O.12 and 0.24"). The easter is After adjustment has been earried out, tighten the
altered to the same extent by elther bolts to a torque of 5.5-7.0 kpm (40-50 IbJt.).
l. removing a shim at one ofthe bolts, To save time and labour adjust the easter and eamber
2. adding a shim to the other bolt, at the same time by removing or adding shims for the
3. moving over half of the required shim thiekness eamber and altering the number of shims for the easter.
from one bolt to the other. If, for example, the eamber is inereased 0.6° and the
For proper easter, adjustment should be aeeording to easter 1/4°, first rem ove 2.5 mm (0.1") in shims at both
alternative 3. the bolts and move 0.3 mm (0.012") in shims from the
After adjustment has been earried out, tighten the front to the rear bolt.
bolts to a torque of 5.5-7.0 kpm (40-50 IbJt.).

ADJUSTING THE TOE-IN

The toe-in should be 0-4 mm (O-O.16"). Ineorreet to e-
CAMBER in is adjusted by slackening the loeknuts on the tie
The eamber for eaeh wheel should be within a toler- rod, after whieh the rod is turned in the required diree-
anee range of 0° to + 1/2°, that is, it should be min. 0° tion . The distanee between the tyres at the front is
and max. l/2° positive. redueed, that is to say, toe-in is inereased by turning
To adjust, slaeken the special bolts at the upper wish- the tie-rod in the normal direetion of rotation of the
bone shaft several turns with tool SYO 2713 (Fig. 6-6). wheels. Tighten the loeknut after adjustment to a tor-
Use one end of the tool for the front bolt and the que of 7.5-9.0 kpm (55-65 IbJt.).

6:5
 A I
41° ~
3,5
3)0 ~
7
-------
2,5 ~ -
2,0
o.."" / ~7
~

/
V ./
V
~
V V
/
/ V
/
17
j /'
/ 7
/ 7
/ 7
/
1/ I
0,4

0,3 I/
l, /
II
In
°
°
1
'

Figo 6090 Diagram far alteratian af easter and eamber

I =Camber
II=Caster
A=Shims (mm )
B=Alteration of angle

6: 6
 VOLVO Fig.6-11. Adjusting screw, max. whee l lock
103127

Fig.6-10. Ad justing the max. wheel lack

ADJUSTING THE STEERING LIMITS

Wheel turning is limited by stop bolts, at the pitman 2. Repeat this procedure with the right wheel and the
arm (Fig. 6-11) and at the relay arm. stop screw on the relay arm .
Adjusting is done as follows : N.B. Check that the break hoses are c1ear at full
l. Turn the left wheel for a left-hand turn as far as wheel lock.
it goes. Check that the lock angle of the wheels
is 45° . If it is not, then adjust to this value with
the stop bolt (A, Fig. 6-11) at the pitman arm .

6 7
 GROUP 62

FRONT END
DESCRI PTION

VOLVO
103 128
Fig . 6-12 . Fron! axle
l. Upper wishbone 10. Shock absorber
2. Upper wishbone ball join! 11 . Slabilizer anchorage
3. Sleering knuckle 12. Slabilizer
4. Slub a xle 13. Slop boll, max. wheel lock
5. Ouler w heel bearing 14. Lower w ishbone bush
6. Inner wheel bearing 15. Frame allachmenl for slabilizer
7. Lower wishbone boll joinl 16. Fronl a xle member
8. Lower wishbone 17. Slop boll, max. wheel lock
9. Spring

6:R
The vehicle has independent front wheel suspension.
This means that there is no actual, front axle, this
being replaeed by a strong box-seetion front axle
member. This member is bolted to the self-supporting
body and the. front wheel suspension and springs are
fitted at the ends of the member. The eonstruction is
illustrated in Fig. 6-12.
The steering knuekle is pivoted on the upper and
lower wishbones by means of ball joints (2 and 7),
whieh are pressed into wishbones. The wishbone
shafts are earried in rubber bushes, whieh are jour-
na lled in the wishbones. Camber and easter are adjust-
ed by means of shims between the upper wishbone
VOLVO
shaft and its attachment in the front ax le member (see 103 129
Fig . 6-13. Upper wishbo ne
Fig. 6-8).
The front whee ls are earried in taper roller bearings
(5 and 6, Fig. 6-12). The front spring assembly consists
of eoil springs (9) inside whieh teleseopie shoek
absorbers (10) are fitted. In order to inerease its anti-
rolling properties, the ear is equipped with a stabilizer
(12), whieh is anehored partly to the lower wishbones
(11) and partly to the body (15).

VOLVO
104574

Fig. 6-14. Lower wishbone

1. Wes her 5. Wes her
2. Rubber rin g 6. W ishbone sheft
3. Specer ring 7. Wesher
4. Bus h 8. Nul

6:9
 REPAIR INSTRUCTIONS
GENERAL
The ball joints require no lubrication and are, there-
fore, not fitted with lubricating nipples. However, the
rubber seals should be inspected every 10000 km (6000
miles) and if necessary replaced when adding grease.
The wishbones may on ly be straightened to a minor
extent and the n only in a cald condition. If the old
wishbone deviates to any great extent when compared
to a new one, it should be replaced.
No straightening whatsoever is permitted for stub
ax les and steering knuckles.
The instructions given below indicate certain tighten-
ing torques. Otherwise see the standard torque for
the respective bolting in question.

FRONT ENO COMPLETE

REMOVING Fig. 6-16. Removing the grease cap
1. tnstall the lifting plate SYO 2811 on the engine
and also lifting tool SYO 2727 together with the 7. Remove the front axle member attaching bolts,
extension rod SYO 2821, see Fig . 6-15. Raise the lower and remove the front end.
engine until the weight is taken off the front en-
gine mounting. Temporarily block the vent-hole DISMANTLING AND ASSEMBLlNG
in the brake fluid container cover to reduce leak- See under the headings "Removing" and "Fitting" for
age. Remove the hub caps and loosen the nuts for the various components.
the front wheels a couple of turns.
FITTING
2. Jack up the vehicle under the front jack attach-
l. Fit the guide pins in the front holes for the front
ments. Remove the front wheels.
axle member.
3. Disconnect the steering rods from the steering
2. Place a jack under the front end and rOlse the
arms with tool SYO 2294 according to Fig. 6-19.
front end so that it comes into position. Fit rear
4. Remove the stabilizer attaching bolts.
bolts provided with plastic plugs. Remove the guide
5. Loosen the brake hoses from the braeket at the
pins and fit the front bolts (also those with plastic
support member.
plug).
6. Remove the lower nuts for the front engine mount-
ings.
3. Tighten the engine mounting bolts to a torque of
2.1-2.5 kpm (15-l8Ib.ft.).
4. Fit the attaching bolts for the stabilizer. Connect
the blake ho ses, see Fig. 5-19, Part 5. Carefully
check the location of the hoses and adjust if ne-
cessary.
5. Fit the steering rods.
6. Bl'e ed the brakes according to the instructions in
Part 5. Remove the temporary seal from the brake
fluid container cap.
7. Fit the wheel~ and wheel nuts. Lower the vehicle
and tighten the wheel nuts to a torque of 10-14
kpm (70-100 Ib.ft.). Fit the hub cap. Remove the
lifting tool.

STUB AXLE
REMOVING
l . Remove the front brake caliper according to the
VOLVO
103131
Fig.6-15. Tool for lifting engine instructions given in Part 5.

6: 10
 Fig. 6·17. Removing the front wheel hub

2. Remove the grease cap with tool SYO 2715, see

Fig. 6-19. Removing the steering rod
Fig. 6-16. Remove the split pin and castle nut. Pull
off the hub with puller SYO 2726, see Fig. 6-17.
If necessary pull off the inner bearing from the
comprehensive cleaning of the bearings. Then wash
stub axle with toolSVO 2722, see Fig. 6-18.
the bearing components in white spi rit and allow
3. Remove the steering rod from the steering arm
them to dry. Drying by means of compressed air
with tool SYO 2294, see Fig. 6-19.
should be avoided since the air often contains water
4. SIaeken but do not remove the nuts for the ball
and dust particles. Accessible bearing components are
joints, knock on the axle with a hammer until the
dried with cotton or cloth rags (but not waste). The
ball joint pins loosen. Raise the lower wishbone
bearing surfaces must be dry of cleaning fluid in order
a little with the jack. Remove the nuts for the ball
no t to reduce the adhesion of the grease which is
joints and then the stub axle .
applied later. A new bearing taken directly from its
packing container should not be cleaned.
EXAMINING THE BEARING COMPONENTS After the cleaning, inspect the parts. If the bearing
Clean the hub and grease cap thoroughly. Make sure races or rol lers are damaged, rusted or are blued,
that all the old grease, even inside the hub, IS re- replace the bearing. If the outer or inner ring is loose
moved. Compressed air can suitably be used for a in its seating, ky a new ring. The sealing rings should
be replaced if they are worn or damaged.
For lubrication of the wheel bearings, use on ly a
high-class, durable grease for wheel bearings. Pack the
bearings manually with as much grease as possible
between the roller retainers and the inner race. Grease
al,so on the outside of the rollers and container. The
intermediate spaces in the hub between the outer
and inner bearing should be filled with grease, see
Groups 46 and 77. Before being fitted, the wheel hub
felt rings should be oiled generously with, for ex-
ample, light engine oi!.
Cleanliness of the bearings is of major importance for
their lifetime. For this reason, do not let ungreased
bearings remain unprotected. Observe the greatest
cleanliness when fitting them.

FITTING
1. Place the inner bearing in position in the hub and
press in the oil seal with tool SYO 2723 and
Fig. 6·18. Removing the inner bearin g
standard handle tool SYO 1801 . See Fig. 6-20.

6 : 11
 S VD 18 01

SVD 2723

Fig . 6-22. Localio n of ba ll joint in upper wishbone

pin can be fitted . Check that the wheel rota tes

VOLVO easily but w ithout any play.
10 1 98i
Fi g . 6-20. Fitting the o il sea l 5. Fill the grease cap half full of grease and fit il
with tool SYO 2715.
6. Fit the front wheel brake unit and wheel accord-
Lubricate the felt ring with plenty of, for example,
ing to Part 5 "Fitting the front wheel brake unit".
lig \ ;· engine oil.
2. Place the stub ax le in position and tighten the ball
UPPER BALL JQ.INT
joint nuts. If the ball joint twists, hold it firmly in
position with a screw vise, see Fig. 6-24. Fit the REMOVING
steering rod on to the steering arm. l . Remove the hub cap and slacken the wheel nuts
3. Place the hub on the axle, fit the outer bearing , slightly.
washer and castle nut. 2. Jack up the front end of the vehicle under the
4. Adjust the front wheel bearings by tightening the f ront jack attachments. Remove the wheeL
nut wi~h a torque wrench to a torque of 7 kpm 3. Slacken but do not remove the nut for the upper
(50 Ib.ft.) while the wheel is rotated. Then slacken ball joint. Tap with a hammer on the steering
the nut one third of a turn. If the slot in the nu! knuckle round the ball joint pin until it loosens
does not coincide with the split pin hole in the from the ax le. Remove the nut and suspend the
stub axle, slacke n the nut fu rther until the spl,it upper end of the knuckle with a wire to avoid
straining the brake hoses, see Fig. 6-21 .
4. Slacke n the nuts for the wishbone shaft a 1/2 turn.
Lift up the wishbone slightly and press out the
ball joint with press tool SYO 2699 and sleeve
SYO 2701, see Fig. 6-21 .

FITTING
l . Before fitting the ball joint, check that the rubber
seal is filled with grease. Bend the pin end over
the slot (A, Fig. 6-22) and check that the grease
forces its way out. If necessary, top up with multi-
purpose grease .
2. Press the ball joint into the wishbone with press
tool SYO 2699, sleeve 2701 and drift 2704, see Fig .
6-23. Make sure that the ball joint recess coin-
cides w ith the longitudinal shaft of the wishbone
either externally o r internally (Fig. 6-22) as the pin
has maximum movement along this line. Should
the ball joint be incorrectly fitted when being press-
ed in, turn the tool SYO 2699 half a turn and then
Fig . 6·21. Removing the upper ball joint press the ball join t into the correct position. The

6 : 12
 Fig. 6-23. Filling the upper ball jaint Fig. 6-25. Removing the lower ball joint

ball joint must not be loose in the wishbone. Turn Disconnect the steering rod from the steering arm
down the wishbone and tighten the nuts for the with tool SYO 2294, see Fig . 6-19, and remove the
wishbone shaft. Tighten the ball joint against the brake lines from the stabilizer bolt.
steering knuckle. If the pin rotates, ho ld it firmly 3. Slocken the nuts for the upper and lower ball
w ith a screw vise. joints, but do not remove them. Top with a ham-
4. Fit the wheel and wheel nuts. Lower the vehicle mer until the ball joints loosen from the ax le.
and tighten the wheel nuts to a torque of 10-14 Raise the lower wishbone with the jack. Remove
kpm (70-100 Ib.ft.). Fit the hub cap. the nuts.
4. Remove the steering knuckle wi th hub and the

LOWER BALL JOINT front wheel brake unit, and place them on a
stand or similar.
REMOVING
5. Press the ball joint out of the lower wishbone with
l . Remove the hub cap and slocken the wheel nuts press tool SYO 2699 and sleeve SYO 2700, see
slightly.
Fig. 6-25.
2. Jack up the vehicle under the front jack atla::h-
ments. Take off the wheel.

VOLVO
101973
Fig. 6-24. Upper ball jaint securely held by vise Fig. 6-26. Fitting the lower ball joint

6 : 13
FITTlNG
l . Check that the rubber seal is filled with grease by
breaking the pin to the side so that grease is for-
ced out. If this does not happen, then fill the seal
with grease. Before fitting, remove any grease
that has squeezed out on to the ball pin taper.
2. Press the ball joints in the wishbone with tools
SYO 2699+2701 +2703, see Fig. 6-25. If the ball
joint is fitted at a slant turn the tool 180 and 0

press the ball joint in correctly. The joint must not

be loose in the wishbone.
3. Fit the steering knuckle and tighten the nuts of
the upper and lower ball joints. If the pins rotate,
fix them securely with a screw vise.
VOLVO
4. Fit the steering rod and lower the jack in order 104410

to take the load off the wishbones. Point the Fig. 6·28. Bushes far radial tyres

wheels straight forwards and fasten the brake

houses to the stabilizer bolt. 3. Slacken but do not remove the nut for the upper
5. Fit the wheel and wheel nuts. Lower the vehicle ball joint. Knock with a hammer on the steering
and tighten the wheel nuts to a torque of 10-14 knuckle round the ball joint pin until it loosens
kgm (70-100 Ib.ft.). Fit the hub cap. from the axle. Remove the nut and suspend the
upper end of the knuckle with a wire to avoid
straining the brake hoses, see Fig. 6-21.
UPPER WISHBONE 4. Remove the bolts for the wishbone shaft with tool
The bushes in the upper wishbone are not replace- SYO 2713, see Fig . 6-8.
able. If the link arm or bushes become damaged, re- N.B. Take care of the shims. Lift off the wishbone.
place the link arm complete together with the bushes
and ball joint.
FITTING
N.B. The wishbone shaft is fixed with a special bolt
REMOVING containing a nylon plug.
1. Remove the hub cap and slacken the wheel nuts l. Place the wishbone in position and fit the bolts
slightly. by hand. Fit the shims in the position they occu-
2. Jack up the front end of the vehicle under the pied previously. Tighten the bolts with tool SYO
front jack attachments. Remove the wheel. 2713. Tighten the nuts for the wishbone shaft to a
torque of 5.5--6.2 kpm (40-45Ib.ft.).
2. Fit the upper bal.1 joint in the steering 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
kpm (70-100 Ib.ft.). Fit the hub cap.

LOWER WISHBONE
REMOVING
l. Remove the hub cap and loosen the wheel nuts a
couple of turns.
2. Jack up the vehicle at the front jack attachments.
Remove the wheel.
3. Remove the shock absorber, see Part 7, "Remov-
ing the sh ock absorber".
4. Disconnect the steering rod from the steering arm
with tool SYO 2294, see Fig. 6-19. Loosen the
Fig. 6·27. Removing the rubber bush, lower wishbone clamp for the brake hoses. Remove the bolt for
A = SYO 2904 for bushes intended for diagonal tyres and
SYO 2905 for radial tyres the stabilizer.

6: 14
 5. Place the jack under the lower wishbone. Slacken 2. Press in the bushes with the wishbone and drift (A,
the nuts for the ball joints, and knock with the Fig. 6-27) facing in the opposite direction.
hammer until. the ball joints loosen from the Note! 80th the bushes should be faced with the flange
steering knuckle. Remove the nuts and lower the towards the rear in the vehicle, see Fig. 6-14. If it con-
jack. Take off the knuckle with the front wheel cerns a bush for radial tyres, its recess must also be
brake unit and place it on a stand or similar. turned downwards at right angles to the longitudinal
6. Lower the jack and remove the spring. direction of the wishbone, see Fig. 6-28.
7. Take off the nut and remove the wishbone shaft.
Turn the relay arm with the tie rod so that the
wishbone sh aft is free and thus can be removed. FITTING
Take off the wishbone. l. Supplement the wishbone with a spacer ring (3,
Fig. 6-14), rubber ring (2) and washers (l, 5 and 7).
Place the wishbone in position and fit the wish-
REPLACING THE BUSHES bone shaft (6). Hold the wishbone roughly hori-
Note that there are special bushes intended for radial zontal and tighten the nut (8) to a torque of 14-18
tyres. When about to replace the bushes, bear in mind kpm (100-130 IbJt.).
if the vehicle is fitted with radial or diagonal tyres. 2. Fit the spring. Raise the jack and fit the steering
1. Tension the press tool SYO 2699 in the vice. knuckle. Tighten the nuts for the ball joints. If the
Remove the washer (1, Fig. 6-14), the rubber ring (2) pins rotate, hold them securely with a vice.
and the spacing ring (3). Press the bushes out with 3. Fit the sh ock absorber according to the instruc-
counterhold SVO 2701. Use drift SYO 2904 for tions given in Part 7.
b ushes where diagonal tyres are fitted and SYO 4. Fit the wheel and wheel nuts. Lower the vehicle
2905 for radial tyres. The tools are placed as shown and tighten the wheel nuts to a torque of 10-14
in Fig. 6-27. The bushes are, of course, pressed out kpm (70-100 Ib.ft.). Fit the hub cap.
in the direction towards their f1anges.

6 : 15
 GROUP 64

STEERING GEAR
DESCRI PTION

MECHANICAL STEERING GEAR

The design of the steering gear is shown In Fig. 6-29. box by means of aflange (4) with rubber disc. Should
Steering wheel movement is transmitted to the wheels a frontal collision involving the indentation of the
via the steering column (S), steering box (3), pitman front end occur, it is possible for the lower section of
arm (10), tie rod (11), steering rods (8 and 13) and the steering column to break away and thus prevent
steering knuckles (7 and 10). the steering wheel from being forced backwards-up-
The relay arm (Fig . 6-42) is supported on a pin in the wards. A splined joint with staved sleeve on the
bracket by means of a bush . The bush consists of upper section of the steering column permits axial
three parts, a rubber bush, an outer sleeve of sheet- compression during powerful impact and so assists in
metai and inside a spacer sleeve. The outer sleeve the above steering column breakage.
has a press fit in the hole of the relay arm. When the The upper section of the steering column is carried in
relay arm is turned, movement tak~s place between ball bearings in the jacket tube. The ends of the tie
the outer sleeve and the rubber bush, the intervening rods and steering rods are plastic-lined and therefore
space of which has been lubricated for life. The bear- require no lubrication.
ing thus requires no lubrication. The car has a turning circle of about 10 m (3S ft.)
The upper and lower sections of the steering column and the number of steering wheel turns from lock to
(S, Fig. 6-29) are connected by means of a universal lock is 4.8.
joint. The lower section is mounted to the steering

Fig. 6-29. Steering gear components

1. Steering knuckle, right
2. Relayarm
3. Steeri ng box
4. lower s!eering column flange
5. lower s!eering column sec!ion with universal joinl
6. Ball join!
7. S!eering knuckle, left
8. S!eering rod, left
9. Ball join!
10. Pi!man arm
11. Tie rod
12. Ball join!
13. S!eering rod, right
14. Ball join!

VOLVO
103 135

6: 16
 Fig. 6-30. Steeri ng box, me chanical
1. Lower ball bearing, slee ring cam
2. Bearing race
3. Guide pin
4. Shims and ga skels
5. Lever shaft
6. Spring guide
7. Springs
8. Stop plale
9. Bush
la. Nut guide
11. Gasket
12. Sleering box cover
13. Shims and gaskels
14. Steering cam cover
15. Relainer
16. Oil seal
17. Bearing race
18. Uppe r slee ring cam bearing
19. Slee ring cam
20. Balls
21. Ball nut
22. Recirculaling ball lube
23. Bush
24. Oil seal

Steeri ng wheel lock

The engine of the vehicle has been made tamper- The steering wheel lock is mounted to the column by
proof by the installation of a steering wheel lock, means of two shear-off bolts, and to the dashboard
which is integrally built with the ignition switch . The with two screw.
ignition switch has four positions, 0-1-11-1 11. Removing
the ignition key, which can on ly take place when it is
in position "O", releases a catch and lock pin (A) is
pressed forwards by a spring. When the steering
wheel is turned, so that a slot coincides with the lock
pin, the lock pin enters the sl.at and locks the steering
column so that the front wheels can not be turned.
When the ignition key is inserted and switched to Ä ------
position "I", the lock pin is pulled back and this
releases the steering column which is secured in a
withdrawn position. At position "I" the vehicle can be
moved with the ignition switch ed 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 on ly be V OLVO
103 294
replaced a s a single unit. Fig. 6-3l. Steering wheel lock

6: 17
SERVO STEERIN'G On the one side the piston IS I[l the form of a rack
gear which mes hes with the tooth segment of the lever
As alternative, this vehicle can be fitted with the ZF
shaft (20).
recircul,ating cam and ball nut type servo steering.
The axial movement of the piston which determines
The mai n components of the servo system are the
the direction the wheel turn, is obtained via steering
steering box, servo pump and oil container with filter.
cam (S) and ball nut. The recirculating balls (4) are
These are connected to the various oil lines, see Fig.
located in ann ular grooves and form the thread for
6-32. From the pitman arm the servo steering system is
the nut. Movement of the steering cam comes from
similar to the mechanical steering arrangement, see
the steering column at the controi spindle (16) and
Fig. 6-29.
The number of st~ering wheel turns from lock to lock the torsion rod (17) secured in the spindie. The steer-
ing cam is jo urna lied in the upper section of the
is 3.7.
steering box partly by means of an axial thrust needle
bearing and partly by means of a taper ban bearing.
Steering gear The inner race of the taper ball bearing also is an
CONSTRUCTION outer race for the double needle bearings of the
The steering gear is of the cam and roller type. In controi spindie.
addition to the mechanical section, the servo cylin- Located in the upper part of the steering cam are
der and controi valves are built into the steering box. the controi valves (9 and 10) : they are drawn out in
The lower part of the steering box (l Fig. 6-33) is in the figures. These valves are influenced by two pins
the shape of a cylinder in which the piston (2) is fitted. in the lower end of the controi spindle (16).

Fig. 6-32. Servo steering

1. Servo pump 4. Oil container with filter
2. Delivery oil line 5. Return oil line
3. Pump suction line 6. Steeri ng box

6: 18
 7

13

rr"nitmL--ll- - 15

VOLVO
103138

Fig. 6-33. Function, neutral position

1. Steering box 7. Return groove 14. Safety valve
2. Piston 8. Intake port 15. Flow controi valve
3. Recirculating tube, 9. Controi valve 16. Controi spindle
ball nut le. Contral valve 17. Torsion rod
4. Balls 11. Intakepor! 18. Annular groove
5. Steering cam 12. Servo pump 19. Annular groove
6. Return groove 13. Oil container 20. lever shaft

The lever shaft (20) is journal led in the steering box the valves are connected to the part of the housmg
and side cove r by means of needle bearings, see Fig . where the servo piston operates, a cross-section has
6-35. Sealing between the valve housing and the been made through the steering valves in addition to
upper section of the housing as weil as between the the longitudinal section. Moreover, extra channels
intermediate piece and steering cam is catered for by have been drawn to link up both sections.
O-rings and plastic rings. As soon as the front wheels have been turned to the
The steering gear reduction ratio is 15.7 :1. desired position, and the forces acting on the steering
The construction of the steering gear differs with re- wheel become less, the controi valves return to the
gard to a left-hand steered and a right-hand steered neutral position under the influence of the torsion rod.
vehicle in the matter of the location of the lever shaft When the steering wheel is turned to the right (see
and the steering cam thread. Fig. 6-32 shows the steer- Fig. 6-35), the piston (2) is screwed to the right in the
ing gear for left-hand steering while Figs. 6-33 and figure. The controi valve (10) is moved to the right
6-35 shows that for right-hand steering. The following and permits oil under pressure to pass to the annular
description of the function appl ies to both. groove (18) of the valve housing and from there to
the left side of the cylinder. Oil under pressure also
flows to the return groove (7) which, however, is
FUNCTION c10sed so that the oil pressure on the left side of the
The location of the steering valves as weil as that of operating piston (2) rises and facilitates turning of the
the oil floware shown schematically in Figs. 6-33, lever shaft. O il at the right side of the cyl,inde r is
6-34 and 6-35. In order to illustrate more clearly how pressed by the piston via the annular groove (19)

6 : 19
 Fig . 6-34. Principle of function, left-hand turn

through the return groove (6) of the controi valve (10) right and opens the intake port (8) wider, while at
back to the oil container (13). the same time the other controi valve (10) is dis-
Oil is conveyed under pressure from the pump into placed to the left and closes the intake port (11). The
an annular chamber round the valve housing (the delivery line of the controi valve (9) is lin ked with the
large circle in the cross-section). In the neutral posi- annular graove (19) in the valve housing. This also
tion (Fig. 6-33) the valves (9 and 10) are so adjusted applies to the return groove (6) of the controi valve
that oil can pass the intake ports (8 and 11) and flow (10). The delivery line of the controi valve (10) is con-
on to the ann ular grooves (18 and 19) in the valve nected to the ann ular groove (18) and to the return
housing . From here the oil is led partly to both sides groove (7) for the controi valve (9).
of the piston (2) through the channels (18 and 19), and Under such conditions, oil under pressure flows in
partly - as long as the valves are in the neutral through the intake port (8) to the annular groove (19)
position - to both the return grooves (6 and 7) at and then on to the cylinder on the right-hand side of
the controi valves. From the return grooves oil flows the piston (2). Oil also flows to the return groove (6).
through the return channel back to the container. Since the out/et port is blocked, pressure will rise and
When the steering wheel is turned to the left (see Fig. assist in pressing the piston (2) to the leH.
6-34) movement is transmitted via the controi spin die Oil in the left-hand section of the cylinder is forced
(16) and the torsion rod (17) to the steering cam (15), away vill the annular groove (18) in the valve housing
so that the piston (2) is screwed to the left in the to the intake port (11) which is closed. At the same
figure (downwards in the vehicle). Since the torsion time, oil flows to the return groove (7) and then
rod is resilient, the steering spindle will be turned in through the return line to the oil container.
relation to the steering cam and thus influence the As soon as the front wheels are turned to the desired
valves placed in the cam . The greater the turning angle and the forces operating on the steering wheel
movement, the greater will be the valve displacement. become less, the controi valve returns to neutral posi-
One of the controi valves (9) is then displaced to the tion as a result of the influence of the torsion rad.

6: 20
 A-B

Fig . 6-35. Function, right-hand turn

Turning the steering wheel to the right (see Fig. 6-35) Servo pump
will screw the piston (2) to the right on the figure . The servo pump (Fig. 6-36) is of the vane type. It is
The controi valve (10) is displaced to the right and mounted 011 a bracket on the left-hand side of the
permits oil under pressure to pass to the annular engine and is pulley-driven by the engine at engine
groove (18) of the valve housing and from there on speed. -
to the left-hand side of the cylinder. Oil under pres- The pump rotor is provided with 10 loose vanes and
sure also flows to the return groove (7) which, how- rotates in a circular-shaped intermediate piece. The
eve r, is closed so that oil pressure on the left-hand vanes are pressed against the wall of the interme-
side of the operating piston (2) rises and facilitates diate piece partly by centrifugal force and partly by
the turning of the lever shaft. Oil at the right-hand oil pressure.
section of the cylinder is pressed by the piston via The space in the intermediate piece is oval, see Fig.
the annular groove (19) through the return groove (6) 6-35. This permits the area between the rotor, the wall
of the controi valve (10) back to the oil container (13). of the intermediate piece and two of the vanes to

6 : 21
 Fig . 6-38. Controi valve, maximum pressure

(2) out into the delivery line (l) and from there to the
steering box. The space to the right of the controi
valve is linked-up with the delivery line (l) by means
Fig.6-36. Servo pump of the link channel (8) and has, therefore, the same
pressure.
alter when the rotor rotates. When a couple of vanes The check valve's (2) funetion is to ensure that the p res-
are moved from the suetion side to the pressure side, sure on the left-hand side of the controi valve piston
the a-rea between them and the sucked-in oil increases is higher than that in the line and also to the right
to start with. When the connection with the suetion of the piston. When the spring pressure is overcome,
side has been passedt o link-up with the pressure side the piston is, therefore, displaced to the right. And
is then attained instead. Since the space betweer] the when the speed is sufficiently high in relation to the
. vanes -contraets at the same time, the pressure will counterpressure, the piston has been displaced so
rise and oil will. be forced out into the delivery .line. much that the surplus oi! can flow back to the inlet
Due to the faet that there are two inlet and two side of the pump, see Fig. 6-37. Since the pump should
outlet channels, the pump has double capacity. deliver a quantity smaller than the maximum capacity,
this valve adjustment can be called normal.
CONTROl VAlVE Should the pump flow through the outlet be stopped,
The pump housing contains a controi valve which for example, because the front wheel turning is block-
regulates partly the oil flow and partly the maximum ed, the pressure in the delivery line (l), will rise and
pressure . the pressure difference between both ends of the
When the pump starts runctioning, the valve (5, Fig. controi valve will be equalized. This will cause the
6-37) maintains the valve pressed to ~he Teft of the spring to be moved to the left, the connection with
spring (7). The oil supplried by the pump passes the return channel to be c10sed and the pressure to
through the delivery channel (3) via the check valve rise even more. At about 75 kp/cm 2 (1066 p.s.i.) the
spring pressure on the safety valve (6) is overcome,
that is, the inner part of the controi valve, and oil
can then pass out to the return channel (4). See Fig. 6-38.
The pressure on the right-hand side of the piston will
then drop and the entire controi valve will be moved
3 to the right 50 that the connection with the return
channel opens. When the pressure drops to its normal
value, the safety valve c10ses and the controi valve
-+ returns to its normal position .

Oil conta iner

VOLVO
1031 42
The oil container is placed in the engine compartment
Fig. 6-37. Controi valve, normal position where it is easily accessible. It is provided with a
1. Delivery line 5. Cantral valve filter, from the centre of which oil is sucked to the
2. Check valve 6. Safety va Ive
3. Delivery channel 7. Spring
pump. By means of the by-pass valves, oil can flow
4. Return channel 8. link channel past the filter should it become blocked. The oil level
can be seen against the level line after removi ng the
cap.

6 : 22
 REPAIR INSTRUCTIONS

REPIJACING THE STEERING WHlEEL

REMOVING
l . Remove the screws (l, Fig. 6-39) for the upper part
of the directional indicator switch housing and
the three attaching screws for the lower part. Lift
off the housing .
2. Remove the attaching screws (2 and 3) for the
IlOrn ring. Turn and lift up the ring and pull out
the cable contact.
3. Remove the steering wheel nut.
4. Point the front wheels straight forwards. Fit on the
steering wheel puller SVD 2711, see Fig . 6-40, and
pull off the steering wheel.

YSIX?
Fig. 6·40. Removing the steering wheel
FITTING
l . Make sure that the front whee ls are pointing
straight forwards.
2. Fit the slip contact and the steering wheel. Tighten
the steering wheel nut to a torque of 3-4 kpm
(20- 30 Ib.ft.).
3. Connect the cable contact and fit the horn ring
so that the ho les come opposite the attaching
screws. Fit the screws (2 and 3, Fig . 6-39). Check
the function of the horn ring.
4. Fit both parts of the directional indicator switch
housing and their attaching screws.

REPLACING STEERING COlUMN

JACKET BEARING
Take off the steering w heel to replace the upper bear-
ing. If the lower bearing is damaged, replace the steer-
ing shaft complete.

Fig. 6-39 Attaching screws

1. For directional indicator 2. and 3. For horn ring
switch housing

VOLVO
105040

Fig. 6-41. Steering column components

1. Un iversal joint 4. Sleeve 7. Upper bearing

2. Lower bearing 5. Steering column sect ion 8. Seat
3. Steering column jacket 6. Lock lug 9. Spring

6: 23
 SVO 736 SVO/ 2699
/
/

Fig. 6-42. Relay arm bearing

l. Reloy orm 5. Sleeve
2. Brocket 6. Sleeve
VOLVO
3. Rubber bush 7. Wosher 102074
4. Beoring pin Fig. 6-44. Fitting the rubber bush, relay arm

REPLACING THE RELAY ARM BUSH 7. Fit the steering rad (in the inner hale on the rela y
l. Jack up the ve hicle at the front end. arm ) and the tie rad . Tighten the Nyloc nuts to a
2. Disconnect the ba'II joints for the steering rad ond torque of 3.5-4.1 kpm (25-30 Ib.fI. ).
tie rad from the relay arm with puller SYO 2294,
see Fig. 6-19. MECHANICAL STEERING GEAR
3. Remove the nut and washer (7, Fig. 6-42) and take
Steering box
down the relay arm (l ).
4. Secure press tool SYO 2699 in a vice and press REMOVING
the bush out with a counterhold SYO 2736 and l. Ja ck up the front end.
drift SYO 2734 (see Fig . 6-43 ). 2. Remove the locknut for the pitman arm . Pull the
5. Turn the relay arm and press in the new bush w ith pitman arm off with tool SYO 2849. When fitting
tools SYO 2699 + SYO 2736 and drift SYO 2735 the puller, turn the whee ls fully to the right, see
(see Fig. 6-44). Fig . 6-45.
6. Place the relay arm in position , fit the washer (7) 3. Slocken the c/amping balt (l ), Fig. 6-46. Remove
and the nut. Tighten the nut to a torque of 7.0- the attaching balts (4). Pull the steering box for-
8.5 kpm (50-60 Ib .fI.). wards (2).

SVO/ 2734 SVO/ 2699

VOLVO
10 2073
Fig . 6-43. Removing the rubber bush, relay a rm Fig. 6-45. Remaving the pitman arm

6: 24
 Fig. 6-48. Removing the pitman arm shaft
Fig. 6-46. Steering box, mechanical steering
5. Pi!man arm shaft 10. Nu! guide 11. Ball nu!
l. Clamping ball 3. Filler plug
2. Steeri ng box 4. Affach ing bolt

DISMANTLING
l. Remove the stop plate (8, Fig. 6-47), spacer (4), 5. Pull out the steering cam with bearing and screw
spring guide (6) and springs. off the ball nut at the same time, see Fig . 6-50.
2. Carefully remove the steering box cover (12, Fig. 6. Collect the 10 balls for the lower ball bearing.
6-30) from the guide pins. 7. Remove the upper bearing from the steering cam.
3. Turn the ball nut (21) to the end position. Remove Collect the 13 balls.
the p itman arm shaft (Fig. 6-48) and the nut guide 8. Remove the balls from the ball nut, a total of 27.
(10). The transfer tube does not need to be removed.
4. Remove the steering cam cover with retainer a nd N.B. Do not mix up the balls from both the bearings
shims, see Fig. 6-49. (7.14 mm) and the ball nut (7.93 mm).

8
6
4

VOLVO
15 16 14 13 103151

VOLVO Fig. 6-49. Removing the steering cam cover

103149
Fig. 6·47.. Removing the stop plate
13. Gaske!s and shims 15. Re!ainer
4. Shims 6. Guide spri ng 8. Stop pla!e 14. Cover 16. Oil sea l

6: 25
 ,;..:::....--svo 1801

VOLVO
103152
Fig. 6-50. Removing the steering cam
VOLVO
\02083
Fig. 6-52. Fitting the bush

INSPECTING Measure the diameters for the bush in the housing

Clean all the parts in white spi rit. and c~ver as weil as the pitman arm shaft. For new
Check thoroughly all the bearing races and balls. Re- parts the clearance is 0.025-0.063 mm (0.0010-0.0024").
place any parts that are damaged. In connection with If the clearance exceeds 0.18 mm (0.007"), replace the
this, replace all the balls and the race if the steering bush according to the following :
cam bearings are involved. If the ball nut or the Use tool SYO 2720, see Fig. 6-51, for pressing the bush
steering cam is damaged, replace these parts com- out of the housing . To press in the new bush use tool
plete. SYO 2716 and standard hand le SYO 1801, see Fig . 6-52.
The race for the lower steering cam bearing is pulled After pressing in the bush, ream it with the help of
out with an angle screwdriver. reamer SYO 2721 and pilot SYO 2850 fitted in the
cover, see Fig . 6-53. After fhe bush has been rea med
and the housing carefully cleaned, fit the oil seal tool
SYO 2719 (see Fig. 6-54) and with the sea lring lip fac-
ing inwards.
The bush in the cover is replaced together with the
o cover and is ready-machined together with it.

ASSEMBLING
To make the assembling possible, the loose balls must
be smeared with a light layer of grease. Use a durable
type of grease for this purpose, that is, the same type
~r--+-- S VO 2720 as used for the wheel bearings.

l . Press the lower ball bearing 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 ball nut (21)
with the help of grease (Fig. 6-55). Screw the
steering cam (19) into the bqll nut. Check to make
sure that it has a good fit.
3. Fit the ball nut together with the steering cam
into the housing (Fig. 6-56). Carefully fit the steer-
ing cam in position in the lower bearing .
4. Pack 13 ba lls (7.14 mm) into the upper bearing and
Fig. 6-51 Removing the bush carefully fit the bearing over the steering cam.

6 :26
- - - - - ---- - - - - - -

2850

Fig. 6·53. Reaming

Fig . 6-55. Ball nut

5. Fit the oil seal (16) in the steering cam cover (14) 7. Turn the steering cam so that the ball nut is mov-
with the seal lip facing inwards. Fit the gasket, ed to the lower end position. Fit the nut guide
shim, gasket, cover and retainer, see Fig. 6-49. The anta the ball nut. Lubricate the oil seal (24) and
gaskets have a thickness of 0.127 mm (0.005") and fit the pitman arm shaft inta position . When doing
the shims are available in thicknesses of 0.05,0.127 this, profect the oil seal with tool SVO 2719, see
and 0.254 mm (0.002, 0.005 and 0.010") . Tighten the Fig . 6-58. Then turn the ball nut to the centre
four balts to a torque of 1.7-2.1 kpm (12-15 position. Fit the gasket (11) and steering box
IbJt.). cover (12). Tighten the two balts to a torque of
6. Check the tension with the steering cam hori- 1.7- 2.1 kpm (12-1SlbJt.).
zontal. With correct tension, a torque of 2.3-4.6 8. Place the spring guide (6) in position but without
kgcm (2.0-4.0 Ib.in.) is required to turn the steer- the springs (7). Fit the paper and steel shims as
ing cam. The torque can be measured with the weil as the stop plate (8). The gaskets have a
help of a spring balance and cord round the thickness of 0.127 mm (0.005") and the shims are
steering cam shaft (Fig. 6-57). The balance should available in thicknesses of 0.05, 0.127 and 0.254 mm
give a reading of 2.6-5.2 kg (5.7-11.5 Ib.). If (0.002,0.005 and 0.010"). Tighten the three balts to a
necessary, adjusf by removing or adding shims or torque of 1.7-2.1 kpm (12-15 IbJt.). N.B. Check
gaskets. to make sure that there is axial playan the pit-

VOLVO
103229
Fi g. 6·54. Fitting the oH seal Fig. 6-56 Fitting the steering cam

6: 27
 10. Remove the stop plate and the spring guide after
correct clearance has been obtained and then fit
the springs (7). Refit the guide, shims and plate.
11. When filling with oil, place the steering box as
when installed in the vehicle, that is, at an angle
of 10° . The box is then filled with hypoid oil up
to the filling hole level.

Fig. 6.57. Checking the torque

VOLVO VOLVO
103158 J03 160

Fig. 6.58. Fitting the pitman arm shaft Fig . 6·60. Pitman arm shaft setting

man arm shaft. If there is not, the balls may be FITTING

damaged when tightening. l. Turn the steering cam to the right to the end
9. Measure the axial play (Fig . 6·59) after the bolts position and then back 21j2 turns. The steering
have been tightened . Then reduce the total thick- gear will then be in the middle position, which
ness of the shims so that there is a calculated pre- can be checked on the pitman arm shaft land
tensioning of 0.025-0.075 mm (0.0010-0.0030"). If, covers, see Fig. 6-60.
for example, the first measured play is 0.05 mm 2. Check that the steering wheel has the position
(0.0020") and the thinnest shim 0.127 mm (0.0050"), for driving straight forwards. Place the steering
replace this shim with one of thickness 0.05 mm box in position and fit it on to the flange . Fit and
(0.0020"). The play will then reduce 0.077 mm tighten the attaching bolts (4, Fig. 6-46). Tighten
(0.0031 ") and become a pre-tensioning of (0.077- the clamping bolt (l).
0.05 = 0.027 mm (0.0031-0.0020 = 0.0011 "). the clramping bolt (l). Check that the distance be-
tween the steering box housing and the lower
flange is 10±S mm (0.4±0.2").
3. Point the front wheels straight forwards and fit
the pitman arm. Tighten the nut to a torque or
17.5-20 kpm (12S-l4SlbJt.).
4. Check to make sure that the steering gear can
be turned from stop bolt to stop bolt without
hindrance. Lower the front end of the vehicle.

SERVO STEERING
Work which can be carried out with the servo
steering installed in the vehicle
NOTE: The utmost cleanliness sh ou Id be observed
for all work on the power steering equipment. AI-
Fig. 6·59. Checking the axial play ways clean the connections before disconnecting

6: 28
them, also the outside of the oil container before
re movi ng its cover.
Only oil ATF, Type A or Dexro n may be used for the
servo system .

CHECKING THE Oll lEVEL

The oil level should be checked every 10 000 km (6000
miles) . The level should first be checked with the
engine stationary in order to see whether there has
been any loss of oi/. The oil level should then come
about 5-10 mm (1,4") above the level mark. If the Fig. 6·62. Steering box fitted
level is lower than this, fill with oil with the engine 1. Nut 6. De livery line (ear ly prod .)
stationary: this will eliminate risk of air being sucked 2. Boll 7. Bleeder screw
3. Flange 8. Adjust ing screw'
in. Start the engine and then check the oil level again, 4. Clamping balt 9. Steering box
which should now fall to the maximum mark, see Fig. 5. Return line 10. Dra in p lug

6-61. When the engine has stopped, the oil level may
rise to 5-10 mm (1,4") above the level mark.

1. Fill with oil up to the edge of the oil container.

2. With oil within easy reach, start the engine. Gra-
DRAINING THE Oll dually fill the container with oil as the level drops.
With the servo steering pump complete, oil is drained When the level has stabil,ized itself, proceed to the
off as follows: next operation.
Jack up the front end. Screw out the drain plug (lO, 3. Turn the steering wheel repeated ly and even ly in
Fig. 6-62). Turn the steering wheel to the left to the both directions. The steering wheel should be
stop position . Remove the cover on the conta iner. turned slowly so that the pump operates at low
Start the engine and allow it to run max. 10 seconds pressure. If necessary, fill with more oi/.
until the oil is emptied out of the container and pump. 4. Open the bleeder screw (7, Fig. 6-62) 1/2-1 turn.
Stop the engine and turn the steering wheel from the Close it when oil starts flowing out.
stop lock to stop lock until all the oil has run out. 5. Continue turning the steering wheel until the oil
in the container is practically free from air
bubbles.
FllLlNG WITH Oll AND BlEEDING 6. Stop the engine. The oil level should then rise 5-
10 mm (1/4") above the leve I mark. If it rises
NOTE: The oil capacity is about 1.2 litres (2.1 Imp.
further than this, there must be air still in the
pints = 2.5 US pints). Drained-off oil. may not be put
system, in which case continue venting.
back inta the system.
7. Lower the front end .
After the bleeding, a small number of air bubbles may
remain in the system . When the pump ca uses p ressure
to be applied to the oil during driving, these a ir
bubbles will eventually disappear in the container.

INSPECTlNG THE SERVO STEERING

The inspection procedure described be low can be
applied with a view to fault tracing or preve nting
possible faults.

I. Checking the outer ceiling

1. Check to make sure that a lll screw unions are not
damaged. Re-tighten if necessary.
2. Check the hoses for damage. Replace those that
Fig. 6-61. Oil level are damaged.

6: 29
 blow clean before screwing out the plug (4,
6-67), which should be done from underneath.
Check the valve piston and drilling in the
housing . The hole in the valve piston must not
be blocked. The piston should run easily in the
housing and not jam . If necessary, fit a new
valve. If this does not help, replace or recon-
dition the pump.
3. Steering box test: With the engine idling and the
instrument operating lever open, turn the steerina
wheel to the right to the end position. Increase
the force on the steering wheel, to about 10 kg
(22 Ib.) and maintain this position for about 5
seconds and read off the gauge. Repeat this pro-
Fig. 6-63. Pressure gauge connec!ed cedure after turning the steering wheel to the left.
If it is established that the steering box oil pres-
sure, with the steering wheel turned either to the
right or to the left or in both directions, is below
II. Checking oillevel and bleeding the previously determined oil pressure for the
l. Connect the test instrument SYO 2864 to the de- pump, then the function of the servo steering is
livery line at the steering box, see Fig . 6-63. The not satisfactory. If no externai leakage can be
inlet hose of the instrument is connected to the discovered, the reason for the pressure drop must
banjo nipple with tool SYO 2865 (Fig. 6-63) and be an internai leakage, in which case the steering
the outlet hose to the steering box with tool SIlO box must be replaced.
2866. Check to make sure that the operating lever
of the instrument is in the open position (to the
IV. Checking the mechanical function
left).
l . Check the mechanical components of the front
2. Jack up the front end of the vehicle. Check that
end and steering such as ball joints, rods, bear-
the oil level is 5-10 mm (1/4") above the level
ings, steering box and flanges concerning play.
mark with the engine stationary.
Re-tighten attaching bolts and replace damaged
3. Start the engine. Check the level, and fill with oil
or worn components.
if the level has fallen below the level mark with
2. Adjust the pressure point between the piston of
the engine running. Turn the steering wheel from
the steering box and pitman arm shaft as follows:
full lock to full lock as long as air bubbles are
a) Remove the locknut for the pitman arm . Pull
visible in the container. With the engine idling,
the pitman arm off with tool SYO 2849. When
the oil level should be at the level mark.
fitting the puller, turn the wheels fully to the
4. When the engine is stopped, the oil level should
right, see Fig. 6-45.
rise 5-10 mm (1/4").
b) Place the steering box in the middle position
(count the number of steering wheel turns).
III. Checking the hydraulic function for steering box
and pump
l. Run the engine warm.
2. Pump testing: With the engine idling, move the
operating lever of the instrument briefly (max. 10
seconds) to the c10sed position. Read off the max.
pressure on the pressure-gauge. This should be
maximum 10 % below the indicated maximum
pressure of the pump, that is, at least 67 kp/cm 2
(953 p.s.i.). If pressure less than this is obtained,
exa mine the pump and drive as follows:
a) Check the tension and condition of the drive
bell". Replace the belt if defective.
b) Remove the pump controi valve, see Fig . 6-64. Fig . 6-64. Removing the controi valve
Observe the utmost cleanliness. Wash and l. Piston 2. Spring 3. Goskel 4. Plug

6: 30
 c) Slacken the nut for the adjusting screw (8, Fig.
6-62).
d) Turn the adj usting screw clockwise until a light
re sistance is fe lt in the fla nge dev ice when it
is turned to the left or to the right o n both
sides of the centre position .
e) Tigh ten the locknut while hol di ng the adjusti ng
screw firmly .
f) Check the adjustment by tu rn ing the steerillg
wheel severa l times mo re past the centre posi-
tion . In the centre positio n a slight increase in
resistance s hould be felt. Fig. 6-66. Filling the sealing ring
g) Set the front wheels stra ight forwards and fit
the pitman arm with the steering box in the
centre position . Tighten the nut to a torque of
(17.5-20 kpm (125-l45IbJt.). 4. Ca refully appl y tool SYO 2860 to the sea ling ring .
Tighten the scre w (Fig . 6-65). Th is a lso tigh tens the
V. Test driving seal ing ring . If the ring sticks in the circl ip groove,
carefully t urn the tool backwards and forwards.
If the servo steering is on ly normally worn and is not
5. Fi ll the space between the ne w sealing ri ng lips
da maged or overloaded, the steering should function
with m"ultipurpose grease. Fit the sealing ring on
satisfactorily during the test driving, that is, the hy·
to installation tool SYO 2863 with the help of the
draulic servo assistance should not be staccatic and
loose guide. Remove the guide and fit the sealing
result in erratic steering .
ring in the steering box, see Fig. 6-66.
6. Fit the circlip and cover.
7. Re-fit the flange according to the line-up marks.
REPLACING THE CONTROL SPINDLE SEALlNG RIN G Check that the distance between the steering box
l. Dismantie the flange device by removing the two housing and the lower flange is 7±5 mm (0.28±
nuts (l, Fig . 6-62) and the screws (2). Move the 0.20").
rubber d isc and lower steering column section to Assemble the other parts.
the one side .
2. Mark up the location of the flange (3) on the
controi spindie. Slacken the clamping bolt (4) and
pull off the flange. Replacing the steering box
3. Remove the rubber cover as wel,1 as the circlip REM OVIN G
for the sealing ring. l. Jack up the front end.
2. Drain the oil, see under "Draining the o il".
3. Remove the I'ocknut for the pitman arm. Pull the
pitman arm off with tool SYO 2849. When fitting
the puller, turn the wheels fully to the right, see
Fig. 6-45.
4. Disconnect the oil I,ines (5 and 6, Fig. 6-62) from
the steering box after the connections have been
cleaned. Slacken the clamping bolt (4).
5. Remove the attaching bolts (11) and pull the
steering box forwards.

FITTIN G
l . Place the steering box in the centre position. A
slight increase in resistance should then be felt
and the position of the pitman arm shaft lands
should be as in Fig. 6-60 and the line-up marks
VOLVO
on the controi spindle and housing should coin-
1031 65
Fig . 6-65. Removing the sealing ring cide.

6: 31
 2. Check to make sure that the steering wheel is
pointing the front wheels straight forwards .
3. Fit the steering box spindle in the flange of the
lower steering column seetion. Fit and tighten the
attaching bolts (11, Fig. 6-62). Tighten the clamping
boll' (4). Check that the distance between the steer-
ing box housing and the lower flange is 7±5 mm
(0.28 ±0.20"). Connect the oil lines. The longer deli-
very line should run in a curve backwards, (see Fig.
6-32) and should be clamped.
4. Point the front wheels straight forwards and fit
the pitman arm . Tighten the nut to a torque of
' 17.5-20 kpm (125-141 Ib.ft.).
5. Fill with oil and bleed, see under the heading "Oil
filling and bleeding".

VOLVO
103 167
Replacing the servo pump Fig. 6-67. Servo pump, filfed

REMOVING l. Tensianing balt 4. Plug for controi valve

2. Servo pump 5. Suction line
1. Clean round the conneetions (5 and 6, Fig. 6-67). 3. Attach i ng balt 6. Delivery line
2. Di.s connect the suction line (5) and colleet the oil
running out.
3. Disconneet the delivery line (6), and unscrew the
2. Fit the attaching bolts and other components, see
tensioning bolt (l) and the attaching bolts (3). Pro- Fig . 6-67. Tension the drive belt so that it can be
teet the nipples and connections from dirt.
pressed in about 5 mm (3/16") in the middle .
4. Unscrew and remove the pump.
Tighten the bolts and the connections.
3. Fill with oil and bleed, see under "Oil filling and
bleeding" .
FITTING
Concerning replacement of pump, supplement the new
pump with brackets, pulley and other parts, see Fig. Replacing the oil filter
6-67. When fitting the pulley, the tolerances may be When changing the oil, which is normally done only
such that the pulley can not be pressed on by hand. in connection with replacement of the servo steering
In these cares, press on the pulley with care. It must components, the filter should also be replaced. This
not be hammered on, otherwice the bearings might is accessible after the spring and retainer in the oil
easily get damaged, resulting in noise in the pump. container have been lifted off. Clean the container
l. Place the pump in position and conneet the oil before fitting the new filter. Also replace the gasket
lines with new sea Is. in the outer cover.

6,32
- - - - - - - - - - - - - - - - - - - -

Part 7

SPRINGS, SHOCK ABSORBERS, WHEELS

 (ONTENTS

Group 70. General

Tools . .. .. . ....... . .. .. .......... . . . . . . . . . ... . . . . . ... . .. . ... 7: 1

Group 73. Springs

Descri ption 7:2
. . : . .. ..... . . . .. . . . . . .... . . . . . . .. . . . . . . .. . ... .
Repair Instructions ..... . . .. . . . . . . . .. ... . ... . . . . .. ........ . 7:3
Front springs .... . ... . . .... . . .. . . ...... . . . . . ...... . . . . . . 7: 3
Rea r springs .. . . .. . ... ... . ..... . .. . .. .. . .. . .. . .. . . . .... . 7:3

Group 76. Sh ock Absorbers and Stabilizing Devices

Description .. .. .... . .. . . ... .. . . ....... . . . . . . ... . .... . 7: 5
Gene ral .... .. . . .. ... . .. . .. . . . . .. . . . . . ... . .. . .... . 7: 5
Shock abso rbe rs . . ... . . ... .. .. . . . . . . . . . . . . . . .. . . . . .. . . . 7:5
Repa ir Instructions . .. . ... . ... ... . . .. ... . .. . . . . . . . . . . . . . . . . 7:6
Ch ~ cking shock absorbers ........ . . ... . . .. ... . . . . . .... . 7: 6
Replacing front shock abso rbe rs ......... . . .. ... . ... .. . . 7: 6
Re placing rear shock abso rbers 7:7
Replacing support arm bushes ...... . . .. .. .. . . . . . ... . .. . 7:7
Replacing track bar bushes .. . ... ........ . . . . .. . . . . . . .. . . 7: 8
Replacing suppo rt stay bushes ... . .. .. .. ... . . ..... . 7:9

Group 77. Whee ls

Repair Instructions . ...... . . .. .. . .............. . . ... ... . . . . 7: 10
Changing wheels .. . ... . . . . . . ...... . .. . . . . . . . ... . . ... .. .. 7: 10
Replacing wheel studs . .... . •. . ..... . ...... .. . .. .. .. . .. . . . 7 : 10
Replacing and adjusting front wheel bearings . . ... . .. ... . 7 : 10
 GROUP 70

GENERAL
rOOlS

SVO 1801 svo 2294 SVO 2722 SVO 2715 SVO 2726 SVO 2723 SVO 2724

SVO 2725 SVO 2730 SVO 2731 SVO 2732 SVO 2733 SV02734 SVO 2862

VOLVO
104284

Fig. 7·1. Tools used for work on the rear axle suspension and hub
SYO 1801 Standard hand le 18X2CO mm.
SYO 2294 Puller for ball joint, steering rad.
SYO 2715 Drift for removing and fil1ing grease cap.
SYO 2722 Puller for inner ring, inner wheel bearing.
SYO 2723 Drift for fining outer ring, inner front wheel bearing
and seal.
SYO 2724 Drift for fil1ing outer ring, outer front wheel bearing,
and removing oufer 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 fil1ing small bush, track bar
and rear bush in support arm (+ SYO 2733).
SYO 2731 Drift for removing and fil1ing large bush, track bar
(+ SYO 2733) .
SYO 2732 Drift for removing and fil1ing front bush, support arm.
SYO 2733 Counterhold for removing and fitting bush, support
arm, support stay and track bar.
SYO 2734 Drift for removing bush in support stay.
SYO 2862 Press too I for replacing wheel balt.

7:1
 GROUP 73

SPRI NGS
DESCRIPTION

The Volvo 164 is provided with coil springs at both axle member is fitted with rubber buffers (4) which
front and rear. The front wheel suspension is in- limit the downward movements of the wishbones.
dependent. The upper ends of the front springs (1, Fig. The upper ends of the rear springs (5, Fig . 7-5) are
7-2) are seated in housings form ed in the front axle bolted to the rear side-members (8) and at the lower
member, and are seated in the bottom of the ends to the support arms (15) behind the rear axle.
lower wishbones. The lower wishbones are also Rubber buffers (4) fitted on the rear side-memQers
provided with rubber buffers (5), which absorb any take up any impacts from loading on the springs.
impads arising from loading on the spring . The front

VOLVO
10 1947

Fig. 7-2. Front spring and shack absorber

1. Spring
2. Shock absorb er
3. Upper shock absorber attachmenl
4. Rubber buffers
5. Rubber buffers
6. Lower shock absorber atlachmenl
7. Attachmenl for slabilizer
8. Stabilizer
9. Attachment (in fra me) for slabilizer

7:2
 REPAIR INSTRUCTIONS
FRONT SPRINGS
REMOVING
1. Remove the hub cap and loosen the wheel nuts o
couple of turns.
2. Jack up the front end at the front jack attoch-
ments. Remove the wheel.
3. Remove the shock absorber occording to the
instructions given in Group 76.
4. Disconnect the steering rod from the steering arm.
Loosen the damp for the brake hoses. Remove
the ottachment (7, Fig . 7-2) for the stabilizer.
5. Place a jack under the lower wishbone. Loosen
the nuts for the ball joints, knock with a hammer
until the bal<! joints loosen from the the knuckle.
Remove the nuts ond lower the jack slightly.
Remove the steering knuckle with the front wheel
brake unit ond place it on a suitable stand.
6. Lower the jack fully and remove the spring.

FITTlNG
l. Place the rubber spacer and spring In position.
With the jack (placed immediotely under the VOLVO
1019<>0
spring) lift up the lower wishbone and fit the Fig. 7-3. Rear spring
steering knuckle.
2. Tighten the ball joints at the steering knuckle.
Firmly screw the stabilizer to the lower wishbone. spring as weil os the rubber spacer (11) ond the
3. Check the rub ber bush ond lower wosher (l, and wosher (10) and then firm ly secure the spring to
7, Fig. 7-7) of the upper sh ock absorber ottoch- the upper otta ch ment.
ment. Place the shock obsorber in position and 2. Raise the jack and securely fix the spring to the
tighten its attachment. lower attachment with the washer (14) ond the
4. Point the wheels stroight forwards (with the lower screw (13).
wishbone unioaded) and damp firmly the brake 3. Fit the upper shock absorber screw, the wheel
hoses to the screw of the stabilizer. ond lhe wheel nuts.
5. Fit the wheel and wheel nuts. Lower the vehide. 4. Lower the vehicle and tighten the wheel nuts. Fit
Tighten the nuts. the hub cap.

REAR SPRINGS
REMOVING
l. Remove the hub cap and loosen the wheel nuts
a couple of turns. Jack up the vehide. Place
oxle props in front of the rear jack attochments
according to Fig. 7-4. Remove the wheel.
2. Jack up the reor oxle with the jack so that the
spring compresses. Loosen the upper and lower
spring ottochments.
3. Remove the upper attochment (9, Fig . 7-5) for the
shock obsorber. Lower the ja ck corefully ond
remove the spring.

FITTlNG Y&Ml'
Fig . 7-4. Lacatian af the axle prap far propping up
l . Fit the upper screw ond the wosher inside the the vehicle rear end

7:3
 19 18 17 16 15

Fig. 7-5. Rear axle suspension

1. Bracket 11. Rubber spacer

2. Support stay 12. Bracket
3. Bracket 13. Screw lower spring atlachment
4. Rubber buffer 14. Washer
5. Rear spring 15. Support arm
6. Bracket 16. Shock absorber
7. Track bar 17. lower shock absorber atlachment
8. Rear side·member 18. Front support sta y at!achment
9. Upper shock absorber at!achment 19. Front bush, support arm
10. Washer

7:4
 GROUP 76

SHOCK ABSORBERS
AN D STABI LIZI NG DEVICES
DESCRI PTION

GENERAL The lower attachment (Fig. 7-8) consists of an eyelet

The 164 is fiited with hydraulic, double-aeting, tele- provided with a rubber bush, which cannot be dis-
scopic type shock absorbers. They require no moin- mantled and a piece of tub ula r piping, the fla ttened
tenance and cannot be dismantled. ends of which are screwed to the bottom side of the
The front shock absorber upper attachment (Fig. 7-7) lower wishbone.
consists of a spindle (S), which with upper bushes (l The stabilizer (8, Fig . 7-2), which is attached to both
and 6), washers (3 och 7) and a spacing sleeve, are the lower wishbones (7) and to the frame (9), in-
fixed into a housing in the front axle member. creases the stability of the vehide.
The rear shock absorber attachment (Fig. 7-9) con-
sists of eyelets prov.ided with rubber bushes (l and 3)
which cannot be dismantled. These absorbers are
bolted at the top to the rear side-members and at
the bottom to the support arms.
The rear axle is attached to the body through two
f1exibly mounted support anms (15, Fig. 7-S). Forces
aeting longitudinally are taken up by two support
stays (2) and the lateral forces are absorbed by a
track bar (7). The support arms are fore -mounted in
rubber bushes (19). The support stays and track bar
are attached to the rear axle frame through the rubber
bushes.

2
SHOCK ABSORBERS
DESIGN
The design of the shock absorbers is shown in Fig. 7-6.
The outer cylinder (l) serves on ly as a proteetion
against dust and dirt. The other two cylinders (2 and
4) are concentrically arranged, one inside the other.
The inner cylinder (2) is the aetual working cylinder,
the lower end of which is provided with a valve (6).
Inside the inner cylinder there is a piston (S) in which
holes are drilled, the passage of oil through these
hol~s being controlled by valves.
The piston is attached to a piston rod (3), the upper
end "of which forms an attachment to the body. At
the opposite end of the sh ock absorber a similar
screw attachment is fitted . The space between the
cylinders (2 and 4) serves as a reservoir and is
only partially filled with fluid. The inner cylinder (2)
Fig. 7-6. Shock absorber, function
is completely filled with fluid on both sides of the
l. Dust cover 6. Valve
2. Working cylinder 7. Baffle ring
piston (S). The cover (8) serves as a seal and guide
3. Piston rod 8. Cover for the piston rod (3). The baffle ring (7) . aets as a
4. Reservoir cylinder 9. Upper attachment
5. Piston
baffle for th.·e fluid .

7:S
FUNCTION caused by turbulence in the fluid passing through
When the shock absorber is compressed or extended the holes in the piston. This dampens any rolling
through the suspension of the vehicle, the piston (S) tendency on the ' part of the vehicle and ensures
is moved in the inner cylinder (2). Fluid then f10ws smoother riding.
through the valve-controlled holes in the piston. The When the sh ock absorber is compressed or extended,
speed with which the piston moves is determjned by the volume on each side of the piston is not altered
the rate at which the flu id passes through the holes by the same amount since the piston rod occupies a
from one side of the piston to the other. Since the certain space. When the shock absorber is compres-
drilled ho les are very narrow, the fluid can only sed, therefore, some of the fluid passe s out through
pass through slowly, thus braking the movement of the valve (6) into the reservoir, and when the shock
the pistml. When the sh ock absorber is sudden ly absorber is extended, fluid is again sucked into the
compressed or extended, a further braking effect is cylinder (2) on the underside of the piston.
,-

REPAI R I NSTRUCTIONS
CHECKING THE 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 3
shock absorbers are functioning on the whole by
noting the damping effect when rocking the ear up
and down and then re leasing it. Testing can also be
carried out by driving the vehicle over a bumpy sur-
face. · The removed absorber can be tested by tightly 2
fixiri'g the lower attachment in a position similar to
that when fitted in the vehicle. If it is then alternately
pulled out and compressed, it is possible to judge
whether it is operating or not. Notice on making this
check that, when the shock absorber is extended, its
resistance is three times as great as when it is com-
pressed, this due to its way of operating .
If the ' shock absorber does not function satisfactorily
in both directions, or if the fixed rubber bus hes are
damaged, the sh ock absorbers should be replaced.

VOLVO
10\ 944

REPLACING FRONT SH OCK ABsORBERs

Fig. 7-7. Upper atlachmenl, fronl shock absorber
1.i!Remove the upper nut (4, Fig. 7-7), the washer (3) 1. Rubber bush 5. Spindle
" and the rubber bush (6). 2. Spacing sleeve 6. Rubber bush
3. Washer 7. Washer
2. Remove the two lower attaching screws (Fig. 7-8) 4. Nut
 S. Fit the upper rubber bush (6), the washe r (3) and
the nut. Tighten the nut until it makes firm contact
with the spacing sleeve.

REPLACING REAR SHOCK ABSORBERS

l. Remove the hub cap . Slacken the wheel nuts a
couple turns. Ja ck up the re a r end of the vehicle
at the jack attachments. Place blocks in front of
the jack attachments according to Fig . 7-4. Remove
the wheel. Unscrew and rem ove the shock ab-
sorber.
2. When fitting make sure that the spacing sleeve
VOLVO in the support arm has not been removed (2, Fig.
10 1 967
Fig. 7-8. Lower attachment, front shock absorber 7-9). Fit and ti ghte n the shock absorber. Fit the
wheel and wheel nuts. Lower the vehicle. Put on
the hub cap.

on the underside of the lower wishbone, and take

down the shock absorber. REPLACING BUSHES
3. Fit the washer (7), the spacing sleeve (2) and the FOR THE SUPPORT ARM
rubber bush (l).
l . Raise the vehicle by placing props in front of the
4. Pull apart the sh ock absorber and then fit it.
rear jack attachments according to Fig. 7-4. Do
Fit and tighten the lower screws.
not remove the jack.
2. Disconnect the shock absorber at the lower
attachment. Remove the lowe r screw of the spri ng
and the n lower the jack until the spring releases
from the support arm . Move the spring back-
wards so that it runs free from thp. support a rm.
Raise the jack unti l the rear axle is in alevei
position .
3. Remove the screw on the support arm at the rear
axle bracket (3, Fig. 7-S). Remove the front screw
and take off the support arm.
4. Press out the front bush with too I SYO 2732. Coat
the new bush with oil and press it in with the
same tool according to Fig. 7-10. Make sure tha t
the plane sides of the bush are at ri ght angles
to the support arm shaft (Fig . 7-10).
S. Press out the rear bush with tool SYO 2730 and
tool SYO 2733.
Press in the new bush with the same toois, using
tool SYO 2730 in the reverse direction.
6. Place the support arm in position and fit the front
and rear screws .
7. Lower the jack under the rear axle, move the
spring in position on the support arm, again raise
the rea r axle to the horizontal position and fit
the lower screw for the spring.
8. Fit and tighten the nuts for the support arm
screws. Fit and tighten the screw for the lower
shock absorber attachment.
N. B. Check that the spacing sleeve and washers
Fig. 7-9. Attachments, rear shock absorbe r are placed correctly, see Fig. 7-9. Remove the
1. Bush 3. Bush
2. Spacing sleeve 4. Washer
props from under the vehicle and lower it.

7. :7
 VO-LvO
102085
Fig. 7-10 . Removing (and fitting) the front bush, suppo rt arm

REPLACING BUSHES FOR THE TRACK BAR

l. Raise the rear end of the vehicle by placing VOLVO
102082
props in front of the rear sh ock absorber attach- Fig. 7-12. Fitting the small bush, track bar

ments according to Fig. 7-4.

2. Remove the nuts at both brockets (6 and 12, Fig.
7-S). Remove the track bar from the brocket
mounted on the rear axle. Remove the screw at S. The large bus hes are pressed out with SVO 2731,
the brocket (12) attached to the frame and toke and SVO 2733 as a counterhold (Fig. 7-11). When
off the track bar. pressing in the bushes, SVO 2731 is reversed
3. Check the bushes and make sure that the bar is (Fig. 7-12).
not bent. 6.Fit the bar with the screw to the frame brocket
4. If necessary, press out the small bushes with (12) .
SVO 2730 using SVO 2733 as a counterhold. 7. Place the other end on the rear ax le brocket (6)
(Fig. 7-13). Pressing in the bushes can be done and fit both washer and nut. Screw on the frame
with the same tools only in this case SVO 2730 is brocket nut.
reversed (Fig . 7-14). 8. Remove the blocks and lower the vehicle.

VOLVO
103778 VOLVO
103 781

Fig. 7-11. Removing the small bush, track bar Fig. 7-13. Removing the large bush, track bar

7: 8
 VOLVO
103 78 2
Fig. 7-14 . Fitting the larg e bush, track bar Fig . 7-15. Fitti ng the bus h, support stav.

REPLACING BUSHES FOR THE SUPPORT STAV

The bushes of the s upport stay a re pressed out with
tool SYO 2734 and counterhold SYO 2733. They are
suitably pressed in with a d rift press directly on the
bush and with tool SYO 2733 as a counterhold (see
Fig. 7-15). Before pressing in the rubber bush, coat
it with oil so that it slides easily in position and is
not damaged.
When fitting the bushes, they should be turned so
that the markings come at right angles to the length
of the stayas shown by the arrows in Fig . 7-16.
Fig. 7-1 6. Ma rking up the support stav bush

7:9
 GROUP 77

WH EELS
REPAI R I NSTRUCTIONS

CHANGING WHEELS components, as shown in Fig. 7-17. Run the nul

When fitting wheels, it is important that all grit and runner until Ihe stud is fully removed. If the old
dirt and any surplus paint is cleaned off from the stud is loose in the hub, the hole must be check-
contact surfaces between wheel and hub. measured. If the hole diamete r exceeds 16.27 mm
.. (0.64"), the hub must be replaced.
3. Insert a new, oversize wheel stud and press il
in by hand as far as possible.
REPLACING THE WHEEL STUDS
4. Place the accessory part, the pin, in the press tool.
The wheel studs can be replaced without removing
5. Place the sleeve on the outer end of the wheel stud.
the front wheel hubs or drive shafts.
6. Place the tool in position (see Fig . 7-18) and use
l. Remove the brake caliper and brake disc accord-
a nut runner to screw in the stud completely.
ing to the instructions in Part 5.
N . B. When replacing a wheel stud, always use a new,
2. Set up tool SYO 2862, without the accessory
oversize stud. The oversize stud can be fitted withouI
previously machining the hole.

REPLACING AND ADJ USTING FRONT

WHEEL BEARINGS
l. Remove the hub cap and slacken the wheel nuts
slightly.
2. Jack up the front end and place props under the
lower wishbones. Unscrew the wheel nuts and lift
off the wheel.
3. Remove the front wheel brake according to the
instructions given in Part 5 under "Removing the
front wheel brake unit".
4. Remove the grease cap with tool SYO 2715 (Fig.
7-19). Remove the split pin and castle nut. Pull off

Fig . 7-17. Removing the wheel stud

VOL VO
104 307 VO LVO
102906
Fig . 7-18 . Fitting th e wheel stud Fig. 7-19. Removing the grease cap

7: 10
 the hub with puller SYO 2726 (see Fig. 7-20). Pull
off the inner bearing from the stub axle with
puller SYO 2722 (see Fig. 7-21) if the bearing
remains in place.
5. Remove the bearing rings. Use drift SYO 2724
(Fig. 7-22) for the inner bearing ring and drift
SYO 2725 (Fig. 7-23) for the outer bearing ring
together with standard hand le SYO 1801.
6. Clean the hub, brake disc and grease cap.
7. Press in the new bearing rings. In addition to
using standard handle SYO 1801, use drift SYO
2723 (Fig . 7-24) for the inner ring, and drift SYO
2724 (Fig. 7-25) for the outer bearing ring .
8. Grease the bearing with the hel p of a pressure
VOLVO
102 910
greaser. If there is not one available, pack the
Fig. 7-20. Removing the hub
bearings by hand with as much thick grease as
there 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 hub. The recess in the hub
is filled with grease all round up to the smallest
diameter of the outer ring of the outer bearing,
see Fig. 7-27.
Use a high-class bearing grease for the bearing.
Place the inner bearing in position in the hub.
Press in the seal with drift SYO 2723 and standard
hand le SYO 1801, see Fig. 7-26.
The felt ring should be weil coated with, for
example, light engine oi!.
9 Place the hub on the stub ax le. Fit the outer
bearing, washer and castle nut.
10. The front wheel bearings are adjusted by firs!
tightening the nut with a torque wrench lo a torque

Y04994
OLVO

Fig. 7-21. Removing the inner bearing

VOLVO VOLVO
102931 1Q 2nO

Fig. 7-22. Removing the inner bearing ring Fig. 7-23. Removing the outer bearing ring
A = SYO 1801 B = SYO 2724 A = SYO 1801 B = SYO 2725

7. : 11
 A

Fig . 7-26. Fitting the sea I

of 7 kgm (50 Ib.ft.). Then slacken the nut 1/3 of

a turn . If the slot in the nut does not coincide
Fig. 7-24. Fitting the inner bearing ring
with the split pin hole in the stub axle slacken it
A = SYO 1801 B = SYO 2723
further to enable the split pin to be fitted . Check
that the wheel rotates easily without any play.
11. Fill the grease cap half full of grease and fit it
with tool SYO 2715.
12. Fit the front wheel brake unit according to Part 5.
13. Lift on the wheel after having cleaned any grit
and dirt from the contact surfaces between the
A wheel and hub, and then tighten up the nuts suffi-
ciently so that the wheel cannot be displaced on
the hub. Lower the vehicle and tighten the wheel
nuts firmly. Tighten every other nut a little at a
time until all of them are finally tightened to a
torque of 10-14 kgm (70-100 Ib.ft.). Fit the hub
cap.

Fig. 7-25. Fitting the outer bearing ring

A = SYO 1801 B = SYO 2724

VOLVO
2H08
Fig. 7-27. Lubrication of front bearing

7: 12
- - - -

Part 8

BODY
 (ONTENTS
Group 80. General
Toots .. . .... . . ...... . .. .. . .. .. . . . 8:l
Group 81. Body Frame
.. Description . . ...... ..... . ...... . .. . . 8:2

Group ~2.. Hood and Mudguards .

Descnptlon .. ... .. ..... . , . ........ . . . . . .. .. . . . . ...... . 8 :4
Repair Instructions .. .. . . . ..... . .. .. ..... . , .. ...... , ... . . .
Front mudguards ............. , . , .... . ' , ..... ,., 8:4
Front section ..... . " .... ,. ' , .. ... " , , , . .. ' .. 8:4
Hood and hood lock .'" . .. . . , .' , . , .... ' .' . . . , , ... , .. , , 8:4

Group 83. Doors and Luggage Compartment Lid

Description ....... .. ... , , .. ... . , . ' , . , , , , .... , 8:5
Repair Instructions . , .. . , .. , , .. . . , ...... . ' . ' .. . ' . .. . ' . ' . ,
Removing and fitting door stops . , .. . .... . .. , . . , .. . . . . , , 8:5
Removing and fitting doors ..... " , .. ,,' . .. ,.,'., . , . , . , 8:6
Removing inner handles and upholstery . , , . , . , . . ' , , . ' . , .. 8:7
Latch plates .... , .. ",., .. " . ... " " "'. ' .. . .. ".,.,, . 8:7
Removing door locks .. .. ' .. .. . . ... . , . . ' . '. , .. . , .. , . ". 8:7
Removing lock handles . . .. ... . , ' . , . , . . . ' .. . . ' . .... . . . ' 8:8
Fitting and adjusting lock handles " . , . , . . ',' . , . ', ... , . , 8:8
Removing door f rames .. . . . .. , .", ... ' . . . , .. '.' . '.' 8:9
Removing winding windows ... , ., ., .. , . ' ., . ',, ' .,.', . . ' 8:9
Removing ventila tion windows , , ' . ' . . ' .. . ' . . 8 : 10
Removing window winders .. ",' .' . . . .. .. . ' . ... , . . , . . ' 8 : 10
Luggage compartment lid, . , .. , . ' . , . ' . , . . ' . . .. , . ' . ' .. .. 8: 11
Sun-roof " ' ,,,' .' ,.,' .,.,,. ' . ' .' . ' 8 : 11

Group 84. Sealing Strips, Trim Moulding and Glass

Repair Instructions
Sealing strips .. . , ... , .. , .. . .. ... , . , .. , . ... . , , . , . , ..... . 8 : 13
Trim mou ldings '" , , , ... ' . , , . ' . ' , , , . ' . ' . ' , . ' . ' . ' 8 : 13
Rear window ..... . , ............ ,., ... , ....... , . , .. ... . 8 : 15
Rear quarter windows .... . . .... . , . , .. . .. . .. , . . , . .. , . .. . 8: 16

Group 85. Upholstery, Interior Equipment and Heating System

Descripti on , . .. .. ... , .. . . . . . ....... . .. ... . , .... ...... .. . 8: 17
Seats .. ... ... ... . ' ..... ,., .. ' ............ , . . . ... .. . ' .. 8 : 19
Replacing the headlining ......... , ., . . . .. . ...... , .... ' 8 : 19
Instrument panel " ........ . ....... . . . .. . . .. . .. .. . .. . . . 8 : 19
Heating system .... . . " . . , ... " " .. .. ...... , ... . ..... , . 8: 20

Group 86. Bumpers

Removin g a nd fitting 8 : 22
 TOOLS

SVO 2739 SVO 2744 SVO 2893 SVO 2847 SVO 2848

SVO 2891

VOLVO
104501

Fig . 8-1. Too ls for the body

SYO 2739 (Iamp far gas spring , lugga ge campartment lid

SYO 2744 Press tool for gas spring, l uggage compartment lid
SYO 2847 Holder for securing fi xture SYO 2777 (2 are used)
SYO 2848 Arm for measuring he i ght of side-member
SYO 2891 Rule for measuring height of side-member
SYO 2893 Holder for fixing measuring rule

VOLVO
104 286

Fig. 8-2. SYO 2777 Fixture for replacing side-members Fig.8-3. SYO 2899 Fixture for fitting windshield

8: 1
 GROUP 81

BODY FRAME
DESCRIPTIO N

The ca r has an integral body so that there is no The tunne l, w hich accomodates the prope ller shaft,
chassis fra me. The body is composed of a number of is spot-we lded to the floor plates. The rear floor
pressed steel plates, each of which forms part of the plate has a longitudinal re info rcing member on each
supporting construction . side at the bottom and between these a number of
The body can suitably be divided up into the floor, cross-members. One of the cross-members is provided
side sections, rea r section , scuttle, roof section, front with an attachme nt for the rear a xle t rack ba r. There
mudguards, doors, luggage compartment lid and is a flanged hole in the rea r floor plate fo r mounting
hood. the fuel tank, the upper port of which forms part of
The floor and frame section (Fig . 8-4) con sist of a the floo r in the luggage compartment. The scuttle
front and rear Hoor plate, inner cantrial, front and (Fig . 8-5) consists of the bulkhead, wheel arches, front
rear cross-members, tunnel and scuttle . The floor upper cross-member and lower cross-member. The
plates are welded together at the rear seat support. bulkhead forms the front transverse wall of the body

Fig . 8-4. Floo r section

8:2
 Fig. 8·5. Body

and has welded end pieces. Two front side members wheel arch member, rear mudguard, back plate and
project from the front floor section . At the front they joining plate. The inner cantrail is manufactured of
are joined together by means of a cross-member and galvanized sheet steel.
at the rear they are connected to the front cross- The roof section (see Fig. 8-5 consists of a number
member under the front seats. The front axle member of pressed steel plates. These roof plates form the
and bumber support bars are attached to the side upper part of the scuttle, the windscreen opening, the
members. roof itself, the opening for the rear window and the
The side section consists of the front pillar, inter- front limit of the luggage compartment lid.
mediate pillar, rear pillar, inner and outer cantrails, The body is noise- and heat-insulated. The insulation
roof former, windscreen pillar, rear wheel arch with consists of self-adhesive foam rubber material.

8:3
 GROUP 82

HOOD AND M UDGUARDS

DE SC RI PTI O N

The hood consists of an outer and an inner plate The front mudguards, front section and hood make
which are bonded together with adhesive. The hood up the front end. The front mudguards are pressed
is hinged at the back on two hinges. In the c10sed in one piece and bolted to the wheel arch plates. The
position it is secured by a lock fitted on the front front section forms the front part of the front end as
section. The lever for hood lock is operated weil as the air duct to the radiator.
by means of a controi placed underneath the dash-
board inside the car.

REPAIR INSTRUCTIONS

FRONT MUOGUARDS the hinges are oval In order to permit hood adjust-
ment.
The front mudguard is removed after the plastic cover
The hood lock (Fig. 8-6) is adjustable longitudinally
over the headlights and the headlight itself have been
since the holes in the front section are oval. The
removed (see Part 3). This is done by unscrewing the
locking pin is adjustable longitudinally since the holes
following bol~s : the bolts joining the mudguard and
in the attaching plate are oval. The length of the
front plate, the bolts on the wheel arch, and the bolts
locking pin is adjustable by means of nuts. The lock-
linking the mudguard rear edge and the brackets on
ing pin and spring are lubricated with grease.
the body. The bolts on the rear edge of the mud-
The hood contact at the corners when c10sed can be
guard are accessible when the front door is opened.
adjusted by screwing out or in the rubber stops at the
hood corners.
FRONT SECTION
The front section is attached to the front mudguards,
wheel arch plates and the front cross-member.
When removing, first take of the plastic cover over
the headlights and also the headlights (see Part 3)
and any extra lights if fitted. Then remove the grille,
the horn, the bumpers and the support irons for the
bumpers. Pull out of the way all electric cables,
remove the radiator, the expansion tank and any
other components which are mounted on the front
plate. Also remove the battery and the hose for the
air c1eaner. Disconnect the wire for the hood lock,
the bolts between the front plate and mudguard,
wheel arch and front cross-member.

HOOD AND HOOD LOCK

The hood is attached in each hinge by means of
bolt,s. It is removed by unscrewing the bolts be-
tween the hinges and hood. The hinges ~re attached
to the body with three bolts each of which are access-
ible for removal under the mudguard. All the ho les in Fig. 8·6. Hood lock

8:4
 GROUP 83

DOORS AND LUGGAGE COMPARTMENT LID

DESCRI PTION
The doors are built up of an inner and an outer plate The luggage compartment lid is built up of an outer
which are Hanged and spot-welded together. The and inner plate bonded together with adhesive . The
hinges are fitted to the inner plate. The doors are catch for the locking device is fitted on the rear ed ge
adjustable both logitudinally, vertically and laterally. of the luggage compartment lid and the hinges are
The doors have bonded cord strips at the windows. fitted on the front edge of the lid . The hinges are bolted
The ~oor locks are screwed to the doors. to t,he body. The luggage compartment lid is counter-
The press button of the outer door handle operates balanced by means of a gas spring and can be set in
a lever which in t,urn lifts a locking pin . The door any desired position when opening. The locking de-
opener inside the car is fitted in the inner door plate vice is fitted on the body below the lid and is of the
with screws. The ha.ndle transmits the movement to a turning type .
lever which lifts the locking pin by means of lin k The vehicle is also available with a ~un-roof. The
rods in the lock. On the front doors the lock mecha- roof is operated by means of a crank handile , which
nism is fitted in (I cylinder under the door hand le. is folded in the recess in the roof upholstery between
The wim:low winders consist of lifting arms with the sun visors when not in use.
toothed segments. The window runs in sliding grooves Any water that· penetrates the joint between the body
in the inner door plate and is set ~o the desired roof and sun-roof is collected in the inner roof plate
position by means of a lifting arm from the toothed and conducted away through four hoses taken through
segment with the assistance of a helper arm. the corner posts of the roof.

REPAIR INSTRUCTIONS
DOORS
Removing and fitting door stops
Remove the door panel in accordance with the
instructions under "Removing inner handles and up-
holstery". Then unscrew the screw between the door
stop and post, and remove the rubber sealing (see
Fig . 8-7). After this remove the three screws securing
the door stop to the door. The door stop can now be
taken out through the upper opening in the inner plate
of the door.
Fitting is in the reverse order.

VOLVO
103377

Fig. 8·7. Door stop

8:5
 Fig. 8-8. Front door
1. Support roller for door window
2. Screw for outer handJe
Removing and fiHing front doors 3. BoJts for door frame

Remove the door stop in accordance with the in-

structions under "Removing and fiNings door stops" .
Unscrew the bolts between the hinges and door. The
bolts are accessible when the door is opened. The
door can then be taken off (Fig. 8-8).
In order to remove the hinges the panel in front of
the door has to be taken off. When this has been
done, the three bolts are unscrewed, after which the
hinges can be removed.
Th .. door and hinges are fitted in the reverse order
Concerning fitting the door stop, see under "Remov-
ing and fitting door stops".
Since the holes in the hinges and in the attachment
between the door hand hinges are oval, the door can
be adjusted laterally. The door can be adjust vertic-
ally and sideways in the attachment between the
hinges and door post. This is possible since the holes
in the door post are larger than the diameter of the
bolts.

Removing and fiHing rear doors

See the corresponding section abov~ and Fig. 8-9. Fig. 8-9. Rear door

8:6
 ·.

Fig. 8-10. Removing winding handle Fig . 8-11. Lalch plale

A. Front door 1.5 0

Rear door 2.5 0

Removing inner handles and upholstery outer hand le pressed In, when the door latch should
1. Remove the armrest in the front door by taking out slide correctly into the latch plate. The I,atch plate
the two plastic plugs with a narrow screwdriver should have an inward incl ination of 1.5 for the
and removing the attaching screws located on the front doors and 2.5° for the rear doors, see Fig. 8-11.
inside. Then turn the plastic ring at the front edge
of the arm rest several turns to the left, push the Removing front door lock
armrest forwards and the hook at the front edge
1. Carry out operations 1-3 under "Removing Inner
disengages leaving the armrest to be removed.
handles and upholstery".
The armrest in the rear door is removed by taking
2. Remove the lock cylinder by unscrewing the attach-
out the plastic pl1ugs and undoing the attaching
ing screw which is fitted in the rear edge of the
screws.
door.
2. Remove the window winding handle by pressing
3. Remove the locking for the pull rod locking knob
in the washer towards the door upholstery and
and take out the pull rod.
then towards the handle in the same direction as
4. Remove the locking for the inner door opener
the handle as shown in Fig. 8-10. This re leases the
push rad.
spring clip and the winding handle can be taken
5. Remove the locking for the outer hand le pull rod.
off.
6. Unscrew the two screws for the rear winder roil
When fitting, make sure that the spring clip is
on the edge of the door.
fitted so that its open end faces towards the wind-
7. Unscrew the three screws for the door lock. These
ing hand le as shown in Fig. 8-10.
screws are placed on the rear edge of the door.
3. Remove the door upholstery by inserting a screw-
8. The lock can then be removed by carefully levering
driver or similar under the upholstery edge and
the rear winder roil forwards.
carefully levering outwards so that the upholstery
comes away.
Removing rear door lock
Latch plates 1. Carry out operations 1-3 under "Removing Inner
The latch plate is made of steel and is fitted with a handles and upholstery"'.
floating nut plate. The latch plate is adjustable since 2. Remove the locking for the pull rod locking knob.
the holes in the body are larger than the diameter of . 3. Remove the locking for the inner door opener
the af;taching screw. push rod.
The vertical position of the latch plate is controlled 4. Remove the locking for the outer handle pull, rod.
by closing the door with the press button of the 5. Wind down the window so that its lower edge

8:7
 comes level with the upper ed ge of the door FiHing and adjusting front door lock handle
lock. When fitting the inner door opener this is adjusted
6. Remove the weather strip for the door frame.
a s follows:
7. Unscrew the attaching screws for the door frame
Fit the inner door opener with out tightening the
and lift it off. screws. Attach the link arm to the lock and fit the
8. Unscrew the ' attaching screws f~r the door lock
spring . By the fact that this spring is fitted, the inner
and rem OVE!" the lock from the door. The attaching
d oor opener is in its correct position so that the
screws for the lock are placed on the rear edge
screws can now be tightened, see Fig. 8-12.
of the door. When fitt ing the outer door hand le, this is adjusted
as follows:
Removing lock handles Fit the hand le with the link arm on it. Then adjust the
When removing the lock handles, the door panel must link arm so that the loop falls easily on the pin on
be re~oved (see under, "Removing inner handles and the lock lever, see Fig. 8-12.
upholste ry"). In order to remove the inner door
opener, it is first necessary to remove the clip for the FiHing and adjusting rear door lock handle
push rod of the lock. The return spring is then taken When fitt ing the inner door opeher, this is adjusted
off. After the s~rews holding the inner door opener as follows:
have been removed, the door apener is pulled down- Fit the inner door opener without tightening the
wards at the same time as the hand le is jerked loose screws. Attach the link arm to the lock and fit the
from the lever. spring. By moving the inner door opener forwards
The outer handle is removed by first taking off the
clip for the pull rod of the lock. The two screws for
the hand le are then unscrewed, the front one of
which is placed inside the door and the rear one on
the edge of the door.

'.........-- 6

Fig.8·12. Front door lock

l. Ouler handle
2. Pull rad for inner lock knob
3. Lever
4. Lever
5. Lever
6. Pull rad for ouler handle
7. Locking device
8. Inner door opener

8:8
to its front stop and the tightening the screws it will
come into the correct position, see Fig. 8-13.
When fitt-i ng the outer doo r handle, adjust as follo ws :
Fit the handle with the link arm on it. Then adjust
the lin k arm so tha t the Ilower part of the loop has
a c1earance of 1 ± 1 mm (O.04 ±O.04" ) on the pin
see Fig. 8-13, after w hich the lin k arm can be fitted.
N. B. The c1earance between the link arm loop and VOLVO
105061
pin must never be less than this amount.
, ,

Removing front door frame Fig. 8·14. Measurement for front side door A= 78.5 ± 2 .min
1. Wind down the window so that it comes near the (3.1 ± 0.08")
bottom position .
2. Remove the door panel in accordance with the Removing front door winding window
instructions under "Removing inner handles and 1. Carry out operations 1-5 under "Removing front
upholstery" . door frame" .
3. Unscrew t he attaching screws for the bracket for 2. Remove the guide roller for the window. The
the lower attachement of the front guide roil and quide roller is placed at the upper edge of the
remove the bracket. door as shown in Fig. 8-8.
4. Remove the sealing strip which runs round the 3. Remove the I,ocking springs and washefs between
door frame . the slide roil and lifting arms. These springs can
5. Remove the two attaching screws on the rear be removed by pressing them ri ght in and then
edge front edge respectively. The door frame releasing them, after which they can be taken
can be removed by lifting it straight up. off.
N.B. Take care that the window does not fall
Removing rear door frame down in the door. Even if the window is placed
See the corresponding section above. However, it is carelessly at the bottom of the door the ,s lide
not necessary to carry out point 3 when removing roil can damage the outer plate.
the rear door frame. 4. Withdraw the window from the pins in _ the
window winder, after which the window can be
lifted straight up.

Removing rear door winding window '.

See the corresponding section above.

Fig.8·13. Rear door lock

l. Outer hand le
2. Pu ll rad for ouler handle
3. Lever
4. Lever
5. Pu II rad for lock knob
6. In ner door opener

8: 9
 2. Remove the door panel in accordance with the
instructions under "Removing inner handles and
upholstery" .
3. Remove the attaching screws between the front
guide rail and bracket between the door and
bracket. Remove the bracket.
4. Remove the locking springs and washers for the
lifting arm. Begin by removing the spring in the
door slide. The springs are removed by pressing
the m right in and then releasing them, after whicp.
A
they can be taken off.
Fig. 8-15. Meosuremen! for reor side door A=169 ±2 mm N.B. Take care that the window does not fall
(6.7 ± 0.08") down into the door. Even if the window is placed
carelessly at the bottom of the door, the slide rail
Fitting a window in the window winder can damage the outer plate.
If the window winder is to function satisfactorily, the 5. Move up the winding window to the top position.
dimensions given in Figs. 8-14 and 8-15 should be Lock the window by placing a screwdriver under
folliOwed when fitting a window in the window winder. the slide rail in the upper rear clip hole for the
door upholstery.
6. Remove the attaching screws for the window
Removing ventilation windows ';:'inder, see Fig. 8-8, and remove it from the door,
l. Carry out operations 1-5 under "Removing front see Fig . 8-17.
door frame.
2. Remove the grooved strip from the front slide
rail of the winding window and unscrew the Removing rear door winder
screws which hold the plate under the ventilation Proceed in the same way as described above. How-
window. Then unscrew the screws on the opposite ever, point 3 does not need to be carried out when
side and remove the p~ate . removing the rear door window winder.
3. After the rubber strip round the ventilation window
has been removed from the groove all round,
the window with strip can be taken off, see
Fig. 8-16.

Removing front door window winder

1. Wind down the window so that it comes near the
bottom position.

Fig. 8-16. Door frome Fig. 8-17. Winding mechonism

8: 10
 SYU 2739

Fig. 8.18. Tools for gas spring

VOLVO
101845

Fig . 8-19. Lock for luggage compartment lid

l. Lock catch, fitted in lid
2. Lock mechanism, fifted in rear section
3. Lock knob, fitted in rear seclion

LUGGAGE COMPARTMENT LID To remove the lock, unscrew the two bolts under the
upper edge of the rear section, after which the lock
The luggage compartment lid is mounted on two
can be taken off. The I,ock is adjustable longitudin-
hinges, both of which are attached by means of two
ally since the bolt holes are oval.
bolts to the inner plate of the lid and with three bolts
The lock knob is removed by unscrewing the large
to the pillar under the rear window.
slotted nut inside the luggage compartment. The lock
The luggage compartment lid is counter-balanced by
knob can then be pulled out backwards.
means of gas springs.
The luggage compartment lid is remoyed by un-
screwing the two bolts on each hinge and lifting it
off. SUN-ROOF
When replacing the gas spring, the lid is first opened Removing the cable
fully. It is then lowered slightly and clamp SYO 2739 l . Open the sun-roof and release the clips securing
applied and the lid opened fully again, after which the roof upholstery at the front end. Then move
the gas spring can be removed. When fitting a new the upholstery back to leaye an opening.
gas spring, press tool SYO 2744 is used as shown in 2. Crank the sun-roof forwards and slacken the
Fig. 8-18 in order to enable clamp SYO 2739 to be screws at its four attachments (9 and 11, Fig. 8-20).
fitted . Fitting is don e in the reverse order. Bend the blade springs (10) to the one side and re-
When removing the hinges, first remove the gas move the reinforcing plates (13) at the rear attach-
springs as described above. The lid is then remoyed ments. Lift off the sun-roof.
from the hinges and after this the hinges from the 3. Remove the wind deflector (2).
body. 4. Remove the intermediate pieces (8), covering strip
The holes in the part of the hinges which fits on the (3) and holders above the drive. Release the front
luggage compartment I,id are oval in order to permit guide rails (6) and pull out the cables (S).
longitudinal adjustment. For yertical adjustment the
holes in the part of the hinges which fits in the body Fitting of cables
are oval. l . Fit the cables so that the attachments for the sun-
The locking deyice (Fig. 8-19) is fitted in the rear ro of come opposite each other, and at the rear
section and is released by turning the lockable knob. end of the roof opening. Screw on securely the
The lock catch on the lower edge of the lid is adjust- front guide rails.
able in order to permit variation of the closing ten- 2. Fit the intermediate pieces, holders and covering
sion of the lid. plate.

8 : 11
 3. Fit the wind deflector. now point straight forwards in the vehicle when
4. Screw on the roof securely and put back the leaf the sun-roof is completely closed.
springs. 8. Put back the upholstery and test the function of
5. Crank the sun-roof forwards until it is completely the sun-roof.
closed and check that it is level with the roof. To
adjust vertically, use the front attachments (9) Replacing the seaHng strips
and the lifts at the rear attachments (11). Also The sun-roof must be removed In order to replace
check that both the lifts stand straight up when the the insulating strip and sealing strip there. See points
roof is dosed. l and 2 under "Removing the cable".
6. Unscrew the crank and ge ar housing (4). Turn the When replacing the insulating strip round the roof
crank to the stop position on the removed gear opening of the sun-roof, all that is required is to crank
housing. the ro of back to its rearmost position.
7. Fit the gear housing and crank. The crank should

Fig . 8-20. Sun roof

A. Rea r atta chm e nl w he n roof is op e n

B. Rea r alla chmen t w hen roof is cl osed
1. Drai n hose 8. Inlerm ediale piece
2. W ind d efl eclor 9. Fronl a ttac hm e nl
3. Coveri ng stri p 10. Blade sp ring
4. Crank ho usin g wilh crd nk 11. Rea r allac hme nl
5. Cables 12. Rear adiu slme nl
6. Fron l guide ra il 13. Re info rcin g pl a le
7. Fro nl ad iu slmenl

8: 12
 GROUP 84

SEALING STRIPS,
TRIM MOULDINGS AND GLASS
REPAIR INSTRUCTIONS

TRIM MOULDINGS
SEALlNG STRIPS
The sealing strips are secured by means of spot- Waist moulding·s
The waist mouldings are attaf hed with plastic clips.
welded fastening rails.
The mouldings are removed with the hel p of a
A sealing strip is removed by pulling it outwards,
wooden putt Y knife with which they are carefully
when the ridge of the strip releases from the rai!.
levered off. The clips can be removed by carefully
When fitting the sealing strip, one of the ridges is
pul:ling them off with pliers.
placed in position in the rail, the other ridge is then
When fitting, begin by placing in the clips and lock-
pressed down into the rail with the help or a wooden
ing them by pressing in the stud in the middle. The
putt Y knife. This is moved along the rail as shown in
moulding is then pressed onto the clips.
Fig. 8-21 .

Removing the windshield moulding

The windshield moulding is fixed by means of clips
pressed into the slits in the windshield opening in the
body.
The moulding can, for example, be suitably removed
with a steel puttY knife. Insert the knife between the
windshield and moulding opposite a clip, see Fig. 8-22
Then prise the moulding loose.

Fig . 8-22. Removing the trim moulding

Fig. 8·21. Fitting the sealing strip

8: 13
Fitting hold it there while pulling the leather cord out up-
wards over the moulding so that it is pressed against
fit the windshield moulding by pressing it in between
the rubber strip as shown in fig. 8-24. Push over the
the body frame and the clips. To ensure that the
joining pieces and repeat the procedure with the
moulding coincides with the corner joints, fitting
other half of the moulding . Adjust the position of the
should be done in the following order. first, fit the
joining pieces over the joints.
lower moulding with a corner joint on. Then fit a side
moulding also with a corner on. finally, fit the remain-
ing moulding together with corners and on to the
body frame .

Removing the trim moulding for rear window

l. Remove the moulding from the rubber strip by
inserting a moistened nylon putt Y knife and mov-
ing it all round between the strips (do not pull
off the trim moulding).
2. Push over the joining pieces to one of the halves
of the moulding.
3. Remove the trim moulding by levering out the
ridge of the rubber strip from the trim moul,ding
with a moistened wo oden putt Y knife and releasing
the trim moulding in the middle with another putt Y
knife as shown in fig. 8-23. lever off the moulding
carefully while releasing the rubber strip with the
other puttY knife.

Fig. 8·24. Filling the trim moulding

WINDSHIELD
Removing the windshield
l. Place protective covering over the hood and front
seats.
2. Remove the windshield wipers arms.
3. Remove the externai trim moulding. See "Removing
windshield moulding".
VOLVO 4. Unscrew the inner covering strips and rearview
24814
mirror.
Fig. 8·23. Removing the trim moulding
5. (ut the windshield loose with a warm soldering
Iron.
Insert the point of the iron in between the wind-
shield and the body, from the inside of the
vehicle, see fig. 8-25. Then draw the soldering iron
all round the windshield. The windshield can now
Fitting the trim moulding for rear window be pressed out by hand. (ut off any remaining
Moisten a 4.0 mm (5/32") leather cord in soap solu- strands with a knife.
tion or paraffin and place it in the groove of the 6. (Iean the body (also the windshield if it is to be
rubber strip for the trim moulding. refitted) of any tape.
Place one half of the trim moulding in position and 7. Remove any defective clips.

8: 14
 mediately before the windshield is installed . Be
careful not to dirty or touch the adhesive surface
of the tape.
8. Use a glass lifter for fitting the windshield. Two
men are required to fit the windshield. It must be
carefully fitted in the opening before being placed
against the tape. Once the windshield has been
placed in positio n, then adjusting possibilities are
very small. The windshield must not lie against
any clip.
9. Fit the fixture SYO 2899 and press the windshield
firmly in position. When the outer plane of the

~vo
windshield lies l ± 1.5 mm (0.04±0.06") from the
_------ 104304 outer edge of the body, then the windshield is in
Fig. 8·25. Removing the windshield the correct position . Let the fixture remain about
45 seconds.
10. If the butyl tape is squeezed outside the edge of
the windshield on its inside, cut it off with a
warm knife.
Note: If any part of the painted edge on which
the butyl tape is fitted is seen through the wind-
Fitting the windshield
.
l . Inject sealing agent into the ho les where the new
shield from the outside of the vehicle, apply
sealing agent 686275 to these points. This is only
clips are to be fitted. Use pump No. 210163. required for light-colored vehicles
2. Fit new clips. 11 . Fit the outer trim moulding, see "Fitting the
3. Clean weil the surfaces where the tape is to lie on windshield moulding".
the body and windshield . Use ethyl or methyl 12. Fit the inner cover strips and rearview mirror.
acetate for the cleaning. Be careful not to touch 13. Fit the windshield wiper arms.
the cleaned surfaces.
4. Coat the clips with sealing agent No. 686275 so
that the agent forms a smooth bridge between REAR WINDOW
the clips and body for the butyl tape to seal Rlemoving the rea,r window
against. 1. Remove the trim mouldings as described in opera-
5. Coat adhesive on the cleaned surfaces on the tions 1-3 under "Removing rear window mould-
body and windshield. Coat an edge between 18 ing".
and 21 mm (3/4 and 7/8") in width round the wind- 2. Remove the cables for the electrically heated rear
shield, measured from its outer edge. Apply the window.
adhesive twice to ensure total coverage . Any 3. Release the rubber strip both from the rear window
adhesive spill on the body or glass surfaces can and sheet metal by inserting a wooden putt Y
be removed with methyl acetate. The adhesive knife moistened in synthetic washing solution (the
can be applied with in 5 minutes after the cleaning. puttY knife should be moistened now and then
6. Fit both the spacers on the lower edge of the during the course of the work) between the rub-
windshield opening. They should lie between the ber strip and rear window and between the rubber
2nd and 3rd dip from each windshield post. strip and sheet metal respectively and moving it
7. Fit the butyl tape on the body not less than 10 all round .
minutes and not more than l hour after the 4. Start removing the rubber strip in the upper left-
adhesive has been applied. Roll the tape round hand corner by levering the rubber strip over the
the whole of the windshield opening with the edge of the sheet metal from inside and at the
protective paper on . The joint should be opposite same time carefully pulling out the strip from out-
one of the side posts and the joint ends should be side with a pair of wide-nosed grips. Then care-
cut at an angle. fully pull off the strip by hand al,1 round and
The tape is best cut with a heated knife. ref110ve the rear window.
Place the tape ed ge to edge with the spot-welded Remove all sealing compound from the sheet
flange. The tape profile may not be altered by metal. If it has dried on, first carefully scrape off
stretching. The protective paper is removed im- the sealing compound and then wash clean with

8: lS
 naphtha. Check that the sheet metal edge is not
deformed. If the sealing compound has not dried
on, clean the rubber strip with naphtha, otherwise
replace it

Fitting the rear window

1. Moisten the outer edge of the windscreen and fit
the rubber strip starting at one of the corners.
Adjust the strip so that it lies correctly all round.
2. Fit a cord (preferably of terylene) of a suitable
size in the groove of the rubber strip for the VOLVO
2~822
sheet metal edge, beginning at the top center as
Fig. 8·27. Fitting the rea r window
shown in Fig. 8-26.

cord is difficult to pull out, this may damage the

strip, in which case the rear window shoulld be
stuck from inside or outside with the palm of the
hand if the rubber strip does not "creep" over the

j; 4.
edge of the sheet metal properly.
Check that the rubber strip seals weil all round.

I/ If necessary adjust the position of the rear window

both vertically and laterally by striking with the
palm of the hand.
5. Seal the joints between the rubber strip and rear
VOLVO window and rubber strip and sheet metal with
24817
Fig. 8·26. Placing card in rubber strip sealing compound using a gun with a flat nylon
nozzle. Make sure that the sea l1ing compound fills
the joint weil. Scrape off surplus sealing compound
3. Place the rear window in position with the rubber and wash the rear window and sheet metal with
strip fitted. Wearing working gloves, carefully strike naphtha. Clean the rear window and sheet metal
the rear window a few blows with the palm of the around it with polish.
hand so that it makes good contact all round. 6. Fit the trim mouldings as previously described.
Then carefully pull out the cord from inside. This 7. Fit the cables for the electrically heated rear
will cause the rubber strip to "creep" over the window.
sheet metal edge as shown in Fig. 8-27. It may
sometimes be necessary to adjust the position of REAR .QUARTER WINDOWS
the rear window with the palm of the hand. If the See the corresponding section under rear window.

8 : 16
 GROUP 85

U PHOLSTERY, INTERIOR
EQUIPMENT AND HEATING SYSTEM
DESCRI PTION
INTERIOR FITTINGS AND UPHOLSTERY 80th front seats are fitted with restraints which can be
adjusted vertically.
Front seats
The front seats (Fig. 8-28) are built up on a tubular
frame . The stuffing consists of foam plastic covered Rear sea t
with c1oth . The seat can be adjusted longitudinally by The rear sea t and backrest are built up on the same
releasing the catch on the front side of the sea t principle as the front seats, although in this ca se the
(driver's side) or the outside of the seat (passenger's sea t has a wooden fra me.
side) and sliding the seat to the desired position . The
driver's seat is adjusted vertically with the lever Door upholstery
placed in front of and under the se at. The passenger's
The door upholstery consists of wood-fibre sheeting
seat is adjusted vertically by means of the rear
lined with non-woven padding and covered with up-
attachments which have been provided with three
holstery material. It is secured to the door by means
holes. 80th seats are inclined to the desired angle by
of clips. The armrests are made of moulded plastic
means of a screw at the front end. The backrest in-
and are screwed to the inner plate of the door.
clination IS variably adjustable by pulling up the lever
on the reclining mechanism, whereby the backrest is
Headlining
tiJ.ted forwards by means of springs or tilted rearwards
by leaning backwards in the seat. The front seats are The headlining consists of plastic fabric stretched on
provided with an adjustable lumbar support, the ten- roof ribs and secured in retainers fitted on the upper
sion of which can be adjusted by means of a knurled limit of the body sides.
knob located on the inner back rest side. The seat
cushions are fastened to the sea t frame by means of Covering for firewall and floor
press studs. The sides of the firewall are lined with millboard
while the bulkhead itself is covered with self-adhesive
insulating material. The floor is covered with carpets.

HEATING SYSiTEM
The heating system is a combined warm air and fresh
air system. The incoming air is forced, by a fan,
through the cellular system of the heater unit and
out into the car. The fresh air can be heated and
directed to the required area of the car by means of
the various controis.
(Fresh air can 0150 enter into the vehicle through the
fresh air intakes in the cowl sides.)
Good compartment ventilation is further improved by
air extractor vents located at the base of the rear
window. These vents have a total area of 50 cm 2 (7.8
sq.in.), see Fig. 8-30.
The temperature of the heated air is regulated by
means of a heat controi valve. The heat controi valve
is intElnded to keep the temperature of the heated
air at a pre-determined and constant temperature.
VOLVO
105140 This is achieved by means of the thermostat which is
Fig. 8-28. Fron! sea! incorporated in the controi valve . The temperature

8: 17
 2 3 4 5

VOLVO
103287
Fig . 8-29. Heater system
1. Fresb air intake 4. Air ducting to rear sea t area
2. Car heater 5. Electricall y heated rear window
3. Windshie ld defroster

controi regulates the supply of heated coolant to the thus acting on the valve in the controi system and
cell system. The heater controi valve is connected in resulting in a lesse r flow of coolant. This means that
series with the cell system so that all coolant which the temperature of a ir flowing through the unit will
passe s through the cell system also passes through be lower and the sensitive body will again be
the controi valve . The heated coolant warms up the effected. The result wiLl be an increased flow of
air which is fed through the heater unit by the heater coolant. This cycle is repeated continuosly so that a
fan or the slipstream . If the coolant temperature in- stable air temperature is achieved.
creases, the sensitive body of the thermostat expands The electrically heated rear window is included in the
heating system of the ear. The degree of heat is con-
trolled by a switch on the dashboard with which one
of two output ranges can be chosen. The one range
has a max. output of 150 watts and the other that of
40 watts. The controi switch is connected via a controi
relay (see wiring diagram) which cuts off the supply
of current when the ignition is switch ed off. This
1-- --\' safeguards the battery from discharging when the
engine is not turned over. See Group 84 concerning re-
placing rear window.

2- --1/

Fig. 8-30. Air exlraclor vents

1. Rear window
2. Inner pa ne l
3. Non-return va lve Fig. 8-31. Wiring diag ram for electrically heated rear window

8: 18
 REPAI R I NSTRUCT IONS

SEATS
Removing the front seats
Unfasten the press-studs which hold the seat cushion
to the frame and remove the sea t cushion. Unscrew
the four attaching screws for the slide rails. Lift off
the seat.

Adjusting the front seat

VOLVO
l . The inclination of the seat adjusted with the
IS 101847

Fig . 8·33. Removing the roof stretchers

eyebolrt at the front edge of the seat. Slocken the
adjusting screw and adjust the eyebolt to the
desired position.
7. Strech the headlining forwards and tuck in the
2. The height of the seat is adjusted by attaching the
plastic strip at the front edge.
rail in a suitable hale in the brocket.
8. Then stretch the headlining backwards hy pulling
both ends of a stretcher at the som e time. Begin
at the front and pull on each stretcher working
backwards, after which the rear plastic strip can
REPLACING THE HEADLlNING be tueked into its groove.
l. Remove the inte rior light, sun visors, and rear 9. Now pullover the headlining towards one side
view mirror. and tuck in the plastic strip. Then stretch the head-
2. Pull down the edge of the headlining with finger lining over towards the other side and tuck in
and thumb on one side as shown in Fig. 8-32 so the plastic strip .
that the plastic edge can be released from its 10. Fit the interior light, sun visors and rearview
fastening in the rail. mirror.
3. Then pull down the headlining all round . 11. Any folds in the fabric can. be removed by pul,ling
4. Take down the stretch ers beginning from the back the headlining in the necessary direction . The
by bending them down in the middle and releas- headlining then moves in the attaching rails.
ing them from the edge of the roof as shown in
Fi g . 8-33. N.B. Be careful when removing and
fitting the stretchers. Careiess handl1ing can cause INSTRUMENT PANEL
the ends to damage the roof plate.
Removing the instrument panel
5. Fit the stretchers in the new headlining. Make sure
that they are provided with rubber caps at the The instrument panel is attached to the body with
ends as shown in Fig. 8-34. screws. These are accessible partly from above at the
6. Fit the headlining by first inserting the stretchers edge of the windscreen and partly from underneath
beginning with the front one. at both sides of the panel.

VOLVO
101848

Fig. 8·32. Removing the headlining Fig. 8·34. Headlining

8: 19
HEATING SYSTEM
Removing the heater unit
Drain off the coolant and disconnect the negative
battery lead. Remove the hoses to the controi valve.
Remove the panel, below the dashboard, by loosening
the two fixing screws, one on the left cowl side and
one beside the glove compartment. Pull the upper
section of the panel rearwards so that it loosens from
the clips in the dashboard and free the panel from
the bonnet release controI. Remove the mat on the
transmission tunnel. Loosen and remove the defros-
ter hoses · ~nd controi wires and remove the switch
for the fan and disconnect the cables to the fan
motor.
Remove the two screws which hold the fusebox to the Fig . 8·36. Removing spring cl ips
heater. Remove the contral valve and loosen the
upper hose to the heater unit. Care must be taken
with the controi valve and the copper tube between Disma ntling the heater unit
the valve and the heater. Plug the outlets on the Remove the four rubber bushes on the sides of the
heater so that the remaining coo~ant does not run heater, Fig. 8·36 and separate the two halves. This
into the car on removal. Loosen the ground cables . sembly. Remove the spring clips which hold the
from the right-hand bracket. Loosen and remove the heater, Fig. 8·33 and separate the two halves. This
four screws which hold the heater unit to the brackets exposes both the cell system with sensitive body for
and loosen the draining hose. Lift out the heater unit contra I valve and the fan motor.
and controi valve carefully.

Replacing the fan motor

Remove the heater unit and dismantie it as described
above. Mark the mounting plate in relation to the fan
casing . Loosen the mounting plate with fan motor
from the fan casing by straightening the tabs as
shown in Fig. 8-37.
Remove the screws which hold the fan motor to the
mounting plate. Exchange the fan motor and replace
the screws which hold it to the mounting plate. Re-
place the mounting plate on the fan casing .
Reassemble the heater unit and mount it in the ve-
hicle in accordance with the following description .

Fig. 8·35. Healer unit, dismantled

1. Heat confrol valve 6. Spring clips
2. Heafer casi ng 7. Heafer casing
3. Cell sysfem 8. Rubber bushing
4. Fan casing 9. Sensifive body for VO LVO
103290
5. Fan heat confrol va lve Fig. 8·37. Dismantling the mounting plate

8: 20
 dashboard. Fit the hoses to the controi valve. Con-
nect the ground battery cable and refill the coolant
system.

Removing the heater unit controls

The controls are of unitary design as shown in Fig.
8-39. The unit is fixed to the dashboard with three
nuts. For removal, first loosen the panel below the
dashboard. Next loosen the wires on the heater unit
and controi valve. The controi lighting lamps are re-
moved by puUing them straight out from the holders.
Remove the three nuts and take out the controi unit.
VOLVO
103291
Fig. 8-38. Fan motor

Assembling the heater unit

Scrape off the previous sealing agent and replace if
with a suitably soft sealing agent. Fit the cell system
with sensitive body and reassemble the casing halves.
Replace the spring clips and the rubber bushings.

FiHing the heater unit

Place tpe heater unit in position and connect the
drain hose. Fit the four screws which hold the
heater to the braekets. Connect the ground cables to
the right-hand braeket. Fit the contrei valve and the
upper hose to the heater. Fit the fusebox to the
heater. Connect the cables from the fan motor to the
switch and mount the switch in the dashboard. Fit the
controi wires to the shutters and controi valve. Fit
the defroster hoses and replace the mat on the trans- Fig. 8-39. Heater unit controls
l. Heat con1rol valve 4. Heat control, floor
mission tunnel. Fasten the panel in position below the 2. Heater con1rol 5. Hoses to defroster nozzles
3. Defros1er controi

8: 21
 GROUP 86

BUMPERS
The bumpers are made of alumin ium and are In one Removing and fitting
piece. They are faced with a hard-rubber strip Ylhich is The front bumber is removed by unscrewing the bolts
fitted in the bumper rail by means of screws. The inside the bumper. The support bars are removed at
bumpers are mounted on four support bars, the front the front frame membe rs.
ones of which are attached to the front side members The rear bumper is removed by unscrewing the bolts
and the rear ones fitted directly in the body. between the support bars and body. The support
bars can then be removed from the bumper by un-
screwing the bolts inside the bumper.
Fitting is done in the reverse order.

8: 22
2 O

8 O 600 400 1000 1200 1400 1600 1800 000 200 400 2600 2800 000 3200 00 3600 8~0
VOLVO
103344

Illustration 8 A. Controi for body flor

A = Max. deviation fram theoretical position fer hole group = 1.5 mm (0.06")
B = 227±1 mm (8.9±0.04") . L = 200 mm (7.9") plane of steering box
C = Max. deviation between these flanges and t he Z·direction±l mm (0.04")