Volvo 164 Operating instructions

instruction book
VOLVO 164
Operating Instructions
Description
Servicing
Reprinting permitted if source quoted
FOREWORD
Before you start driving your new Volvo
please read through this instruction book
carefully. It contains all the information
you need to be able to drive and service
your vehicle in the best possible way. By
following the instructions given in this
book, you will find that your Volvo will
come up to all the expectations concern2
i ng economical operation and excellent
performance that you have every right to
expect of a top-quality vehicle.
This instruction book is not intended to
be a comprehensive technical manual and
does not claim to make the reader into a
perfect car mechanic. It will, however,
show you how to look after your vehicle
so that trouble in the future can be avoided. The better you know your Volvo, the
better service it can give you. Even for an
experienced motorist this book can contain some valuable information. For a
more detailed mechanical description as
well as repair procedures, we refer you
to the special Service Manual for the car.
CONTENTS
SERVICING
INTRODUCTION
Volvo Service Organization
Warranty and Service Booklet
Type Designations
4
4
5
OPERATING INSTRUCTIONS
Instruments and controis
Interior and body
Starting and driving
Running-in
Starting the engine
Gear-changing
Towing
Braking
6
14
19
19
20
21
23
23
General
Maintenance scheme
Lubrication
Oil changes
Engine
Electrical system
Power transmission
Brakes
Front end
Wheels and tyres
Body
Servicing before a long-distance trip
Procedure in cold weather
Lubricating chart
FAUL T TRACING
When the engine stalls
56
SPECIFICATIONS
TECHNICAL DESCRIPTION
Engine compartment
Engine
Power transmission
Front end and steering
Electrical system
Brakes
33
34
36
37
41
44
49
49
50
50
52
54
54
62
24
25
26
29
30
32
Measurements and weights
Engine
Electrical system
Power transmission
Front wheel alignment
Wheels and tyres
Capacities
57
57
58
59
59
59
59
3
I NTRODUCTION
Volvo Service Organization
To get the most out of the invested capital
represented by a car, it must be looked
after and serviced regularly. Volvo has
gone to a great deal of trouble in the
design and selection of material to ensure that the car in question only requires
a minimum of servicing. We rely, however,
on your co-operation with regard to the
future maintenance of your vehicle. To
help you with this, Volvo has built up a
world-wide service organization. All Volvo
dealers have specially trained personnel
and receive a continuous supply of technical information from the Volvo Service
Organization concerning repairs and adj ustments. They have also special tools,
designed at the Volvo factory. Moreover,
all Volvo dealers have a comprehensive
stock of spare parts which is your guarantee for genuine Volvo spares. That is why
our dealers are in the best possible position to give your vehicle first-class ser4
vice concerning both maintenance operations and repairs. You should also refer
to your dealer for any information about
your Volvo that is not included in this
i nstruction book.
I n addition to having a Volvo workshop
within easy reach, in your own country,
Volvo has also a widely distributed service
network in other countries.
I f our six-month, guarantee is to apply,
we make one absolute condition and that
i s that the above-mentioned cost-free inspection is carried out at roughly the
mileage shown and that the vehicle has
been looked after in accordance with the
i nstructions given in this book.
Service Inspections
Warranty and Service Booklet
A warranty and service booklet accompanies each vehicle when it is delivered.
This booklet contains a coupon entitling
you to a free service inspection after 2,500
km (1,500 miles) running. If possible, let
the dealer who supplied the vehicle carry
out this service inspection. Any of our
dealers, however, can do this if required.
After the cost-free service inspection has
been carried out, you should make an
agreement with your dealer , concerning
continued, regular service inspections in
accordance with the suggestions made in
our Service Book. Thorough and regular
servicing is of vital importance for the
performance and length of life of the vehicle.
Always use genuine Volvo spares.
I NTRODUCTION
Type designations
I n all correspondence concerning your
vehicle with the dealer and when ordering
spare parts, the type designations, chassis
and engine number should always be
quoted.
1. Vehicle type designation, code numbers for colour and upholstery; on bulkhead.
2. Body number.
3. Type and model designation and
chassis number; stamped on right door
pillar.
4. Type designation, serial number and
part number of engine; stamped on
engine left-hand side.
5. Type designation, serial number and
part number of gearbox; underneath
gearbox.
6. Number of final drive gear teeth and
reduction ratios; on a plate on the
l ower part of the inspection cover.
5
OPERATING INSTRUCTIONS
6
OPERATING INSTRUCTIONS
I NSTRUMENTS AND CONTROLS
1.
Windscreen wiper and washer switch
2.
Fog light switch
3.
Choke control
4.
I nstrument panel
5.
6.
Lighting switch
7.
Turn indicator switch, dimmer and
headlight flasher
Combined ignition switch and
steering wheel lock
8.
Fan switch
9.
Warning hazard flasher switch
Cigarette lighter
10.
11.
The instruments and controls are described in more detail in the following
pages with a reference to the numbers in
the picture opposite. Note that variations
may occur between different markets.
Heater/ventilation controls
12.
Ashtray
13.
14.
Place for radio and loudspeaker
Handbrake
15.
Fresh-air intake, left
16.
17.
Bonnet release
Switch for elec. heated rear window
18.
Clutch pedal
19.
20.
Brake pedal
Accelerator pedal
21.
Gear lever
22.
Fuses
23.
24.
Glove locker
Fresh-air intake, right
1 Windscreen wiper and
washer switch
The windscreen wipers are operated electrically and can be adjusted to two speeds.
Normal speed is attained by pulling the
switch out to the first position. This speed
i s recommended for driving normally in
rainy weather or snow.
When the switch is pulled out fully, the
wipers operate at full speed. Full speed is
only recommended when driving in heavy
rain or when driving at high speed when
i t is raining.
When the switch is pressed in fully, the
wiper blades stop in their parking position.
The windscreen washers are operated by
turning the switch clockwise. When rel eased, the switch automatically returns to
i ts starting position and shuts off the
washers. The washers can be used without
the windscreen wipers. The fluid container for the washers is located in the
engine compartment and holds about 1 1/2
litres (2 3/4 Imp. pints= 31/4 US pints).
2 Fog light switch
On certain markets the Volvo 164 is fitted
with 2 extra fog lights. These are switched
on by pulling out the fog light switch, providing that either the parking or dippedbeam lights are on.
Because of regulations on certain markets, the fog lights are connected across
the parking and headlights or only the
parking lights.
3 Choke control
The choke control is used when the engine is started from cold. When the control is pulled out about 10-15 mm (1/2"),
the idling speed is increased. Pulling the
control out further, enriches the fuel-air
mixture. This steps up the idling speed.
7
OPERATING INSTRUCTIONS
C Speedometer
The speedometer consists of a horizontal
scale marked in intervals of 20 m.p.h. The
speed is indicated by a red ribbon.
4 Instrument panel
A Panel light 'switch
A Panel light switch
B Fuel gauge
C Speedometer
D Coolant temperature gauge
Turning the knob clockwise or anticlockwise increases or dims the lighting on the
i nstrument panel.
E Speed warning indicator
F Warning light, charging
G Turn indicator control light
H Handbrake warning light (functions
also as warning light for both service
brake circuits)
I
Mainbeam control light
J
Oil pressure warning light
K Mileometer
L Trip meter
M Trip meter reset knob
8
D Coolant temperature
gauge
The temperature gauge shows the temperature of the coolant and thus indicates
the working temperature of the engine.
The pointer on this should normally remain within the green sector.
I t is permitted for the temperature gauge
pointer to enter the red-lined field during
town driving and idling when the weather
i s particularly hot.
B Fuel gauge
E Speed warning indicator
The fuel gauge indicates approximately
the amount of fuel in the tank. The gauge
i s graduated "full", "half", "reserve" and
"empty". The red field between "reserve"
and "empty" is a reminder that the tank
should be filled. When the gauge pointer
i s on "reserve" there are approx. 8 litres
(2 Imp galls=21/2 US galls) in the tank.
The speed warning indicator is mounted in
front of the speedometer and consists of a
manually adjustable sliding arrow. Its
purpose is to remind the driver of the
particular maximum permissible speed in
connection with speed limit regulations.
OPERATING INSTRUCTIONS
K Mileometer
F Warning light, charging
This lights red when the battery is discharging, which is normal at idling speed.
As soon as you accelerate a little, it
should go out. Should it light up during
driving, either there is some fault in the
electrical system or the fan belt is not
sufficiently tensioned and is thus slipping
on the alternator pulley, causing poor
charging.
G Turn indicator
control light
the car should be driven without delay
to a workshop for a check on the brake
system. Observe due care when driving
under such conditions.
I Mainbeam control light
This lights blue when the headlights are
switched to mainbeam by the switch
l ever (6).
L Trip meter
This lamp flashes with a green light when
the turn indicator switch is moved upwards or downwards and the ignition is on.
J Oil pressure warning light
H Handbrake warning light
(functions also as warning
light for both service
brake circuits)
This lights red when the handbrake is
applied and the ignition is on.
The light also functions as a warning light
should a failure arise in one of the brake
circuits. If the light goes on during driving,
The mileometer shows the total distance
covered in miles. After 999999 miles it
returns to zero and starts to go round
again.
This lights yellow when the engine oil
pressure is too low. When the ignition
i s switched on, the light should go on
and then go out again when the engine
starts. Never start driving until the light
goes out. If the light goes on during
driving, stop the engine and find out the
reason for this, In most cases it means
that the oil level is too low. After hard
driving it may happen that the warning
l i ght comes on when the engine is idling.
This is normal providing it goes out again
when engine speed is increased.
The trip meter measures distances of up
to maximum 999 miles. The window
furthest to the right is graduated in tenths
of a mile and can thus be used to measure
short distances.
M Trip meter reset knob
The trip meter is set to zero by pushing
i n the reset knob.
9
OPERATING INSTRUCTIONS
5 Lighting switch
The headlights are operated by means
of a push-pull type switch on the dashboard as well as a lever (6) on the
steering column.
All the lights are extinguished when the
l i ghting switch is pushed fully in. Pulling
i t out to the half-way position, switches
on the parking lights and when it is fully
out, the full or dipped headlights are
switched on, depending on the position
of the lever (6).
Since the lighting system is not connected
across the ignition switch, the lights will
function irrespective of whether the ignition key is in position or not.
On certain markets the Volvo 164 is fitted
with side lights. These are located on the
sides of the mudguards and are switched
on by pulling out the switch for the parki ng lights and headlights.
6 Turn indicator switch,
dimmer and headlight flasher
The switch lever on the left-hand side of
the steering column behind the steering
wheel controls the turn indicators, dipped headlight and headlight flasher. Movi ng the lever upwards, operates the righti ndicator, and downwards the left-indicator.
Switching from mainbeam to dipped beam
and vice versa is carried out by moving
10
the lever towards the steering wheel and
then releasing it. Here the lighting switch
(5) should be pulled out fully.
The lever is also used for flashing with
mainbeam when the headlights are not
switched. on. The headlight flasher is
switched on by moving the lever towards
the steering wheel and it remains switched on until the lever is released.
7 Combined ignition switch and
steering wheel lock
The switch has four positions; (0) Locking
position, (1) Garage position, (2) Driving
position and (3) Starting position.
The key can only be inserted or taken out
of the lock in the Locking position.
Removing the key automatically locks the
steering wheel.
On certain markets the ignition switch is
provided with an acoustical warning
buzzer. This buzzes to warn the driver
when the driver's door is opened that the
OPERATING INSTRUCTION
key has been forgotten in the ignition
switch.
Except for the engine ignition system, the
electrical system is switched on with the
key in the Garage position.
To start the engine, turn the key to the
Starting position and this automatically
engages the starter motor. As soon as
the engine starts, release the key which
automatically returns to the Driving position.
9 Switch for warning hazard
flashers
All the four warning lights start flashing
simultaneously when the switch is pull ed out. A control lamp mounted in the
switch blinks in unison. The warning lights
are not connected across the ignition and
therefore function irrespective of whether
the ignition key is inserted or not.
These warning lights should be used only
when you have to stop the car where there
i s possible danger to other traffic. Note
that regulations governing the use of
these lights may vary on different markets.
8 Fan switch,
The fan is operated by means of a pushpull switch which can be set at two different positions. Pushing the switch fully in
stops the fan, pulling it out to the first
position operates the fan at full speed
and when pulled out fully, the fan operates at half speed.
Due to the aerodynamic design of the
car, the overpressure in the air intake is
relatively small. Therefore, at speeds
below 80 km.p.h. (50 m.p.h.), the fan
should be allowed to operate at full
speed if maximum air capacity is desired.
On the other hand, however, the fan
should not be used if cooling air is
required on a hot summer's day. Instead,
open both the fresh-air controls (15, 24),
the defroster control "DEFR" and the
ventilation control "FLOOR".
10 Cigarette lighter
11 Heater/ventilation
controls
The control on the left, TEMP, regulates
the temperature of the incoming air.
The middle control, DEFR, regulates the
air flow to the windscreen. And the control
to the right, FLOOR, regulates the air
flow to the front seat and rear seat floor.
The temperature, also the air flow, is increased by moving the controls downwards whereby a red strip marked down
the middle of the control in question
i ndicates the size of the opening. Note
that when altering the temperature control, there will be a slight delay before
the desired temperature is reached.
To avoid mist on the windows, set the
fan and defroster controls at maximum
output and close the FLOOR control. The
fresh-air controls (15, 24) should be closed. Try to avoid water on the floor and
under the mats as this increases the humidity and thereby misting, particularly duri ng the wintertime.
To use the cigarette lighter, push it in.
The lighter releases automatically when
i t attains sufficient heat.
11
OPERATING INSTRUCTIONS
14 Handbrake
the handbrake lever is on the outside of
the driving seat and operates on the rear
wheels only. When the handbrake is
applied and the ignition is on, a red
warning light (4, H) shows on the instrument panel.
Remember that the footbrake warning
system is also connected to this light.
Should the light show when the handbrake is not on, this may be due to a
failure in one of the brake circuits. If this
i s the case, drive immediately (but with
due care) to a workshop for a check.
16 Bonnet release handle
The bonnet lock is released by pulling
out the handle situated to the left of the
steering column lower down on the dashboard.
This releases the bonnet which is still
retained by the safety catch.
The bonnet is opened by inserting the
fingers under its front edge and pressing
i n the catch as shown in the picture
15, 24 Fresh-air controls
Sliding the control forwards opens a
fresh-air intake on the driver's or passenger's side. Note that the fan should not
be operating if cool air is desired through
these intakes.
12
above. Raising the bonnet causes a light
i n the engine compartment to go on
automatically. Make sure that the bonnet
i s locked properly when closed.
The level of the bonnet can be adjusted
i f necessary by screwing out or in the
rubber plugs under the bonnet at the
front and on the mudguards.
OPERATING INSTRUCTIONS
17 Switch, electrically heated
rear window
I n order to obtain a clear view through
the rear window during cold and damp
weather, the Volvo is fitted with an electrically heated rear window.
Heating is by means of wires on the inside
of the rear endow. For this reason, avoid
placing anything on the rear shelf which
could damage the wires.
The switch has two positions. Pulled out
to the first stop, there is an output of
approximately 40 W, and when pulled out
to second stop, the output will be about
150 W. As long as the electric heating is
on, a warning lamp lights in the switch.
As soon as the rear window is free from
moist and ice, push in the switch, either
one stop or fully, in order not to overload
the battery unduly.
22 Fuses
The electrical equipment is protected by
a number of fuses housed in a compartment under the dashboard. If a fuse has
to be replaced, always make sure that
i t is replaced with a fuse of the correct
rating. If fuses burn out repeatedly, do
not replace with a fuse of higher rating
but have a workshop check the electrical
system.
On the inside of the cover of the fuse
compartment there is room for a number
of spare fuses.
Both fuses (8A) for the fog lights are
l ocated in a box in front of the relays on
the left wheel housing.
1. Windscreen wipers, washer
2. Horn, reversing lights
8A
8A
3. Heater fan, control relay for elec.
heated rear window
4. Warning lamps
I nstrument panel
Flashers
8A
5. Elec. heated rear window, overdrive
6. Interior lighting
Glove locker
Dimmer relay
Engine compartment lighting
Boot lighting
Acoustical warning buzzer
7. Brake lights
Safety hazard warning flashers
8. Left rear light
parking light
side light
I nstrument panel light
Number plate light
9. Right rear light
parking light
side light
5A
16A
5A
8A
5A
5A
13
OPERATING INSTRUCTIONS
I NTERIOR AND BODY
Front seats
Length and height adjustment,
Lumbar support
Backrest adjustment
driver's seat
The front seats are provided with an
adjustable lumbar support. This is operated by means of the knob on the inside of the backrest. To tension the lumbar support, and thus exert more pressure
against the small of the back, turn the
knob clockwise, "FIRM", and to relieve
the pressure against the small of the
back, turn the knob
anti-clockwise,
"SOFT".
Bench-type front seats have the knob
mounted on each side of the seat.
The front seat backrest is adjusted with
the lever on the outside of the backrest
(see picture). Lift up the lever, adjust to
the desired angle, and lock the backrest
there by pushing down the lever.
The backrest can be folded backwards to
a comfortable rest or repose angle.
The driver's seat can be adjusted forwards-backwards by lifting catch A upwards. Exert leverage with your feet on
the floor and slide the seat to the most
comfortable position. On bench-type
front seats, the catch is located at the
driver's seat.
Adjustment is made vertically by lifting
catch B upwards and then setting the seat
to one of the four height positions. If
necessary, the seat can then be adjusted
l ongitudinally.
14
OPERATING INSTRUCTIONS
Length and height adjustment,
front passenger's seat
The front passenger's seat can be adjusted forwards-backwards by pressing down
catch C on the outside of the seat. Vertically the seat is adjustable to three different positions. Remove the seat cushion
to get to the bolts in the seating bracket.
Remove the two bolts holding the seating
frame to the seating brackets. Place the
frame in the desired position and refit
the bolts in the suitable holes.
I n connection with this adjustment, it may
be desirable or necessary to adjust the
i nclination angle of the entire seat. This
i s done with the eyelet bolt at the front
under the seat frame. Remove the bolt
which goes through the eyelet screw and
fold the seat backwards. Then release
the lock-nut in the floor of the car and
adjust the eyelet screw to the desired
position. Relock securely the eyelet screw
with the locknut.
On vehicles with a bench-type front seat,
corresponding adjustments can be made
vertically.
The passenger's seat can be used facing
opposite the driving direction in order to
hold a safety seat for a child. This is
done by removing the four bolts holding
the seat frame to the sliding rails. Lift off
the seat, turn it back to front on the
slide rails and retighten the nuts. Note
that the lock fittings should remain on
the right-hand side in order to be able
to lock the seat.
Headrests
The front seats are provided with adjustable headrests. If the headrest is to fulfil
i ts function properly, it is important that it
i s correctly adjusted, that is, it supports
against the head and not only against the
neck. The car is delivered with the headrests adjusted to standard height. To adj ust slacken the plastic nuts on the headrest retainers. After adjusting lock the
headrest by turning the plastic nuts clockwise.
15
OPERATING INSTRUCTIONS
Safety belts
Always use the safety belt for all types of
driving. Remember that it is possible even
i n slow city traffic to incur serious injury
from sudden, unexpected stopping.
Automatic safety belts with emergency
l ocking retractors
The Volvo 164 is equipped with automatic
safety belts with emergency locking retractors. The practical construction of the
belt makes it extremely easy to use.
To fasten the belt, pull out the webbing
slowly. If the webbing is pulled out too
quickly, the emergency-locking retractor
reacts and stops the withdrawal of the
belt. Normally the safety belt retractor is
"unlocked". Locking takes place when the
16
webbing is pulled out rapidly or when the
car is braked suddenly. The retractor also
l ocks when driving on a gradient more
than 10.5° or when taking a fast corner.
Should the webbing lock when being
pulled out, slacken off slightly and then
continue pulling out more slowly to the
required length. Place one strap round
the waist and the other across the shoulder - chest and secure the belt by pushi ng the buckle tongue into the locking slot
i n the lock between the seats. An audible
clicking sound is a sign that the belt is
l ocked.
Make sure that the webbing fits comfortably across the body and is not twisted.
The belt is released by pulling up the
nearest lever in the locking device. Keep
hold of the buckle-tongue and let the
webbing roll back towards the door post.
Make a habit of letting the roller roll up
the webbing on removing the belt.
Safety belts in rear seat
On certain markets safety belts for three
passengers are installed in the rear seat.
The belts are of the lap type.
The belts are fastened by pushing the
buckle-tongue on one section of the belt
i nto the lock on the other and are rel eased by lifting up the "cap" on the lock.
To shorten the belt, pull in the upper part
of the lap strap, and to extend it, pull
i n the lower part.
OPERATING INSTRUCTIONS
Do not leave the keys in the car.
The door locks have been designed with
a view to providing maximum possible
protection against freezing during the
wintertime. As an extra measure, however,
you should lubricate the locks regularly
during very cold weather with a suitable
anti-freeze agent. If the lock is already
frozen, be careful not to break the key in
the lock. Instead, heat the key and immediately place it in the lock. This should
unfreeze the lock. Should you lose the
car keys, contact your nearest Volvo
dealer for new ones and quote the code
number of the keys which have been lost.
Do not let the belt lie on the floor otherwise it will get entangled and dirty as well
as hinder getting in and out of the vehicle.
Now and again check that the bolts anchoring the belts are properly tightened
and that the belt is otherwise in good
condition. Water mixed with some synthetic washing agent can be used for
cleaning the belt. If the belt is exposed
to violent stretching, for example, in connection with a collision, it should be replaced even though it may appear to be
undamaged. Also replace the belt if well
worn or damaged.
Never modify or repair the belt on your
own, but have this done by a Volvo workshop.
Doors and locks
Ventilation window lock
The car is fitted with a lock and keyhole
on each of the front doors.
All the doors can be locked on the inside
by pressing down the lock plunger on the
window ledge. On the front doors this
l ock plunger lifts automatically when the
door is opened from the inside. On the
rear doors, however, the lock plunger must
first be pulled up before the doors can be
opened from the inside. This is an advantage if children are alone in the back
of the car.
The front doors can be locked from the
outside by pressing the lock plunger on
the window ledge down and shutting the
door while pushing in the outside door
handle button. To lock the rear doors it
i s not necessary to push in the buttons.
To open the ventilation window first
slacken the small lock screw a couple of
turns, push it in and then turn the handle
forwards. On certain markets the window
i s opened merely by pressing in the button
and turning the handle.
Rearview mirror
The inside rearview mirror can be switched to anti-dazzle by pushing the knob at
the bottom sideways.
I f it is to fulfil its function well, the outer
rearview mirror on the passenger side
should be turned so that the arm is vertical.
17
OPERATING INSTRUCTIONS
I nterior lighting
Sun-roof
1. The light comes on when either front
door is opened.
2. The light is always extinguished.
3. The light is always on.
On certain cars, the Volvo 164 is available
with a sun-roof.
The sun-roof is opened and closed by a
winding handle. When not in use, the
handle is folded in the recess in the roof
between both the sun visors.
To close the sun-roof, wind it forwards
fully, then wind back the handle a little
and fold it into the recess in the roof.
18
Boot compartment
The boot lid is locked with the same key
as that used for the doors. The lid is opened by turning its handle clockwise and
lifting it at the same time. Note that the
key must be removed from the lock in
order to turn the lock knob. The lid is
balanced and will remain stationary in its
opened position.
The boot light goes on automatically
when the lid is opened. The spare wheel
i s securely held in position to the right.
The jack and tool kit are fastened to the
spare wheel. Under the boot floor to the
l eft there is space sufficient for an extra
spare wheel , for stowing tools or a reserve fuel can.
OPERATING INSTRUCTIONS
STARTING AND DRIVING
Running-in instructions
When the vehicle is new, we recommend that a certain amount of caution be observed
during the running-in period, for it is during this time that the movable parts of the car
must be properly bedded in so as to obtain smooth and durable sliding surfaces. The
maximum permissible speeds, therefore, should not be exceeded.
1st speed
during the first
1000 km (600 miles)
30 km.p.h. (20 m.p.h.)
between 1000 and 2000 km
(600 and 1200 miles)
2nd speed
55 km.p.h. (35 m.p.h.)
50 km.p.h. (30 m.p.h.)
75 km.p.h. (45 m.p.h.)
3rd speed
80 km.p.h. (50 m.p.h.)
100 km.p.h. (60 m.p.h.)
4th speed
110 km.p.h. (70 m.p.h.)
130 km.p.h. (80 m.p.h.)
Avoid driving at low speed in high gear and using the kick-down (concerns vehicles
with automatic transmission) during the first 2000 km (1200 miles).
Warranty inspection
After 2500 km (1500 miles), the vehicle
should be taken to a Volvo workshop for
the free warranty inspection. The procedure then carried out includes an engine
oil change. It is very important to ensure
that this oil change is carried out since
during the first period the engine oil usually collects a lot if impurities. After 5000
km (3000 miles), the oil in the engine,
gearbox and rear axle should be changed.
After this oil change, future changes
should be carried out at approximately
those intervals indicated in the maintenance scheme on page 34 and in the lubricating chart at the end of the book. All
Volvo engines are test-run before being
19
OPERATING INSTRUCTIONS
delivered. We are therefore assured that
all clearances are satisfactory and we thus
accept no responsibility for damage caused by careless running-in.
Before your first drive
Before you begin driving your new Volvo,
we would advise you to become familiar
with the vehicle and the various instruments and controls used during driving.
Sit in the car, go through all the various
i nstruments, test the controls and adjust
the seats and rearview mirror to the position which suits you best. When you are
comfortably seated and acquainted with
the location of the various controls, you
are ready to begin driving.
4. Turn the ignition key to the starting position. Release the key as soon as the
engine has started.
5. Push in the choke until the best idling
speed is obtained. As the engine becomes warmer, push in the choke more and
more. Drive for as short a period as possible with the choke out.
When the engine is thoroughly warm, the
choke should be pushed right in.
After starting a cold engine, do not race
i t immediately but run it at moderate speed
and do not subject it to heavy loading until
the engine temperature has reached normal level.
When starting with a warm engine, depress the accelerator pedal lightly.
I f a warm engine does not start immediately, depress the accelerator pedal fully
and keep is depressed until the engine
starts.
Start the engine
as follows:
1. Check that the handbrake is on and the
gear lever is in neutral.
2. When the engine is cold, pull the choke
control out fully.
3. Always make a habit of depressing the
clutch pedal until the engine fires normally.
20
Warming up the engine
Experience has shown that engines in
vehicles used with frequent stopping and
starting are subject to abnormally rapid
wear. The reason for this is that the engine
i s not given a chance to reach its normal
working temperature. When the engine is
cold, it should just be taken up to its normal working temperature as quickly as
possible. Therefore, do not idle the engine
too long but start driving with a light load
on the engine as soon as the oil pressure
l i ght has gone out.
Starting in a garage
Before starting your car in a garage, always open the garage doors. The exhaust
gases from the engine contain carbon
monoxide gas which is poisonous and
particularly dangerous since it is invisible
and odourless.
Driving with the boot lid open
While driving with the boot lid partly or
fully open, exhaust gases can be sucked
i nto the car through the boot. Normally,
this involves no risk to the passengers.
However, the following advice should be
followed on such occasions:
1. Keep all windows closed.
2. Set the fresh air and defroster controls
to the fully-opened position and the fan
control to full speed.
OPERATING INSTRUCTIONS
GEAR-CHANGING
The Volvo 164 is fitted either with a floormounted gear lever, a steering columnmounted gear lever, a floor-mounted gear
l ever with overdrive or an automatic transmission.
Note that not all these types of transmissions or combinations are available on a
number of markets.
Floor-mounted gear lever
Gear-changing with the floor-mounted
gear lever is quite conventional and the
different gear positions are shown in the
picture above.
Steering column-mounted
gear lever
Gear-changing with the steering columnmounted gear level is also quite conventional. The various gear positions are
shown in the picture above.
Overdrive
The overdrive is engaged by means of the
l ever under the steering wheel on the
right-hand side of the steering column.
When the overdrive is engaged, a red light
shows on the dashboard. Any extra manoeuvring with the clutch pedal is normally
not required.
Recommended speed ranges, km.p.h. (m.p.h.) for the different gears')
1)
Applies after 2000 km (1250 miles). See page 19. 2) 70 km.p.h. (45 m.p.h.) with overdrive engaged.
21
OPERATING INSTRUCTIONS
wheel before it can be moved into any of
the other positions. If the car is temporarily
stopped and the selector is moved to the
"R", "D" or "L" position, apply the handbrake or the footbrake to stop any tendency for the car to "creep".
Selecting
Automatic Transmission
At the bottom of the instrument panel in
the middle there is a quadrant for indicating the selector lever position. The
selector lever has the following positions:
Parking
Reverse
Neutral
Driving
Low gear
Move the selector lever either to the "P" or
"N" position. The starter inhibitor switch is
automatically disconnected if the selector
l ever is moved to any of the other positions. The selector lever can be moved
freely between the "N" and "D" positions,
while the other positions are provided with
a catch. For this reason, the selector lever
must first be lifted towards the steering
22
Normally position "D" should be used for
driving.The transmission then starts in first
gear and automatic upchanges to second
and third gear occur in accordance with
road speed and accelerator position. Automatic downchanges from third to second
and first occur with decreasing vehicle
speed.
Low gear position "L" is used for
1. Obtaining immediate manual downchanging
Driving
Select the position, release the brake and
the car will start rolling slowly. The most
rapid acceleration is obtained by depressing the accelerator fully. The car is
stopped in the normal way by releasing the
accelerator and applying the footbrake. No
manoeuvring of the selector lever is required.
I f the car has to be extricated from snow,
l oose sand or similar, it can be "rocked"
l oose by moving the selector alternately
between the "R" and "D" positions under
continuous , li ght accelerator pressure.
Do not select the "P" or "R" position
when the car is moving.
Do not select "D", "L" or "R" position at
a higher engine speed than idling when
the car is stationary.
Do not select the "L" position at speeds
above 90 km.p.h. (55 m.p.h.).
2. Providing powerful engine braking
when, for example, going down a steep
gradient.
3. Obtaining a high engine speed, if so
required
The "N" position is the neutral position,
that is, no gear is engaged.
The "R" position is used for reversing.
The "P" position is selected for parking
with or without the engine running. When
parking on a hill, the handbrake should
also be applied.
Starting with towing
Place the selector in the "N" position and
pull out the choke slightly. Switch on the
i gnition when the car has obtained sufficient speed and move the selector to position "L". This will start the engine.
OPERATING INSTRUCTIONS
Towing
I f necessary, the car can be towed with
the selector lever in "N" position, providi ng the gearbox is properly adjusted and
the oil at the correct level. If a fault in the
gearbox is suspected, disconnect the propeller shaft before towing.
Towing loop, front
Towing l oop, rear
I f the vehicle is to be towed, the tow line
must not be attached directly to the bumpers, but should be attached to the towing
l oop on the front axle member according
to the picture above.
During towing, the tow line should be kept
evenly stretched.
I f the vehicle is to be used for towing, the
tow line should be attached to the rear
towing loop located under the spare wheel
well. See the picture above.
BRAKING
When driving in the rain or through pools of water, even when washing the car,
water may splash up onto the brake discs and linings. This may alter the frictional
properties of the linings.
The brake linings, however, dry fairly quickly with braking, but a certain delay
i n the braking effect can sometimes be noticed.
I f you drive long stretches in the rain or slush, lightly depress the brake pedal
now and again to warm up the linings and thus dry them. This should also be
done when you drive your car immediately after washing it.
23
TECHNICAL DESCRIPTION
Engine compartment
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
24
Radiator
Battery
Voltage regulator
Air preheating unit
Alternator
Air cleaner
Carburettors
Oil filler cap
Fuel filter
Oil dipstick
Distributor
I gnition coil
Starter motor
Brake servo cylinder
Brake fluid container
Windscreen washer motor and
container
Engine compartment lighting
Relay for rear lights
Relays for horn
Step relay for main beam and
dipped lights
Relay for fog lights
Fusebox for fog lights
Steering box
Cooling system expansion tank
TECHNICAL DESCRIPTION
ENGINE
The B 30 A type engine is a six-cylinder,
water cooled carburettor unit with overhead valves. The engine has a very rigid
cylinder block made of special cast iron
and is cast in one piece. The cylinder
l i ners are machined directly in the block.
The cylinder head has separate inlet and
exhaust ports, one for each valve.
The statically and dynamically balanced
crankshaft is carried in seven main beari ngs.
Lubricating system
Engine lubrication is taken care of by a
gear pump located in the oil sump. The
pump is driven by a gear from the camshaft. From the pump the oil is forced
through the full-flow type oil filter and
to the various lubrithen along oilways
cating points. A relief valve is built into
the oil pump and prevents the oil pressure
from reaching excessively high values.
The oil filter is of the full-flow type, that
i s, all the oil passes through the filter before continuing on to the engine lubricating points.
Fuel system
The engine is fitted with twin carburettors
of type Zenith-Stromberg. The diaphragmtype fuel pump draws fuel from the tank
and pumps it to the carburettors. A filter
built into the fuel pump removes any impurities in the fuel.
On certain markets the vehicle is fitted
with a gas fume evaporation control
system which takes care of fumes from the
carburettors and fuel tank.
Air preheating
The engine has thermostatically controlled
air preheating. This keeps the intake air
temperature constant and thus counteracts ice forming in the carburettors and
makes for shorter warming-up after cold
starting.
25
TECHNICAL DESCRIPTION
Exhaust emission control
The engine is fitted with an exhaust emission control system which produces a
more exact and leaner mixture ratio between fuel and air resulting in a more
complete combustion and thereby cleaner
exhaust gases.
The system consists of specially adapted
carburettors and an intake manifold provided with a preheating chamber and control throttles.
When driving at low speed, the throttles
are closed so that the fuel-air mixture
passes the preheating chamber. When
higher output is required, the throttles
open, so that fuel flows directly to the
cylinders.
26
Cooling system
The cooling system is of the sealed pressure type and incorporates a circulation
pump. When the engine is cold the cool ant circulates only inside the engine. As
the engine warms up, a thermostat valve
starts opening the outlet to the radiator.
A special expansion tank prevents air from
circulating with the coolant as this would
cause corrosion in the cooling system. The
fan is driven by a slip-coupling which
keeps the fan speed at a max. of about
3500 r.p.m., this resulting in a lower noise
l evel and somewhat increased output.
POWER TRANSMISSION
Clutch
The function of the clutch is to transmit the
power from the engine to the gearbox. The
clutch is of the single dry plate type. Pressure on the pressure plate is obtained
from a diaphragm spring which in turn is
controlled mechanically by the clutch
pedal via the throw-out yoke. (Hydraulic
operation for vehicles with right-hand
steering.)
TECHNICAL DESCRIPTION
Gearbox
The gearbox has synchromesh on all the
forward gears. Due to the generously dimensioned synchronizing rings the gearbox has smooth gear-changing.
As alternative the Volvo 164 can be fitted
with a fully automatic transmission, BW 35.
Overdrive
For certain markets, the Volvo 164 model
i s fitted with an overdrive (see upper right)
which makes it possible to reduce engine
speed while maintaining road speed. This
i s less wearing on the engine and saves
fuel at the same time.
Propeller shaft
The propeller shaft, which is the connecti ng link between the gearbox and the rear
axle, is divided into two sections. The forward section is flexibly mounted at its rear
end in a bearing suspended in a rubberized
ring.
27
TECHNICAL DESCRIPTION
Final drive
Engine torque is transmitted via the propeller shaft to the rear wheels through the
final drive. The final drive is of the hypoid
type, that is, the drive pinion lies below
the centre line of the drive shafts.
28
Differential brake
On certain markets, a differential brake
can be obtained as extra equipment. A rear
axle with a differential brake automatically
transmits the tractive power to the wheel
having the best road grip when a wheel
begins to skid. Except for the differential
unit, the rear axle is similar in design to a
conventional rear axle.
Warning. Do not rotate a jacked-up rear
wheel if the other rear wheel is still on the
ground. Due to the differential unit, there
i s still drive on the wheel in contact with
the ground. Rotating the jacked-up rear
wheel would thus move the other rear
wheel and may cause the car to topple off
the jack.
Rear axle
The rear axle is carried on two support
arms, the front ends of which are bolted to
the body. The rear axle casing is secured
to the support arms by means of levers.
Two torque rods are journalled on the
casing and the body. A torque rod prevents
l ateral movement of the body and rear axle
i n relation to each other.
TECHNICAL DESCRIPTION
FRONT END AND STEERING
Front end
The car has independent front suspension.
The front suspension units are mounted
on a strong box member. The member is
bolted firmly to the front section of the
body. The front wheels are journalled in
tapered roller bearings. The front springs
consist of coil springs in which telescopic
shock absorbers are fitted. The car is
provided with stabilizers secured to the
l ower control arms and to the body.
Mechanical steering
The steering is of the cam-and-roller type.
Movements of the steering wheel are
transmitted via the worm on the steering
column to the ball nut for the pitman shaft,
which in turn operates the wheels through
a linkage system.
Servo steering
Certain variants of the Volvo 164 are
fitted with servo steering.
The servo cylinder and guide valves are
built into the cam-and-roller type steeri ng gear. When the steering wheel is
turned, the guide valves direct the pressure oil from the servo pump to one of
the sides of the piston in the servo cylinder. The resultant pressure on the piston
side affected assists in turning the steeri ng wheel.
29
TECHNICAL
DESCRIPTION
ELECTRICAL SYSTEM
The electrical system is of the 12-volt type
and is fitted with a voltage-regulated alternator. The starter motor is operated by
means of the ignition switch. This switch
i s also the main switch for the rest of the
electrical system. The cables to the headli ghts, parking lights, interior lighting, radio,
engine compartments and boot, however,
are not controlled by the ignition switch,
but can be switched on and off without
the ignition key being in position.
Lighting
The front lighting
consists of two headl i ghts (full and dipped beam), two extra
fog lights (on certain markets) together
with two turn indicators and a parking
l i ght. At the rear, the lighting consists of
two tail lights, turn indicators, brake warning lights and reversing lights. There are
also two lights for the rear number plate.
The interior lighting consists of a roof
l i ght and one in the glove compartment.
On certain markets the vehicle is fitted
with side lights mounted on the sides of
the mudguards. Both the engine compartment and boot are fitted with lights, which
function automatically when the bonnet
or boot lid is opened.
For replacement of bulbs, see pages 46,
47, 48 and 49.
30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Direction indicator light 32 Cp
Parking light 5 W
Dipped light 40 W
Mainbeam light 45 W
Distributor
Battery 12 V 60 Ah
Connection to instrument
Terminal
Part of 6-pol. terminal block
Horn ring
I gnition coil
Horn relay
Starter motor 1 h.p.
Brake warning switch
Resistance
Relay for elec. heated rear window
Cigarette lighter
Step relay for manbeam/dipped lights and
headlight flasher
19. Alternator 12 V 55 A
20. Horn
21. Control lamp for mainbeam 1.2W
22. Fusebox
24. Engine compartment lighting 18 W
25. Charging control
26. Switch for glove compartment lighting
27. Bulb for glove compartment lighting
28. Flasher unit and warning safety hazard
l i ght switch
29. Brake switch
30. Warning lamp for handbrake 1.2 W
31. Warning lamp for oil pressure 1.2W
32. Warning lamp for charging 1.2 W
33. Oil pressure sensor
34. Switch for turn indicators and light
signal
35. Voltage regulator
36. Fuel gauge
37. Temperature gauge
38. Temperature pick-up
39. Control lamp, flashers 1.2 W
40. I nstrument panel lighting 2X3 W
41. Lighting for heater controls 3X1.2 W
42. Luggage compartment lighting 18 W
43. Windscreen wipers
44. Heater
45. Windscreen washer
46. Roof light 10W
47. Heater switch
48. Rheostat for instrument and wiper switch
49. Rheostat for instrument lighting
50. Lighting switch
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
I gnition switch
Door switch
Switch for elec. heated rear window
Elec. heated rear window
Switch for handbrake control
Fuel level indicator unit
Reversing light 15 W
Brake light 25W
Rear light 5 W
Number plate light 2X5 W
Control lamp for overdrive 1.2 W
Switch for overdrive
Switch for overdrive on a gearbox
Solenoid for overdrive
Switch for automatic transmission BW 35
Switch for reversing light
Only for M 400 and M 410 gearboxes
Relay for reversing light on M 400
M 410 and starter relay on BW 35
Side lights 4 cp
Warning buzzer for ignition switch
Door switch, left
Fog lights 55W
Fusebox for fog lights
Relay for fog lights
Switch for fog lights
SB BLACK
W WHITE
Y YELLOW
GN GREEN
GR GREY
R RED
BR BROWN
BL BLUE
Differences may occur for different markets.
The wiring diagram shows the fog lights connected
across the parking and dipped lights. On certain
markets they are connected across the parking and
main beam lights. On this occasion the brown lead
between the fog light relay (73) and the stop relay (18)
i s connected to 56 b. If the fog lights are connected
across only the parking lights, the lead goes to 56.
TECHNICAL DESCRIPTION
..
.
r--I,D....~----_./
!
!
31
TECHNICAL DESCRIPTION
BRAKES
The brake system is of the two-circuit type
with disc brakes all round. The system is
provided with a tandem-type master cylinder and a directly-operating booster cylinder. When the brake pedal is depressed,
the master cylinder is operated mechanically via the booster cylinder, this boosti ng the pedal force about four times. The
brake pressure is transmitted hydraulically
from the master cylinder through the brake
l i nes to the wheel cylinders. The pistons in
these are then pressed outwards and operate the brake pads. The pressure lines to
32
the rear wheel brakes are provided with a
reducer valve for each circuit to prevent
l ocking of the car wheels.
The principle of the two-circuit system is
that both the front wheels are connected
to one rear wheel, that is, should there be a
failure in one of the circuits, there is always braking power on both front wheels
and the other rear wheel. At normal pedal
pressure the braking effect of each of the
circuits is 50 % , but when pedal pressure
i s increased, about 80 % of the full braking
power can be obtained in the one circuit.
This provides maximum safety and prevents lateral dragging and rear-end lurchi ng. With the engine stopped, the booster
assists the braking a further 2 or 3 times
after which the pedal pressure must be
i ncreased about four times in order to
obtain a braking power corresponding to
the braking power available with the engine running.
The handbrake operates the rear wheels
mechanically as the brake discs have also
been designed as brake drums in order to
i ncorporate the shoes for the handbrake.
SERVICING
GENERAL
Before the vehicle was delivered from the
factory it was subjected to a very thorough
i nspection. Your dealer, in his turn, carried
out a further delivery inspection in accordance with the specifications of the Volvo
Factory. In addition to this there is the free
service inspection after 2500 km (1500
miles). The oil in the gearbox and final
drive should be changed after the first
5000 km (3000 miles). Servicing of the vehicle should thereafter follow the routine
of the service book which is based on a
system with a service inspection after
every 10 000 km (6000 miles). The simplest
way to provide the vehicle with the servic-
i ng it requires is to have all the servicing
done by a Volvo workshop. You will then
have the work specified in the service
book carried out in accordance with recommended prices and the workshop
stamp in the service book will show when
the vehicle was serviced.
When the car was being designed, particular attention was given to the "safety
details" (e.g. front end, brakes and steeri ng). They are calculated to withstand the
severest stresses with a wide safety
margin. However, if you use your car for
hard driving, you should take the precau-
tion of checking these parts during the
useful lifetime of the car, for instance,
when front-end components are being reconditioned.
I f you prefer to carry out the simpler servicing procedures yourself or if you are
sometimes obliged to have them done by
a workshop outside the Volvo organization,
this chapter contains some advice as to
when and how they should be carried out.
For the sake of convenience, the servicing
procedures have been summarized in a
maintenance scheme in the next two
pages.
33
SERVICING
MAINTENANCE SCHEME
I n the maintenance scheme below the
servicing procedures have been given certain numbers which refer to the detailed
descriptions on the following pages.
34
Some of the work must be carried out by
skilled mechanics or requires the use of
special tools and these have been marked
0.
SERVICING
I n addition to the servicing procedures
mentioned in this scheme you should also
check regularly the following from the
point of view of traffic safety:
a) lighting, including brake warning light
b) direction indicator lights
c) horn
35
SERVICING
LUBRICATION
Chassis maintenance
To simplify maintenance of your Volvo, the
vehicle has been equipped with ball joints,
steering rods and propeller shafts of such
a construction that they do not require regular lubrication. This has been possible
due to the fact that points that normally
require lubricating have been packed with
very durable grease at the factory and then
carefully sealed, thus obviating the need
for subsequent lubrication.
However, to ensure that these parts are
functioning properly, it is necessary to
i nspect their seals and rubber sleeves
thoroughly after every 10 000 km (6000
miles) or at least once a year.
Oil should be changed or the oil level
checked after every 10 000 km (6000 miles)
i n accordance with the lubricating chart at
the end of the book. The measures taken
i n this inspection are also to be found in
the lubricating chart.
Always use only first-class lubricant of a
well-known make. The right lubricants in
the right quantity at the right time will increase both the lifetime and the reliability of your car.
36
1 Body lubrication
I n order to avoid rattle and unnecessary
wear, the body should be lubricated once
a year. The hinges on the bonnet, doors
and boot lid as well as door stops should
be lubricated every 10 000 km (6000
miles)*). Moreover, during the winter
months the locks on the doors and boot
l i d should be given some anti-freeze to
prevent them from freezing up.
*)
I ncluded in the 10 000 km (6000 mile) inspection.
filler hole on the rocker-arm casing with
new oil of the same type already in the
engine.
2 Check the oil level in the engine
The oil level in the engine should be
checked each time the fuel tank is filled.
The check should be carried out with the
engine switched off but warm and, in order
to obtain comparable values, about 1
minute after the engine has been stopped.
Wipe the dipstick before measuring. The
oil level should be between the two marks
on the dipstick. It must never be permitted to go down below the lower mark
but, on the other hand, it should not be
above the upper mark since oil consumption will then be abnormally high. If
necessary, top up by filling through the oil
3 Change oil in engine
With a new or newly reconditioned engine,
the oil should be changed after the first
2500 km (1500 miles). Subsequent oil
changing is according to the intervals
given below. The intervals will depend to a
great extent on the type of oil used. For
engine lubrication, oil quality "For Service
MS", is to be used. As far as viscosity is
concerned, multigrade oil is recommended. These oils are better suited for demanding driving conditions, for example
continuous driving in city traffic with incessant stopping and starting and with
l engthy idling periods.
For engine oil with viscosity SAE 10 W-30
(multigrade),10 W-40,10 W-50 or 20 W-50
the oil should be changed every 10 000 km
(6000 miles), or at least once a year.
If engine oil with viscosity SAE 10 W singl egrade), 20/20 W or 30 is used, the oil
should be changed every 5000 km (3000
miles), or at least twice a year.
At very low temperature (below -20° C,
-4° F) multigrade oil SAE 5 W-20 is recommended. However, this oil should not
be used when the temperature is continuously above 0° C (32° F).
The old oil is drained off by removing
the drain plug on the sump. Drainage
should take place after driving when the
oil is still warm.
37
SERVICING
4 Carburettors
At each oil change check that the oil level
i n the centre spindle of the carburettors
i s about 6 mm (1/4") from the top of the
spindle. If it is not, fill up with oil ATF Type
A (Automatic Transmission Fluid).
The carburettors are adjusted and tested
i n a test bench at the factory with a COgauge. No adjustment of the carburettors
i s required other than when carrying out
repairs to them.
Oil, ATF Type A
38
5-6 Gearbox M 400
The oil in the gearbox should be checked
after every 10 000 km (6000 miles). The oil
l evel should be up to the filler hole. If
necessary top up with the recommended
oil.
After every 40 000 km (25000 miles) the
oil in the gearbox should be changed.
I n the case of a new or reconditioned
gearbox the oil should also be changed
after the first 5000 km (3000 miles) and the
gearbox thoroughly flushed with the same
type of oil subsequently used. The old oil
should be drained off immediately after
the vehicle has been run while the oil is
still warm.
7-8 Gearbox; with overdrive M 410
For cars fitted with an overdrive, the oil
l evel should be checked and the oil
changed parallel with similar procedure
for the gearbox. The overdrive and the
gearbox have a common oil level and oil
filler hole. Make sure when topping-up
that the oil runs over into the overdrive.
The oil is drained out by removing the
gearbox drain plug and the cap for the
overdrive oil strainer. At each oil change
the oil filter of the overdrive should be
cleaned. This should be done by a Volvo
workshop.
SERVICING
9 Automatic transmission BW 35
The oil in the automatic transmission
should not be changed but the oil level
should be checked every 10 000 km (6000
miles). The filler pipe with graduated dipstick is to be found under the bonnet just
i n front of the cowl.
N.B. The dipstick has different graduation
marks for a warm and cold transmission.
When the oil level is being checked, the
car should be standing level. With the engine idling in position P, the level should
be between the upper and lower graduation marks on the dipstick. When toppingup is necessary, use only special oil for
automatic transmissions, type A.
up is necessary, use only oil ATF, Type F.
I f this is not available, use Type A or
Dexron.
10-11 Rear axle
The oil level in the rear axle should be
checked after every 10 000 km (6000 miles).
The oil level should be up to the filler hole.
I f necessary top up with the recommended
oil. The oil in the rear axle should be
changed after the first 5000km (3000 miles).
The old oil should be drained off by removing the rear axle cover plate. This
should be carried out immediately after
driving while the oil is still warm. Oil can
also be sucked up through the filler hole
with a syringe. The rear axle should be
thoroughly flushed with the same oil as
used in the rear axle before being filled
with new oil. After this only the oil level
need be checked and topping-up with the
recommended oil carried out if required.
12-13 Differential brake
Cars fitted with a differential brake are
delivered from the factory with a transmission oil according to the American
Military Standard MIL-L-2105 B provided
with an additive for rear axles with differential brake. A similar type of oil should
be used for subsequent topping-up and
changing. Oil level checking and oil
changing are to be carried out at the same
i ntervals and in the same way as for a rear
axle without differential brake.
The dipstick should be wiped with a nylon
cloth, paper or chamois leather. Cloths
which leave residues on the dipstick must
be avoided.
Transmission oil MIL-L-2105 B with
additive for differential brake.
SERVICING
14 Steering box (mechanical steering)
15 Servo steering
The oil level in the steering box should be
checked after every 10 000 km (6000 miles).
The oil level should be up to the filler plug.
I f necessary, top up with new oil. As a
rule, the oil in the steering box does not
need to be changed except during overhauling. Should the oil for any reason need
to be changed, the old oil should be sucked up by means of an oil syringe which is
i nserted into the filler hole.
The oil level in the servo steering should
be checked every 10 000 km (6000 miles).
Before checking wipe the oil container
clean. Then remove the cap and check the
l evel with the engine not running. The oil
l evel should be about 5-10 mm ( 1/4") above
the level mark in the container. If the level
i s lower than this, top up with oil, with the
engine stopped to prevent air from being
sucked into the container. Start the engine
and recheck the oil level, which should
now fall to the level mark. When the engine
stops, the level should rise to about 5-10
mm ( 1/4") above the mark.
The oil and filter in the servo steering do
not need replacing other than during repairs or reconditioning.
16 Brake fluid
The brake system is fitted with a tandemtype brake fluid container with a section
for each circuit but with the same filler
hole. The brake fluid level should be
between the "Max" and "Min" marks.
( On a right-hand steered vehicle the clutch
fluid container should be filled almost to
the top with brake fluid.)
Use only brake fluids conforming to
specification 70 R 3 for the hydraulic
brake system.
40
SERVICING
ENGINE
17 Crankcase ventilation
The engine is provided with positive crankcase ventilation which prevents the gases
i n the crankcase from being released into
the atmosphere. Instead, they are sucked
i nto the intake manifold and take part in
the combustion process whereupon they
are blown out through the exhaust pipe
together with the other combustion gases.
Every 40 000 km (25 000 miles) remove and
clean the nozzle (1), the hoses (2 and 4)
and the flame protector (3). Rubber hoses
should also be replaced if they are in a
poor condition.
18 Oil filter
The engine is fitted with a full-flow type oil
filter, which means that all the oil passes
through the filter on its way from the oil
pump to the various lubricating points.
I mpurities in the oil are collected in the
filter and gradually block it. For this reason,
the filter must be changed every 10 000 km
(6000 miles). Scrap the old filter then.
I f the oil filter is replaced without the
engine oil being changed, the engine
should be topped up with 0.8 litre (1.4 Imp.
pints=l.7 US pints) of oil.
19 Fuel filter
The fuel filter should be cleaned after
every 10 000 km (6000 miles). Loosen the
plug and clean the filter in the plug. Check
that the gasket is not damaged and make
sure that it seals properly when the plug
with filler is re-fitted.
41
SERVICING
20 a Replacing foam plastic filter for
gas evaporation unit
On vehicles fitted with a gas evaporation
unit, the foam plastic filter in the holder
on the cowl to the right in the engine compartment should be replaced every 40 000
km (25000 miles).
21 Valves
The valve clearances should be checked
after every 10 000 km (6000 miles).
This check should be carried out by a
workshop.
20 Replacing the air cleaner paper filter
The air cleaner consists of a plastic cover
with replaceable paper filter insert. The
i nsert should be replaced after every
40 000 km - (25 000 miles). Replacement
should be carried out more frequently if
the driving conditions are often dusty. No
other kind of servicing is required outside
these intervals.
To replace release the tensioning clips
securing the air cleaner cover. The cover
can then be opened so much that the insert is accessible for replacement.
42
22 Compression test
To get some idea of the condition of the
engine, a compression test should be
made after every 10 000 km (6000 miles).
This test should preferably be carried out
by a workshop.
24 Check the coolant level
23 Fan belt
The fan belt tension should be checked
every 10 000 km (6000 miles). Due to wear
or dirt, this belt can start slipping with
poor cooling and poor alternator output
as the result.
The check can be suitably carried out by
a Volvo workshop.
To test the tension provisionally press in
the fan belt at a point midway between the
alternator and the fan. It should be possible to press down the belt about 10 mm
(3/8") with normal pressure (7-9 kp/cm 2 =
100-128 p.s.i.).
The cooling system must be well filled
with coolant and not leak if it is to operate
at maximum efficiency. Check the coolant
l evel when filling up with fuel. The level
should be between the "Max" and "Min"
marks on the expansion tank.
The check should be carried out with
particular thoroughness when the engine
i s new or the cooling system has been
empty.
Do not remove the filler cap other than
for topping-up with coolant. Frequent
removal interferes with the coolant circul ation between the engine and the expansion tank during engine warming up and
cooling.
SERVICING
Top-up with coolant
lop up with coolant by filling the expansion tank when its level has gone down
to the "Min" mark. Use 50% good quality
anti-freeze mixed with 50 % water all the
year round and top up to the "Max" mark.
NOTE. Do not top up with water only.
Water by itself reduces both the rust-protective and anti-freeze qualities of the
coolant. It can also cause damage to the
cooling system if ice should form in the
expansion tank.
Note. In countries with very warm climate
where risk of frost is rare, ordinary water
can be used in the cooling system.
25 Change the coolant
The coolant retains its properties for
approx. 2 years when it should be changed
A suitable time to make the change is duri ng the autumn to ensure against any
damage by frost during the coming winter
months. To drain the cooling system, open
the drain tap located at the right-hand side
of the engine and disconnect the hose
attached to the bottom of the radiator.
The expansion tank is emptied by removi ng it from its brackets and lifting it to a
sufficient height so that the coolant flows
i nto the radiator.
Before filling with new coolant, flush the
entire system with clean water.
The cooling system is filled with coolant
through the filler opening on top of the
radiator. When this is being done, the
heater control should be set to max. heat
to ensure that the entire system will be
filled.
Fill the radiator to the top and fit on the
cap. Then fill the expansion tank to the
"Max" level or slightly above this.
Run the engine warm and then check that
the radiator is full and that the coolant in
the expansion tank is at "Max". If necessary, top up the system.
43
SERVICING
When changing the spark plugs, check
that the suppresser connectors are in
good condition. Cracked or damaged connectors should be replaced.
28-29 Ignition system
The distributor contact breaker gap and
the engine ignition timing should be
checked every 10 000 km (6000 miles).
26-27 Spark plugs, adjusting the
electrode gap, changing the plugs
The spark plugs should be removed after
every 10 000 km (6000 miles) and the electrode gap measured. The gap should be
. 7-.8 m m (.028-032").
After 20 000 km (12500 miles) the spark
plugs should be changed. Tightening
should preferably be done with a torque
wrench. When fitting new plugs, be sure to
fit the right type.
As standard use spark plug type Bosch W
200 T 35 or corresponding from other
makers.
I f the car is mostly used for town driving,
Bosch W 175 T 35 spark plug, or corresponding from other makers, should be
used.
44
All adjusting work should be done by a
workshop with the proper equipment.
The distributor is one of the most sensitive
units in the engine and careless handling
can lead to decreased engine output and
high fuel consumption or even serious
damage to the engine.
Fuel
Fuel with an octane value of 100 (ROT*) is
primarily recommended for normal driving.
Knocking or pre-ignition can occur if
petrol with low octane value is used. However, if highway motoring is often involved,
an octane value of at least 97 (ROT*)
should be used.
ROT* =Research Method.
ELECTRICAL SYSTEM
30 Check the battery electrolyte level
To ensure that the battery functions
properly, the electrolyte level should be
checked regularly. A suitable time to do
this is when the fuel tank is being filled.
The electrolyte level should be up to the
slit tubes. If the level is too low top up with
distilled water. Never add too much distill ed water since this can cause the acid to
splash over and possibly damage the
engine compartment. Never check the
electrolyte level by lighting a match. The
gases formed in the cells are highly explosive.
SERVICING
31 Check the state of charge of the battery
The state of charge of the battery should
be checked after every 10 000 km (6000
miles). The check is made with the left of
an hydrometer which shows the specific
gravity of the battery acid (this varies
with the state of charge of the battery).
See page 58. At the same time, check also
the lead terminals and terminal studs to
make sure that they are tight, smeared
with rustproofing and that the battery is
firmly fixed. If necessary, wipe the lead
terminals and terminal studs clean with a
cloth or brush them with a wire brush and
re-grease them.
This car is fitted with an alternator.
When changing the battery or when
carrying out work involving the electrical system, the following should
be observed:
1. A battery connection to the wrong
terminal will damage the rectifiers.
Before the connections are made,
32 Check headlight alignment
The alignment of the headlights should be
checked in a workshop after every 10 000
km (6000 miles). Remember that the section of the road lit up by the headlights
can vary according to the load in the vehicle.
check the polarity of the battery with
a voltmeter.
2. If extra batteries are used for
starting, they must be properly connected to prevent the rectifiers from
being damaged.
The negative lead from the auxiliary
battery for starting must be connected to the negative terminal stud of
the car battery and the positive lead
from the auxiliary battery for starting
3. If a rapid charger is used for
charging the battery, the car battery
l eads should be disconnected.
The rapid charger must never be
used as an auxiliary unit for starting.
4. Never disconnect the battery
circuit (for example, to change the
battery) while the engine is running,
as this will immediately ruin the alternator.
Always make sure that all the battery,connections are properly tightened.
5. Before carrying out any electrical
welding on the car, first disconnect
the battery earth lead and all the
cables to the alternator and voltage
regulator. Make sure that the ends
of the loose cables do not earth
against the car framework. Insulate
well if necessary.
to the positive terminal stud.
45
SERVICING
Replacing the bulb for the lights for the
luggage and engine compartments
Replacement of bulbs
To obtain maximum lighting effect and to forestall the chances of lights going out,
the headlight bulbs should be changed every year, suitably during the autumn.
Slacken the screw holding the lamp shade.
The bulb i s now accessible for replacement.
The following pages explain how the bulbs in the various lighting units are
replaced. Make sure when fitting lamps that the guide pin on the socket fits into
i ts corresponding recess.
Replacing the bulb for the glove
compartment light
When installing headlight bulbs, do not touch the glass with your fingers. The
reason for this is that grease, oil or any other impurities can be carbonized onto
the bulb and this could damage the reflector.
The bulb is mounted under the dashboard
above the compartment lid. To remove
the bulb, press it in a bit and then turn it
anti-clockwise.
Replacing lamps for instrument panel
and heater control lighting
Because of the location of the above
l amps, a Volvo workshop should be given
the job of replacing them.
Replacing the side light bulbs
Remove the two cross head screws holdi ng the glass. Take out the bulb by pressing it in slightly while turning it anticlockwise at the same time.
Replacing the roof light bulb
When replacing the roof light bulb, the
l amp shade is pulled straight out so that
the bulb is accessible for replacement.
See pictures opposite.
46
SERVICING
Replacing the bulbs for the front
Replacing the bulbs for the rear
Replacing the bulbs for the
flashers and the parking lights
flashers, parking lights, stop lights
number plate light
Remove the two Philips screws which
hold the glass. The bulbs can now be
removed by pressing them inwards and
then turning them a little anti-clockwise.
The inner bulb is for the parking light, the
outer for the flasher.
and reversing lights
The two bulbs for the number plate light
are mounted on a holder located under the
l uggage compartment locking device.
Loosen the two screws which hold the
glass and remove it. The bulb is now
accessible for changing.
Remove the two Philips screws which hold
the glass. The bulbs can now be removed
by pressing them inwards and turning them
slightly anti-clockwise at the same time.
The top bulb is the flasher, the one under
that is the reversing light, the next one
under that the stop light and the one at the
bottom the rear light. Make sure that the
sealing strip fits well against the glass
when it is refitted.
47
SERVICING
Replacing the headlight bulbs
1
2
3
4
48
The headlight bulbs are replaced from inside the engine compartment in the foll owing way;
1. Remove the protective cover over the
space behind the headlight.
2. Remove the contact for the bulb holder
and rubber sleeve.
3. Remove the spring which fixes the lamp
holder in the correct position.
4. Lift out the bulb holder with the bulb
complete as one unit. Do not grasp the
bulb glass with your fingers. When fitting
the bulb holder spring into the insert make
sure that the guide pin engages in its
notch.
SERVICING
POWER TRANSMISSION
BRAKES
33 Check the release arm free travel
To avoid risk of the clutch slipping, the
release arm free travel should be checked
and adjusted if necessary every 10 000 km
(6000 miles). For data see page 59.
The clutch should be checked and
adjusted at a workshop which has the
proper equipment.
35 Check the brakes
After every 10 000 km (6000 miles) the
vehicle should be taken to a Volvo workshop for a check on the functioning of the
brakes.
36 Replacing the booster cylinder air filter
and overhaul of brakes
Replacing the fog light bulbs
The bulbs for the fog lights are replaced
from inside the engine compartment. Remove the protection covering the space
over the headlight and fog light. Squeeze
together the spring holding the bulb and
lift out the spring and bulb. The bulb is
now accessible for replacement.
Because. of the two bosses on the bulb
socket, the bulb can only be fitted in one
way.
34 Check the propeller shaft
After every 10 000 km (6000 miles) or once
a year the rubber seal on the spline shaft
and the universal joints should be checked.
I f the rubber seal is damaged, it should be
replaced and the new seal filled with
molybdenum disulphide grease.
Every 60 000 km (36 000 miles) the car
should be taken to a Volvo workshop for
replacement of the booster cylinder air
and damper filters.
Replacement should be more frequent
when driving often on dusty roads. The
brake system seals should also be replaced every 3rd year or 60 000 km (36000
miles).
49
SERVICING
FRONT END
37 Check the front wheel alignment
Correct front wheel alignment is of vital
i mportance for the steering of the vehicle.
Faulty adjustment can mean heavy wear
on the tyres. For this reason, have the front
wheel alignment checked regularly at your
l ocal Volvo workshop every 10 000 km
(6000 miles). If the vehicle has been in a
collision involving heavy impact and it is
suspected that the front end may have
been affected, take the vehicle to a Volvo
workshop for a check on the front wheel
alignment as soon as possible. Volvo
workshops have special measuring equipment for this purpose and can carry out
this control quickly and efficiently. The
front wheel alignment angles are given on
page 59.
38 Check the ball joints, steering rods, etc.
After every . 10 000 km (6000 miles) the
vehicle should be taken to a workshop
for a check on the front end concerning
excessive play in the ball joints, steering
gear, etc.
After every 10 000 km (6000 miles) or at
l east once a year, the ball joint seal should
also be checked for damage and leakage.
When new seals are fitted they should be
filled with the recommended grease.
50
WHEELS AND TYRES
General
The car is fitted with pressed steel wheels
with attachments for the hub caps. All
wheels are accurately balanced. The tyres
are tubeless with size 6.85-15 (on certain
markets 165 SR 15). Size 165-15 (65-380)
i s recommended for use in the winter with
or without studs. Snow chains can only be
fitted on the rear wheels. Rapid links cannot be fitted on the Volvo 164 because of
i nsufficient space between the disc brake
pad holders and the rims.
39 Check the tyre pressure
Make a habit of checking the pressure
i n the tyres regularly. The simplest way
to do this is to check the pressure at a
service station while filling up with fuel.
See page 59 for the correct air pressure.
Do not forget the spare wheel when
checking the air pressure.
During driving, the temperature of the
tyres rises and also the air pressure in
relation to the speed of the vehicle and
i ts load. Normally the air pressure should
only be checked when the tyres are cold.
When the tyres are warm, a change in
pressure should take place only when air
must be pumped into the tyres.
Excessively low air pressure is one of the
most common reasons for tyre wear.
I f the pressure is too low, the tread
shoulders bear the entire load and wear
down very quickly. Tyres which are insufficiently inflated also result in difficult steeri ng and high fuel consumption. Too high
air pressure means tyre wear along the
centre of the tread. It also tends to make
travelling less comfortable.
At regular intervals check the tyres for
damage, abnormal wear and for any small
stones which may have fastened in the
tread pattern. Check also that the tread
pattern is not less than 1 mm (1/32"). If it
i s less than this, the tyre must be changed.
Be careful when parking the car next to
the pavement not to damage the tyres
against the pavement kerb.
SERVICING
Changing a wheel
Before the vehicle is jacked up, the handbrake should be applied and one of the
gears engaged.
Removal
1. Prise off the hub cap with the help of the
removal lever.
2. Loosen the wheel nuts 1/2-1 turn with
the help of the box spanner. All the nuts
have right-hand threads which are loosened by turning them in an anti-clockwise
direction.
3. Insert the lifting arm of the jack in the
appropriate jack attachment of the wheel
to be changed. Jack up the side of the
car far enough for the wheel to turn freely.
4. Unscrew the wheel nuts completely and
lift off the wheel. Be careful when lifting
off the wheel that the threads of the studs
are not damaged.
1
Fitting
1. Clean the contact surfaces between the
wheel and hub and fit on the wheel.
Tighten the nuts until the wheel makes
good contact against the flange.
2. Lower the vehicle and tighten the nuts
alternately, re-fit the hub cap.
Do not rotate a raised wheel if the
car is fitted with a differential brake,
since turning the jacked-up rear
wheel will also move the other rear
wheel on the ground, and this may
cause the car to topple off the jack.
3
4
51
SERVICING
BODY
40 Washing
The car should be washed often since
dust, dirt, dead insects, tar spots, etc.
adhere firmly to the body and may damage
the paintwork. Washing is also important
to counteract rusting. During the winter,
special care should be taken to ensure
that all road salt residue is washed off
as soon as possible, otherwise corrosion
can occur. A vehicle, the bodywork of
which has been well taken care of, has
of course a higher second-hand value,
should the owner consider selling it.
When washing the car, make sure that it
i s not exposed to direct sunlight since
this can cause drying patches. Begin by
softening up the dirt on the underside of
the body with a jet of water and use if
necessary a soft brush. Then rinse down
the whole body with a light jet until the
dirt has loosened up. After this, wash off
the dirt with a sponge using plenty of
water. Start at the roof of the vehicle and
work down the body. Use preferably
l ukewarm but not hot water.
Washing is facilitated with the help of a
reliable car washing agent. Ordinary fluid
dish washer can also be used. A suitable
mixture is 5-10 cm (2-4") fluid dish washer
to 10 litres (2.2 Imp. galls=2.6 US galls)
52
of water. Asphalt spots and tar splash can
be removed with white spirit or similar.
This should be done after the washing.
When a washing agent is used, the car
should be well rinsed down with clean
water afterwards. Begin with the roof of
the car and work down the body. Then
dry carefully with a soft clean chamois
l eather. Use different leathers for the
windows and the remainder of the car,
since using the same leather can cause
greasy smears on the windows. When
washing the car, remember to clean the
drainage holes in the doors and bottom
rail.
41 Polishing (waxing)
The vehicle does not need polishing until
the surface finish begins to lose its lustre
and normal washing is no longer sufficient
to make it shine again and remove the
l ayer of dirt on the surface. Under normal
conditions it is sufficient to polish the
vehicle a couple of times a year on condition that it is carefully looked after and
thoroughly washed as soon as it has become dirty or dusty.
Before the vehicle is polished, it should be
carefully washed and dried to avoid
scratches on the paintwork.
When about to apply wax, make sure that
the surface is absolutely clean before
application. It is often necessary to use
cleaning naphtha for cleaning.
Waxing is no substitute for polishing. Nor
i s it necessary as a protection for the
paintwork against unfavourable weather.
Very often waxing should first be carried
out at the earliest one year after delivery
of the car.
SERVICING
42 Anti-rust treatment
The Volvo 164 is anti-rust treated at the
factory. Underbody sealing compound is
applied to the underbody on those places
exposed to damage from flying stones
thrown up by the wheels, i.e. the wheel
arches, the entire floor plate and the
underside of the sills. Anti-rust fluid is
sprayed on the chassis parts. Inspection
and any touching-up of the anti-rust
protection should be done at regular
i ntervals and at least once a year. The
enclosed body sections should also be
anti-rust treated by means of spray application at least once a year.
I f any touching-up of the anti-rust protection is necessary, this should be done
i mmediately to prevent moisture from
seeping in and consequently damaging it.
Wipe up as much of the stain as possible
before treating it with spot remover. Use
a damp cloth or similar. Use a dry cloth to
suck up the spot remover and repeat the
treatment. Normally many stains can be
removed with soap and water or washing
agent followed by washing with water. If
carbon tetrachloride petrol (equal parts
carbon tetrachloride and chemically pure
petrol) is used, it should be allowed to
evaporate before the stain is treated with
water. Always work on the stain from the
outside, in order to avoid spreading.
We give below some tips as to suitable
spot removers for different types of stains.
Stains on plastic can be cleaned with
water or a mild washing agent.
Water can be used to remove the followi ng stains: blood (cold water), milk, tea,
soft drinks, coca-cola, and beer.
For spots from berries, fruit, coffee and
vomitings, water can be used if the stain
i s treated immediately.
Carbon tetrachloride petrol is used for the
following stains: asphalt, oil, grease, chocolate, ice-cream, chewing gum, shoe
polish, lipstick, butter and margarine.
Urine stains are treated with 5 °lo ammoniac and rinsed with water. This should be
repeated when necessary.
43 Cleaning
Cleaning the upholstery
Stains on any leather and plastic parts of
the upholstery can be removed with water
or a mild washing agent.
The fabric upholstery can be cleaned with
a vacuum cleaner or brush. Stains should
be removed before they dry.
Cleaning the floor mats
The floor carpets should be vacuumcleaned or brushed clean regularly. Now
and again, and specially during the wintertime, they should be taken out for
drying. Mild washing agent will remove any
spots.
Touching-up surface finish damage
Chromed parts
The touching-up of any extensive damage
to the synthetic finish requires the use of
special equipment and skill, so that the
repairing of any such damage should be
entrusted to a Volvo workshop. Minor
damage caused by flying gravel, etc. and
small scratches can, however, be attended
to by the owner himself.
The chromium-plated and anodized parts
should be washed with clean water as soon
as they become dirty. This is particularly
i mportant if you drive on gravel roads
which are treated with chemicals to keep
the dust down or in the winter when salt is
used to melt the snow. After the car has
been washed, wax or anti-rust preparation
can be applied.
Damage caused by flying stones requires
i mmediate treatment if damage from rust
i s to be avoided. Always make a habit,
therefore, of checking the finish regularly
and carrying out touching-up if required.
Volvo dealers can supply you with suitable
touching-up paint in tins or spray bottles.
Always make sure that you get exactly the
right colour. Touching-up is as follows:
1. If flying gravel should penetrate down
to the metal, the damaged surface should
be scraped completely clean with a penknife or similar.
I f the paintwork has not been damaged by
flying gravel, a light scraping will remove
the dirt.
2. In the event of severe damage due to
flying stones, it is necessary to treat the
spot concerned with anti-rust primer. The
primer should cover completely the scratched and "chamfered off" surface.
3. When the anti-rust primer has dried,
genuine Volvo paint is applied. Stir the
paint well or shake the spray bottle
thoroughly before use. Apply several thin
coats of the paint allowing it to dry
thoroughly between each application.
53
SERVICING
SERVICING BEFORE A
PROCEDURE IN COLD
LONG-DISTANCE TRIP
WEATHER
I f you are thinking of taking your car
abroad or on a long journey, have it checked at a Volvo workshop. You will enjoy
your journey better if you know that your
car is in perfect trim. Irritating incidents
can be avoided as well as expensive and
ti me-absorbing stoppages. Wherever you
go there should be a Volvo workshop withi n easy reach to attend to your car if required.
However, it is always a good idea before
making a trip to ensure that, at least on a
minor scale, you have with you a comprehensive touring kit. This is particularly the
case if you anticipate widely varying conditions as regards climate, roads and
the prevalence of much dust. Many workshops stock special kits for this purpose.
Remember when filling up with fuel to
observe the existing fuel recommendations. If you prefer to look over your vehicle yourself, the following hints are
worthwhile noting:
1. Check the brakes, front wheel alignment
and steering gear.
2. Check the engine and drive units with
regard to fuel, oil, coolant leakage.
54
3. Examine the tyres carefully. Replace
worn tyres.
4. Check that the engine is running perfectly and that fuel consumption is normal.
5. Examine the state of charge of the
battery and clean the terminals.
6. Look over the tool equipment and check
the spare wheel.
7. Check that the lighting functions properly.
When cold weather is on the way, it is
ti me to think of the winter servicing of
your car. The first night of frost can come
as a very unpleasant surprise unless preventive precautions have been taken.
Engine cooling system
A good quality anti-freeze should be used
all the year round. Thus, the cooling
system should always contain water plus
anti-freeze and rust inhibitor, even during
the summer.
The coolant keeps its properties for approximately two years, when it should be
changed. A suitable time for doing this is
i n the autumn. This would ensure against
possible damage from frost during the
winter months. When the coolant is being
changed, the cooling system should be
flushed out with clean water. For further
details, see page 43. If the coolant has to
be topped up during the winter, do not use
only water as water by itself weakens both
the anti-frost properties as well as the
SERVICING
rust-proofing effectiveness of the coolant.
I t is a good idea when topping up with
coolant to have the concentration checked
Experience has also shown that extremely
weak anti-freeze solutions (10-25 % ) are
very unfavourable from the point of view of
rust protection. For this reason, the quantity of anti-freeze should amount to about
50 % of the coolant, that is, 6.2 litres (11
I mp. pints=13 U.S. pints), this lowering
the freezing point to -35° C (31 0 F).
Radiator spirit is not recommended as an
anti-freeze agent since it evaporates at
normal engine temperature.
Electrical system
The electrical system in the vehicle is
subjected to greater stresses during the
winter than during the warm summer
months. The lighting and starter motor are
used more and since the capacity of the
battery is also considerably lower at low
air temperature, the state of charge must
be checked more often and, if necessary,
the battery charged. If the battery voltage
i s excessively low, there is risk of the
battery being damaged by frost.
Brake system
Engine lubricating system
During the winter multigrade oil or engine
oil SAE 10 W should be used for the engine lubricating system. At very low temperatures (below -20° C=-4° F) multigrade
oil SAE 5 W-20 is recommended. These
oils reach the lubricating points in the
engine more easily at low temperature
and also facilitate cold starting. See page
37.
During very cold weather the brakes are
subjected to splash and condensation
water which can result in the handbrake
freezing up if left on.
When you park the car, do not apply the
handbrake but engage the first gear or
reverse and if possible place blocks behind the wheels. See also page 23.
the windscreen washers. This is particularl y important because the windscreen duri ng the winter frequently becomes dirty
and is often splashed with water which
rapidly freezes and thus necessitates the
frequent use of the windscreen washer
and wipers. Your Volvo dealer can supply
you with suitable anti-freeze for this purpose.
Anti-freeze for door locks
A frozen door lock is one of the most irritating things that can happen to a carowner. Many valuable minutes early in the
morning can be wasted warming up keys
and melting ice in locks. Remember this
i n good time and lubricate the locks in
advance with some suitable anti-freeze
agent. Such agents are now available in
small handy tubes which can easily be
placed in a handbag or coat pocket.
Windscreen washer
I n the same way as anti-freeze is added to
the cooling system during the winter to
prevent frost damage, anti-freeze should
also be added to the water container for
55
FAULT TRACING
WHEN THE ENGINE STALLS
OR WILL NOT START
The information given below is only intended to serve as a guide in localizing
and temporarily correcting minor faults.
After having carried out any such measures, have them checked and adjusted by
an experienced mechanic.
The engine does not start although the
starter motor turns it round at normal
speed
1. Check that there is fuel in the tank.
2. If the engine is warm, starting should be
done with the accelerator pedal slowly
depressed as far as it will go.
3. In wet weather the sparking plug insulators should be wiped clean and the distributor cap removed and wiped dry if flashover is suspected.
4. Check that the fuel line connections on
the pump and carburettor are not leaking
and that fuel is supplied to the carburettor.
5. If the engine is turned round for a while
without having started, too rich a fuel mixture can enter the cylinders so that the
sparking plugs become wet. Blow the
cylinders clean by screwing out the sparki ng plug and turning round the engine with
the starter motor. Dry the sparking plugs
before fitting them.
56
If the engine still does not start
1. Remove the ignition lead from each
plug in turn. Hold the end of the lead
about 1/4" from the cylinder block while
turning round the engine with the ignition
switched on. If there is a strong spark,
the fault is probably in the sparking plugs,
so these should be changed.
2. If only a weak spark is obtained or none
at all, check to see whether the ignition
l eads are properly inserted in the distributor and ignition coil.
3. Remove the distributor cap, check and
clean all contact surfaces. Check that the
contact breakers close properly when the
engine is turned round. If the contact
breaker arm shaft binds, oil it very spari ngly.
If the engine misfires, the reason can be:
1. That one of the ignition leads has
l oosened in the distributor cover or from
the sparking plug.
2. That one or more of the sparking plugs
i s coated with soot or oiled up, in which
case the plug concerned should be cleaned or changed and the sparking plug gap
adjusted.
3. That the distributor cap and rotor arm
are cracked or damaged.
4. That one of the ignition leads is in a
poor condition.
5. That the contact breaker gap in the
distributor is insufficient or non-existent.
6. That the contact breakers are badly
burnt.
How to start your car downhill
Switch on the ignition, pull out the choke if
required, engage 3rd gear or even 4th and
l et the car roll downwards with the clutch
pedal depressed. When the speed is up to
15-20 km.p.h. (9-12 m.p.h.), and not before, release the clutch pedal slowly.
Being towed: Secure the towline to the
towing loop. The car is towed at an even
speed in 2nd gear. Try starting as suggested in the previous paragraph.
SPECIFIKATIONS
MEASUREMENTS AND WEIGHTS
Length
Width
Height uniaden (ready to drive)
Wheelbase
Ground clearance, uniaden
(ready to drive)
driver and 3
passengers
Track, front
rear
Turning circle
Kerb weight
Permissible total weight
Permissible load (excluding driver)
Permissible axle pressure, front
rear
Permissible ro of rock load
Max. permissible trailer weight
ENGINE
4705 mm
1735 mm
1437 mm
2700 mm
210 mm
(185")
(68.3")
(56.5")
(106.3")
(8.3")
160 mm (6.3")
1350 mm (53.2")
1350 mm (53.2")
9.6 m (31.6 ft.)
1330-1370 kg
(2926-3014Ib.)
1750 kg (3850 Ib.)
310-350 kg
(682-770Ib.)
depending on chassis
type
820 kg (1804Ib.)
960 kg (2112 Ib.)
100 kg (220 Ib.)
1200 kg (2640 Ib.)
Type designation
Output (DIN) at r.p.m.
Output (SAE) at r.p.m.
Max. torque (DIN) at Lp.m.
Max. torque (SAE) at r.p.m.
Number of cylinders
Bore
Stroke
Displacement
Compression ratio
Val ves
Valve clearance, war m and cold, inlet
exhaust
Idling speed (warm engine)
B 30
130 h.p./5000
145 h.p./5500
21 kpm (152 Ib.ft.)/2500
22.5 kpm (163 Ib.ft.)/3000
6
88.90 mm (3.50")
80 mm (3.15")
2.98litres
9.3: 1
Overhead
.50-.55 mm (.020-.022")
.5.0-.55 mm (.020-.022")
800 Lp.m.
(700 Lp.m. with BW 35)
Fuel system
Carburettor, type
designation
Horizontal
Zenith-Stromberg
175 CD 2 SE
Cooling system
Type
Thermostat, begins to open at
fully open at
Positive pressure
closed system
approx. 0.7 kp/cm'
(10 p.s.i.)
81-83° (178-182° F)
90° C (194° F)
57
SPECIFICATIONS
Ignition system
Firing order
Ignition setting
stroboscope setting at 600-800 r.p.m.
with both vacuum hoses disconnected
Spark plugs, normal driving
mostly town driving
spark plug gap
tightening torque
Distributor, direction of rotation
contact breaker gap
1-5-3-6-2-4
10° B.T.D.C.
Bosch W 200 T35*
Bosch W 175 T35*
.7-.B mm (.02B-.032")
3.5-4.0 kgm (25-29Ib.ft.)
Anti-clockwise
.25 mm (.010")
Power
Lamp bulbs (12 V)
45/40 W
Headlights
55W
Fog lights
5W
Parking lights, front
32 cp
Flashers, front and rear
4 cp
Side lights
32 cp
Stop lights
32 cp
Reversing lights
5W
Rear lights
5W
Number plate light
10W
Interior lighting
2W
Glove compartment light
Engine and luggage compart1BW
ment lights
3W
Instrument lighting
1.2W
Lighting, heater controis
1.2W
Warning lamp, charging
1.2W
turn indicators
1.2W
brakes
1.2W
headlights
1.2W
oil pressure
elec. heated rear
1.2W
window
1.2W
overdrive
warning hazard flashers 1.2 W
Electrical system
Voltage
Battery, type
capacity
electrolyte, specific gravity
recharged at
Alternator max. output
max. current
Starter motor, output
1<
58
or corresponding
12 V
Tudor 6 EX4 F o. p.*
60Ah
1.2B
1.21
770 W
55A
1 h.p.
Fuses
4
4*)
1
5A
8A
16A
*) 6 luses il vehicle is lilted with log Iights.
Socket
P45T
P 14.5 S
Ba 15 s
Ba 15 s
Ba 15 s
Ba 15 s
Ba 15 s
Ba 15 s
SVB.5
SVB.5
Ba9s
Number
2
2
2
4
4
2
2
2
2
1
1
SVB.5
W2.2d
W1.Bd
W1.Bd
W1.Bd
W1.8d
W1.8d
W1.8d
2
2
3
1
1
1
1
1
W1.8d
W1.Bd
W1.8d
1
1
1
SPECIFICATIONS
POWER TRANSMISSION
WHEElS AND TYRES
Clutch
Tyre size
Release lever free trave I
right-hand steering
Air pressure, cold tyres,
kg/cm' (p.s.i.)
4-5 mm (approx. 3/16")
2-3 mm (3/32")
1-2 persons
Fully loaded
Gearbox
Type designation M 400
Reduction ratios :
3.140:1
1st speed
1.9.7:1
2nd speed
1.34: 1
3rd speed
1: 1
4th speed
(with overdrive)
3.54: 1
Reverse
M 410
BW35
3.14: 1
1.97: 1
1.34: 1
l :1
0.797: 1
3.54: 1
2.39: 1
1.45: 1
1: 1
1
X
I h " "ratio
verter
2.09: 1
Rear axle
Type
Reduction ratio
Hypoid bevel gear
3.73: 1 3.31:1 (for BW 35)
FRONT WHEEl ALlGNMENT
The alignment values apply to an
uniaden car but include fuel,
coolant and spare wheel.
Toe-in
Camber
Caster
King pin inclination
0-4 mm (.157")
Oto + 1/20
Oto + 1°
7.5 0
6.85-15
165 SR 15
Front
Rear
Front
1.6 (23)
1.7 (24)
1.7 (24)
2.1 (30)
1.7 (24)
1.8 (26)
I
Rear
1.8 (26)
(30)
I 2.1
For prolonged driving at high speed, 140 km.p.h. (90 m.p.h.)
with 6.85-15 tyres, the pressure should be increased by 0.3
kg/cm' (4.5 p.s.i.). Maximum pressure must not, however,
exceed 2.1 kg/cm' (30 p.s.i.).
The pressure in the 165 SR 15 tyre should also be increased
by 0.3 kg/cm' (4.5 p.s.i.) for long-distance drivin~ at a speed
near that of maximum for the vehicle.
CAPACITIES
Fuel tank
Cooling system
Oil capacity,
engine, at oil ch ange
incl. oil filter
gearbox (M 400)
(M 410)
(automatic)
rear axle
steering gear
servo steering
TOOl KIT
Wheel nut spanner
Tommy bar
Pliers
58 litres (12.76Imp. galls.=15.31 US galls.)
12.4litres (2.73 Imp. galls=3.27 US galls)
(of which expansion tank 1.5 litres = 3.2
I mp. pints = 2.6 US pints)
5.2litres
6.0litres
0.6litre
1.4litres
8.2litres
1.6litres
0.6litre
1.2 litres
(9.1 Imp. pints=10.9 US pints)
(1O.6Imp. pints=12.6 US pints)
(1.1 Imp. pints=1.3 US pints)
(2.46Imp. pints=2.95 US pints)
(14.4lmp. pints=17.3 US pints)
(2.82 Imp. pints = 3.38 US pints)
(1.1 Imp. pints=1.3 US pints)
(2.11 I mp. pints = 2.53 US pints)
Adjustable spanner
Philips screwdriver
Plain screwdriver
59
LUBRICATING CHART
About every other week check the tyre
pressure and the battery acid level.
Note 3. Check that the fluid reaches up to
the MAX mark. (Right-hand steering:
Check also the clutch fluid level.)
Notes for lubricating chart
Check the following when filling the tank
1. Check the engine oil level.
2. Check without removing the cap that
the level in the brake fluid container is
above the MIN mark. (Right-hand steering:
Check also the clutch fluid level.)
3. Check that the coolant level is between
the MAX and MIN marks on the expansion
tank.
4. Check that the fluid container for the
windscreen washers is filled.
62
Note 1. The wheel bearings are packed at
the factory with a special type of grease
i ntended to last for the entire lifetime of
the bearings. Normally, therefore, the
sealed-for-life bearings do not require a
change of lubricant or additional grease.
I n connection with such workshop operations involving uncovering the wheel beari ngs, the bearings should be cleaned and
then lubricated with high-class, durable
grease according to the instructions in the
service manual. Except on the above
occasion, subsequent adding or changing
of lubricant is not required.
The rear wheel bearings are lubricated so
replacement of grease is not required.
However, if the bearings have been removed, they should be lightly greased with
wheel bearing grease.
Note 2. Mechanical steering:
Check that the oil reaches up to the filler
plug. Use hypoid oil SAE 80 all year round.
Servo steering: Check that the oil level in
the servo steering container is 5-10 mm
(5/16") above the level mark. Use Automatic Transmission Fluid, Type A, or Dexron.
Note 4. Lubricate the felt wick under the
rotor and fill a few drops of light engine
oil into the lubricating cup.
Note 5. Check every 10 000 km (6000 miles)
that the oil reaches up to the filler plug.
Concerning oil change, see page 38.
N.B. The type of gearbox will decide the
type of lubricant to be used.
Note 6. At every engine oil change check
that the oil level in the centre spindle of
the carburettors reaches up to about 6 mm
(1/4") from the edge of the spindle. Use
oil ATF type A (transmission oil).
Note 7. Change the oil filter every 10 000
km (6000 miles). See page 41.
Note 8. Check the oil level when tanking.
Concerning oil changing, see page 37.
Note 9. Check every 10 000 km (6000 miles)
that the oil reaches up to the filler plug.
Concerning lubricant for rear axle with
differential brake, see page 39.
Wheel bearings
Note 1
Wheel bearings
Note 1
Steering box
Note 2
Carburettors
Note 6
Brake fluid
container
Note 3
Oil filter
Note 7
Distributor
Note 4
Engine
Note 8
Gearbox
Note 5
Rear axle
Note 9
Wheel bearings
Note 1
Wheel bearings
Note 1
Oil capacities
Engine excl. oil filter
i ncl. oil filter approx.
Gearbox, M 400
M 410
BW 35
Rear axle
Steering gear (meth.)
Servo steering
approx. 5.2 litres (9.1 Imp. pints= 10.9 US pints)
approx. 6.0 litres (10.6 Imp. pints=12.6 US pints)
approx. 0.6 litre (1.1 Imp. pints=1.3 US pints)
approx. 1.4 litres (2.46 Imp. pints=2.95 US pints)
approx. 8.2 litres (14.4 Imp. pints= 17.3 US pints)
approx. 1.6 litres (2.82 Imp. pints=3.38 US pints)
approx. 0.6 litre (1.1 Imp. pints=1.3 US pints)
approx. 1.2 litres (2.11 Imp. pints =2.53 US pints)
The specifications and constructional details
given in this book are not binding.
We reserve the right to carry out modifications
without previous notice.
AKTIEBOLAGET
672/1
18.000 Engelska 10.69
VOLVO
GÖTEBORG
SWEDEN
Printed in Sweden
Handelstryckeriet, Göteborg 1969