Table Of Contents - Volvo 164, 1970 Service Manual

Table of Contents

General4
Type Designations6
Dimensions And Weight6
Type Plates6
Lubrication7
Servicing And Maintenance22
Instructions For Oil Level Checking And Changing24
Carburetors24
Gearbox24
Gearbox With Overdrive25
Automatic Transmission25
Final Drive26
Steering Box Mechanical Steering26
Instructions For Lubricating27
Servo Steering27
Checking The Brake Fluid Level27
Checking The Oil Level27
Lubricating Points On The Body28
Hinges28
Striker Plate28
Door Lock With Guide Plate28
Checking When Filling The Tank29
Brake Fluid Container29
Expansion Tank29
Fluid Container29
Instructions For Lubricating Chart30
Symbols30
Oil Changing Quantities30
Other Lubricating Points30
Table Of Contents32
Tools33
Engine Stand34
General Description35
Repair Instructions36
Removing The Engine36
Installing The Engine37
Oil Sump37
Toois38
Engine Description39
Cylinder Block39
Cylinder Head And Valves39
Camshaft And Valve Tappets39
Group 21. Engine39
Positive Crankcase Ventilation40
Dismantling The Engine41
Cleaning41
Assembling The Engine41
Valve Grinding And Decarbonizing42
Removing The Cylinder Head42
Fitting The Cylinder Head43
Replacing The Valve Guides43
Replacing The Rocker Arm Bushes And Grinding The Rocker Arms44
Adjusting The Valve Clearance44
Pistons, Piston Rings And Gudgeon Pins45
Measuring The Pistons45
Piston Ring Fit45
Assembling And Fitting The Piston And Connecting Rod45
Connecting Pods46
Gudgeon Pins46
Replacing The Bushes46
Straightening46
Crank-Sham46
Replacing The Crankshaft Rear Oil Seal47
Main And Big-End Bearings47
Grinding The Flywheel47
Pilot Bearing For Clutch Shaft47
Replacing The Oil Seal In Timing Gear Casing48
Replacing The Timing Gears49
Removing The Camshaft Gear49
Removing The Crankshaft Gear49
Fitting Camshaft Gear49
Oll Pump, Relief Valve51
Oll Filter51
G Roup 22. Lubricating System51
Replacing The Oil Filter52
Oil Pump52
Oil Filter52
Oil Filter Ready For Fitting52
Oil Pump And Relief Valve53
Removing The Oil Filter53
Measuring Tooth Flank Clearance53
Oilways54
Fitting The Oil Pump54
Fuel System Description55
Float System56
Cold Start Device And Fast Idle57
Idling59
Normal Running59
Acceleration59
Exhaust Emission Control System59
Gas Evaporite Control System And Hot Start Valve60
Air Cleaner62
Fuel Pump63
Periodical Check63
Setting The Carburetor64
Setting Without Co-Meter64
Setting With Co-Meter65
Fast Idle65
Funnel For Exhaust Evacuation65
Faulty Carburetor Function66
Temperature Compensator66
Cold-Start Device66
Removing The Carburetors67
Fitting The Carburetors67
By-Pass Valve67
Checking The Secondary Throttles67
Cleaning The Floatchamber68
Float Level68
Replacing The Diaphragm68
Replacing The By-Pass Valve69
Replacing The Temperature Compensator69
Replacing The Metering Needle69
Damper Device69
Flap Housing For Constant Air Temperature Device70
Cleaning The Strainer70
Checking Condition Of Fuel Pump70
Venting Filter71
Cooling System Description72
Sealed Cooling System72
Fan Coupling72
Cooling System Inner Circuit73
Coolant System Outer Circuit73
Water Pump73
Topping Up With Coolant74
Draining The Cooling System74
Filling Empty System With Coolant74
Cooling System Leakage Check75
Thermostat75
Replacing The Radiator75
Replacing The Water Pump75
Electrical System78
Battery Description80
Alternator Description81
Exploded View Of Alternator81
Alternator Inner Circuit81
Alternator Output Curve81
Special Instructions For On Alternator Equipment82
Dismantling The Alternator82
Removing The Alternator82
Checking The Dismantled Alternator83
Stator83
Rotor83
Replacing The Rectifier Diodes84
Brush Holoer84
Replacing The Bearings85
Drive End Shield Bearing85
Slip Ring End Bearing85
Replacing Slip Ring End Shield O-Ring85
Assembling The Alternator86
Fitting The Alternator86
Voltage Regulator Description87
Voltage Regulator Function87
Testing The Alternator And Voltage Regulator88
Checking The Alternator Circuit88
Testing The Battery88
Checking The Voltage Drop88
Fault Tracing90
Starter Motor91
Bosch Special Tools91
Dismantling The Starter Motor93
Removing The Lock Washer94
Removing Adjusting Washers94
Starter Motor With Bearing Shield Removed94
Starter Motor With Brush Bridge Removed94
Checking The Control Solenoid95
Replacing The Brushes95
Fitting The Self-Lubricating Bushes96
Replacing The Field Windings96
Testing The Rotor96
Holding Device For Removing Field Windings96
Ignition System Description98
Ignition Coil98
Distributor98
Distributor Removing100
Distributor Dismantling100
Distributor Inspecting101
Distributor Assembling101
Removing The Circlip101
Removing The Driving Collar101
Replacing The Contact Breaker102
Testing The Distributor In Test Bench102
Ignition Setting104
Lighting Description105
Headlights105
Replacing Headlight Insert105
Replacing The Bulb106
Fog Lights107
Checking And Adjusting The Headlights107
Parking And Directional Flasher Lights108
Rear Lights108
Number Plate Light108
Side Flasher Lights109
Other Electrical Standard Equipment110
Directional Indicator System110
Ignition Switch110
Horn111
Windshield Wipers111
Windshield Washer111
Switches111
Control Relays112
Luggage/Engine Compartment Lighting112
Fuses112
Brake Light Switch112
Replacing The Directional Indicator Lever Switch113
Replacing The Ignition Switch113
Removing And Adjusting The Horn Ring113
Removing The Switches114
Dismantling The Windshield Wiper Motor114
Fitting The Windshield Wiper Unit Complete114
Replacing The Interior Light Bulb115
Replacing Luggage Or Engine Compartment Light Bulb115
Replacing The Brake Light Switch115
Instruments Description116
Speedometer116
Temperature Gauge117
Warning Lamps117
Charging117
Directional Indicators117
Removing The Combined Instrument118
Replacing Control Lamps And Instrument Lighting Lamps118
Full-Beam Headlights118
Oil Pressure118
Removing The Instrument Base Plate119
Removing The Fixing Plate For Speedometer And Mileometer/Trip Meter119
Checking The Speedometer Cable119
Removing And Checking The Temperature Gauge119
Removing And Checking The Fuel Gauge120
Checking The Voltage Stabilizer120
Wiring Diagram122
Power Transmission123
Rear Axle123
Clutch Tools125
Clutch Descriptions125
Work Winch Can Be Carried Out With The Clutch Installed126
Adjusting The Clutch Pedal Play126
Replacing The Clutch Wire126
Replacing The Clutch Pedal Or Bushes126
Removing The Clutch127
Reconditioning The Release Components127
Replacing The Input Shaft Pilot Bearing127
Clutch Control, Right-Hand Steered Vehicle128
Master Cylinder128
Bleeding The Hydraulic System128
Gearbox Tools129
Gearbox Description130
Gearbox Repair130
Work Which Can Be Carried Out With The Gearbox Installed130
Replacing The Oil Seal130
Fixture For Removing Gearbox131
Removing Intermediate Shaft Front Bearing131
Removing Intermediate Shaft Rear Bearing131
Dismantling The Mainshaft133
Assembling The Gearbox134
Overdrive Tools136
Overdrive Description137
Direct Drive Position137
Overdrive Position137
Relief Valve138
Function With Direct Drive138
Overdrive In Function139
Checking The Oil Pressure141
Replacing The Solenoid And Operating Valve141
Checking And Replacing The Relief Valve141
Removing The Overdrive142
Cleaning The Orifice Nozzle142
Checking And Replacing The Check Valve142
Cleaning The Filter142
Dismantling The Overdrive143
Inspecting The Overdrive143
Removing The Front Casing143
Dismantling The Clutch Unit143
Assembling The Overdrive144
Assembling The Rear Casing144
Assembling The Clutch Unit145
Fitting The Overdrive146
Assembling And Fitting Front Casing146
Automatic Transmission Bw-35 Tools147
The Torque Converter149
Mechanical Power Transmission System150
Planetary Gear150
Clutches150
One-Way Clutch150
Oil Cooler151
Checking The Fluid Level151
Oil Cooler Connections151
Removing And Fitting The Control System152
Adjusting The Selector Controls152
Adjusting The Throttle Cable152
Adjusting The Starter Inhibitor Switch154
Adjusting The Front Brake Band154
Adjusting The Rear Brake Band154
Air Pressure Checks155
Front Clutch And Governor Feed "A"155
Rear Clutch "B"155
Front Servo "C"156
Rear Servo "D"156
Gearbox With Converter156
The Valve Bodies Assembly157
Front And Rear Servos160
Front Pump Assembly160
Front Clutch Assembly160
Rear Clutch Assembly161
Centre Support And Planet Gears162
Governor162
Rear Pump162
Driven Shaft162
Transmission Case, Shaft, Parking Pawl And Levers163
Installing Driven Shaft Oil Rings164
Gear Train Components164
Rear Brake Band And Servo165
Planet Gear And Centre Support165
Front Brake Band And Servo166
Rear Clutch166
Front Clutch167
Front Pump167
Extension Housing168
Valve Bodies Assembly168
Fitting169
Selector Controls169
Replacing The Selector Control Indicator170
Road-Testing171
Fault-Tracing Scheme172
Fault-Tracing On The Converter173
Propeller Shaft174
Replacing The Support Bearing175
Dismantling The Propeller 5Haft175
Dismantling The Universal Joints175
Replacing Bearings And Drive Shaft Oil Seals179
Replacing The Pinion Oil Seal180
Removing The Rear Axle181
Dismantling The Rear Axle181
Dismantling The Differential182
Inspecting The Rear Axle182
Assembling The Differential183
Fitting The Pinion183
Fitting The Differential186
Assembling The Rear Axle188
Fitting The Rear Axle188
Hydraulic Control Faults189
Mechanical Faults189
Clutch And Clutch Controls190
Brakes195
General Tools197
Footbrake System198
Description198
Brake Fluid199
Repa Ir Instru Ctions199
Fa Ul T Tracing200
Checking The Brake Pads202
Servicing202
Wheel Brake Units203
Construction Of The Front Wheel Brake Units203
Construction Of Rear Wheel Units203
Hydraulic Function204
Brake Components, Rear Wheel204
Rear Brake Caliper204
Rest Position204
A.s.b. Device (Rear Brake Calipers)205
Replacing The Brake Pads206
Front Wheel Brake Units206
Rear Wheel Brake Units207
Front Brake Calipers208
Recondition In G T He Wheel Brake Units208
Rear Wheel Brake Shoes210
Removing The Piston211
Checking The A.s.b. Device211
Rear Wheel Brake Caliper Assembled211
Brake Disc212
Hydraulic Footbrake System213
Master Cy Lind Er213
Warning Valve214
Brake Valve215
Brake Lines220
Replacing The Brake Lines221
Venting The Hydraulic System221
Venting With The Venting Unit221
Mechanical Venting223
Adjusting The Brake Light Switch223
Replacing The Brake Pedal223
Replacing The Bushes In The Brake Pedal And Lever224
Auxiliary Brake System225
Servo Cylinder225
Replacing Air Cleaner And Damper For Servo Cylinder227
Repai R I Nstructions227
Replacing The Check Valve228
Replacing The Servo Cylinder228
Handbrake229
Adjusting The Handbrake230
Replacing The Cable231
Replacing The Handbrake Lever Or Ratchet Parts232
Rear Wheel Brake Unit232
Front End And Steering Gear235
Wheel Alignment239
Wheel Angles239
Caster239
Camber239
Procedure Before Wheel Adjusting240
Measuring The Wheel Angles240
Checking The King Pin Inclination240
Checking The Toe-Out240
Adjusting The Wheel Angles241
Adjusting The Caster241
Adjusting The Camber241
Adjusting The Toe-In241
Adjusting The Steering Limits243
Front End244
Front Eno Complete246
Examining The Bearing Components247
Ball Joint, Upper Wishbone248
Lower Wishbone249
Steering Gear252
Steering Wheel Lock253
Steering Gear Construction254
Control Valve258
Oil Container258
Servo Pump258
Replacing The Steering Wheel259
Replacing Steering Column Jacket Bearing259
Replacing The Relay Arm Bush260
Mechanical Steering Gear260
Springs272
Front Springs273
Rear Springs273
Shock Absorbers And Stabilizing Devices275
Checking The Shock Absorbers276
Replacing Front Shock Absorbers276
Replacing Rear Shock Absorbers277
Replacing Bushes For The Support Arm277
Replaci Ng Bushes For The Track Bar278
Replacing Bushes For The Support Stav279
Wheels280
Changing Wheels280
Replacing The Wheel Studs280
Replacing And Adjusting Front Wheel Bearings280
Body283
Body Frame286
Bonnet And Mudguards288
Front Mudguards288
Front Section288
Doors And Luggage Compartment Lid289
Removing And Fitting Door Stops289
Removing And Fitting Front Doors290
Removing And Fitting Rear Doors290
Removing Inner Handles And Upholstery291
Removing Front Door Lock291
Latch Plates291
Removing Rear Door Lock291
Removing Lock Handles292
Fitting And Adjusting Front Door Lock Handle292
Fitting And Adjusting Rear Door Lock Handle293
Removing Front Door Frame293
Removing Rear Door Frame293
Removing Front Door Winding Window293
Removing Ventilation Windows294
Removing Front Door Window Winder294
Removing Rear Door Winder294
Luggage Compartment Lid295
Sealing Strips, Trim Mouldings And Glass296
Removing The Trim Moulding For Rear Window297
Fitting The Trim Moulding For Rear Window297
Removing The Windshield297
Fitting The Windshield298
Removing The Rear Window298
Fitting The Rear Window299
Interior Fittings And Upholstery300
Front Seats300
Rear Seat300
Door Upholstery300
Replacing The Headlining302
Removing The Front Seats302
Adjusting The Front Seat302
Removing The Instrument Panel302
Removing The Heater Unit303
Dismantling The Heater Unit303
Assembling The Heater Unit304
Fitting The Heater Unit304
Removing The Heater Unit Controls304
Bumpers305