Volvo 164 User manual

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Part # 284056-9
INSTALLATION INSTRUCTIONS

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Part #284056·9
FOR INSTALLATION ON 1975
164 SERIES, 6 CYLINDER WITH AUTOMATIC
TRANSMISSONS ONLY
Volvo af America Corporation
Rockleigh, N.J. 07647
RETAIN THIS GUIDE IN STUDENT NOTEBOOK FOR FURTHER USE.
The Volvo Cruise Controi is a safety related accessory and it is very im·
portant that each component be assembled, located, installed carefully and
correctly. It is, therefore, suggested that you take a few minutes to familiar·
ize yourself with the parts and the Installation Instructions. The Cruise
Contral is designed to maintain set vehicle speed within approximately +2,
-4 m.p.h . on level roads and moderate grades. When the vehicle is heavi ly
loaded or when negotiating steep grades these tolerances may be temporarily
exceeded.
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TABLE OF CONTENTS
Parts Check List ........ .. . ...... ...... . .... . ............ .
Installation Instructions ... ..... .... .... ..... ... .... . ..... .
Operational Check Procedure ... .. ......................... .
Vehicle Road Check ...................................... .
Electrical
Checks ......... ..... ......... . ................ .
Brake Release Check .. . .............. .. .................. .
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Page
4·5
6
18
18
19
20
Vacuum Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Regulator Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Circuit Diagram ........... . . . ..... ... .... . ....... ... ..... 21
Trouble Shooting Guide ................. .. . . ............ . . , 22-23
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4
2
• 4
~
3
~
~ 23
y,\
"""
~ 2
~ ..
'- .
20
""' 21
"-
19
. ~ ....
"-- .
17 -'
\ ' lO
~ 7
;.,
~· · 11
,. 8
13
~'15
C{-$1Z
..
...- .... - ....... -' 14
.~ 9
PARTS CHECK LIST
Place all components in front of yo u as show n in the illu strated parts list. Repla ce ment parts can be
ordered thr ou gh the Vo lvo parts system u si ng the part number li ste d below.
~igure
Figu re
Number
Pa rt Number
De sc ription
Number
Part Number
Descript i on
75222 ·0
Vacu um servo
13
75228·7 Meta l cha in gui de -ou ler lube with
2
75223·8
Regul ato r
Cctte r pin .
,.
75229·5 Mel al cham guide w i th inner
3
7522 6- ' $peedomeler cable
tu be 3113ched.
4
75 227·9
Tran smissi on cable
15
S id . Hard wa re Self sH
ippin g connectio ns
5 N55
Mou nlin g temp late -seryo lre gu -
ISlCr br ac kel.
16
Sid . Ha rdwa re
Strap s, plast ic
17
75 22 5·3 W iring harness
6 NSS
Mou ntin g t empla te·fu el can·
is ter.
18
75 224·6
Enga geme nl switch assembly
7
SId. Hard wa re
Nul and l oc k vvasher assemb ly
19 S Id .
Ha r dware
$crews-br ac ket mounting
1/4-20.
20 75230 -3
Servo / regulator m ounli ng bracke!.
8 SId. Ha rd ...... are
Jam nul 1 /4·2 0.
21 75231-' Va
cuu m l ee
9 Sid . Hard ...... are
BolH eg ulalor mo unting
22 Std. H ard ...... are
1 2" vac uum hos e-regulator to
1 0- 11
SId .
Hard ...... are
S cre ...... and cl am p for tran s· lee
connec tion .
mi
ssion cab le mount ing. 23 S
td . H ard ...... are
9" vacuum hose· regulaT or tO
12
Sid. Hard ...... are
Cl amps for v acu um hoses
se rvo conn ec tio n.
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INSTALLATION INSTRUCTIONS
MUL TlPLE CONNEC TOR
VIOLET
TO POW"ER - -..:=:,
SOUR Cf
(SEE lNST!l.UC T~l~O~ NS~)~',Z ~==r:~ ~
T AP SPLlCE
SEE ne. 6
COLD SID E or 8RAKE
LIGHT SWITCH
Hor SID E or B RAKE
LIGHT SWITC II
WALL
CRUISE CONTROl
INSTALLATION DI AGRAM·
l WIR!. CO N!CECTOIt
BL UE TO 'l
BRO lIN to 12
YF.LLOW TO Il
6
Referring to the installation diagram, note the location of each group of par ts. The servo, regu lator, and vacuum hose
groups are l
ocated in the engine compartment. The engagement switch group is cl amped on the tum signal lever. The
wi ring harness and cab le gro up connect th e varlous groups . Since the groups are connected with either cables, electrical
reads, or vacu
um hoses, il is sugg ested th at the unjt s be positioned in the ;r app roximate l ocations prior 10 actual
m ount in g.
INSTALLATION INSTRUCTIONS
The numbers in (parentheses) refer to Speed Co ntroi C ompo nents
Illustra ted in the parts picture page 4.
STEP NO. 1 - Disconnect negative batte ry
cable. Remove air cleaner. I
STEP NO. 2 - Remove fuel canister. Usi ng tem-
plate (6) provided, drill new 1/ 4" mounting holes
for the fue! canis ter. Do no t reinstall fuel cani s-
ter at this time.
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CABLE CONNECTION
STEP NO. 3 - Remove panel underneath
steering wheel
to expose under das h area.
STEP NO. 4 - Disconnect speedometer cable
from speedometer and transmission. Remove
cable clamps and firewall grommet. Remove
cable from vehicle.
NOTE: Oil seal at transmission cable connec·
tion. This seal must be in place when new cable
is installed.
STEP NO. 5 - Insert new speedometer cable (3)
through firewall and connect plastic nut end to
speedometer. Route free end of cable toward
regulator area and install grommet suppli ed on
new cable i
nto firewall hole.
STEP NO. 6 - Route transmission cable (4)
from
engine compartmen t to transmission and con·
nec!. Reattach al l existing cable clamps so that
new cable follows original cable routing.
STEP NO. 7 - Approx. 12 inches forward of
the existing transmission cable clamp, drill a
5/ 32" hole and mount new transmission cable
clamp (11) with sheet metal screw (10) pro ·
vided.
NOTE: The purpose of this new clamp is to
keep the transmission cable away from the
exhaust
manifoid.
SERVO MOUNTING
STEP NO. 8 - Assemble 1/4·20 jam nut (8) to
servo s tud and run jam nut to bottom of stud.
Assemble servo (1)
to bracket (20) with 1/4· 20
nut and lock (7) washer assembly. Leave jam nut
and nut /lock washer loose for later adjustment
of bead chain.
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STEP NO. 9 - Position servo/regulator braeket
mounting template (5) in place on right wheel
weil rib with tape and drill two (2) 11 / 64" hales .
Remove template and attach servo and braeket
with three 1/4 x 3/4 (19) washer head tapping
screws with short leg of braeket painting down .
Tighten braeket screws securely.
NOTE: It will be easier to secure braeket if
af ter drilling you pre-drive screws, and then
back them out.
ATTACHING CHAIN TO SERVO
STEP NO. 10- Remove cotter pin from down ·
shift cable clevis pin. Attach bead chain coupling
and chain assembly (14) to downshift cable
elev is pin. Replace cotter pin.
STEP NO. 11 -Install outer tube (13) of
metal chain guide over bead chain. Do not as vet
secure to chain with cotter pin.
NOTE:lt is necessary to install metal chain guide
for safety reasans.
STEP NO. 12 - Attach bead chain to servo hook
and adjust servo jam nut and nut/lock washer to
remove slack from bead chain. Tighten jam nut
and nut /lock washer assembly.
CAUTION: CHAIN MUST NOT BE TIGHT
ENOUGH TO AFFECT ENGINE IDLE SPEED .
THROTTLE CABLE
=n --s e HAlN eOUPLlNG (t'ltL<T)
DEAD CKAIN ''''S'- EXISTlNG eoTTER PIN
,..----- 1-- 3..-.:C@
o
10
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STEP NO. 13 -Slide metal bead chain guide
outer tube as close to servo hook as possible
and secure to chain with cotter pin. Crimp servo
bead chain hook alter installation.
REGULATOR MOUNTING
STEP NO. 14 - Assemble regulator (2) to
servo/reg mounting braeket using two
1/ 4·20 x 1/2 hex head balts (9) Do not tighten
regulator mounting balts at this time.
STEP NO. 15 - Attach both new cables to
regulator and tighten nuts. Check bot h cables
to see that:
A. Neither cable interferes with any hot or
moving parts (servo. bead chain assembly,
exhaust pipe, etc.).
B. Cables are Iree 01 kinks and sharp bends
(minimum six (6) inch radius lor all
bends).
NOT E: Speedometer cable must be installed
behind bead chain and A/ C hoses.
ENGAGEMENT SWITCH MOUNTING
STEP NO. 16 - Attach the engagement switch
assembly (18) to turn signal lever with clamp
provided and tighten set screw to hold in place.
STEP NO. 17 - Remove lower half of plastic
steering column shroud and route engagement
switch harness inside shroud alongside steering
column to under dash area. Replace steering
column shroud.
EXISTING
TURN-SIGNAL
LEVER
o
"
ENGAGEMENT SWITCH
'--',
~CLAMP
i- S ET S CREW
12
13

STEP NO. 18 - Route wiring harness (17) from
passenger compartment, through firewall into
engine compartment and over to the right wheel
weil area for connection to regulator. Use exist ·
ing grammet and hale located above speedometer
cable grammet for this harness routing .
STEP NO. 19 - Attach blue and white wires of
wiring harness to vehicle brake light switch. The
blue wire is connected to vehicle blue/red stripe
wire and the white wire is connected to vehicle
green wire. Use the self stripping connectors (15)
• to make these connections.
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STEP NO. 20 - Attach special female terminal
on violet wire of wiring harness to #1 to # 2
vehicle fuse terminal.
STEP NO.
21 - Connect wiring harness to
engagement switch harness (four'way connector
red, brown, green and yellow wires).
NOTE: Relay
of wiring harness may get hot
during operation.
STEP NO. 22 - Connect wiring harness to
regulator. Plug the three wire connector onto
the three terminals on back of regulator and
the single connector (green wire) anta the
threaded screw.
STEP NO. 23 -Install grounding eyelet (black
wire) under one of regulator mount i ng ba lts
and tighten both balts securely.
VEHICLE'S
EXlSTlNC
~
SPEED CONTROt
uIRt
SELF STRIPPING
cm/NECTOR
INSTALtED
14
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VACUUM TUBING GROUP
STEP NO. 24 - Route and attach 9" length of
vacuum tubing (23) from servo to "S" connector
of regulator.
STEP NO. 25 -Locate the 3/ 8" vacuum hose
routed from the vacuum pump thru the firewall
into the passenger compar tm e nt . Cut this hose
approx i mately 6 inches from the firewall. Slip
damps (12) over hoses and insert 3/8 x 3/8 x 1/4
vacuum tee. (21) Attach remaining vacuum tube.
with clamp to tee, rout e to regu lator and attac h
to "M" co nne cto r.
STEP NO. 26 -The vacuum tubing and wiring
harness may be
tied together or out of the way
with plastic st raps (16) to prevent damage from
moving parts, hot manifoid, etc. Also, excess
wiring harness may be tied up under the dash
area.
STEP NO. 27 -Install fuel canister in new
position.
STEP NO. 28 -Replace panel under steering
wheel and reconnect battery cable.
Fire Wall
MO s
Engine
t Vacu
um Pump
, .. ... /,
~- _ __ • J _ •• _ ,
.. ,/ \,
Tee
1~>i;tQ:===~ ' 4- 3/8" Vacuum Hose
. s
INSTALLATION IS NOW COMPLETE
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OPERATIONAL CHECK PROCEDURE
CAUTION: CRUISE CONTROl SHOUlD NOT BE ENGAGED ON WET OR SLICK ROADS.
Perform the following checks alter "Cruise C ontrol" installation is comp leted. If problems
are experienced during this operational check, refer to the Trouble Shooting Guide.
IGNITION SWITCH OFF
UNDER HOOD. Manually operate veh icle 's throt ·
tie linkage though its full travel, thus allowing the
"Cruise Control" linkage (chain and cover) to go
slack. Check to see that th ere is no possibility of
the chain and cover becoming entangled with any
adjacent parts (which
would tend to hold the
th rottle open).
TURN IGNITION SWITCH ON AND
START ENGINE
1. Set emergency brake and put transmission in
"park" ,
2. Move slide switch to "o n" position.
3. Depress set speed bulton and hold for approxi·
m ately 2 seco nd s. Sys tem should NOT engage. If
system DOES engage, (engine racesl, immediately
turn ignit ion off, and c he ck all connections for
proper adjustment.
4. Start Engine. Disconnect vacuum
hose at regu·
lator
from the "M" connector. Engine speed
ELECTRICAL CHECKS
11 is not al ways necessary to remove the regul ator in case of
inoperative Cruise Contral. The following checks should be
performed
as part of the diagnosis to determine the cause
and correction of Cruise Contr oi trouble:
1. Disconnecl push on con nect ors at regulator (single and
triple). Grounding lug may be leh connected.
2. Turn ignition switch to accessory position .
3. Move slide switch to th e "O n" position.
4. Using a test light. ground one test light read and touch
the othe r read to the brown wire and the n the green
wire at the conn ecto r s. Test light shou ld light. If test
light does not lig ht on brown wire. check fuse, engage·
ment switch, and newly made connection at power
source. If test light dees not light on green wire, check
engagement
switc h and newly made connec tion s at
power source and br ake light switch.
5. Push "set speed" butten all the way in a nd hold.
G roun d one test light lead and tou ch the other lead to
each wire in the conne ctor. Test light sho uld light on
th e brown and yellow wires and should not light on the
green
or blue wire.
6. Release "set speed" switch butt on.
7. Move slide sw
itch to "resume" posi tion and hold.
Ground one test lamp lead and touch the othe r lea d to
each wi re in the con ne ctor. Test bulb sh ou ld light on
all wires except th e blu e wi re (b lu e connects to brake
lamp side of the brake light switch).
should increase somewhat and idle will be rougher.
There should
be vacuum available at the hose end.
If not reconnect vacuum hose and check all con·
nectio ns for le ak age.
VEHIClE ROAD CHECK
(Should be made on open or uncongested high·
way.)
1. Move slide switch to "ON" position.
2. Dri ve at 10 miles per hour, depress and release
set speed button. The system should not engage.
(Normally system should engage at speeds above
30 mph.)
3. Drive at 45 miles per
hour . Depress the se t
speed
button and release. System should engage
and hold within plus or minus 2 mph.
4. Depress brake pedal. System will disengage.
5. Move slide switch to "Resume" position and
release. Vehicle wi ll re Sume pre·set speed.
6. Move slide switch
to "O FF " position . System
w ill be completely disengaged.
To ma ke an indepe ndent check of the eng age ment
switc h before removal from the vehicle, disconnect the
switch from the wi ring harness. at the multiple con·
nector (see Diagram Page 4) in the passenger compart·
ment, and make the following checks: (Omit steps 8
thru 1S if st ep 1 thru 7 check out.)
8. Attach a jumper wi re from a 12· vo lt power so urce to
the red lead of the engagement switc h.
9. Move s
lid e swit ch to the "off" position ,
, O. Using the test light. ground One test li ght lead and
touch the other lead, in turn, to the brow n wire , the
green
wi re and the ye !low wire. The te st light s hould
not li ght on an y of these wires.
11 . Move slide switch to "on" position.
12. Touch test light lead to the b rown wi re and then th e
green
wi re . The te st light s hou ld light on each of these.
Touch the l ead 10 the y ellow wire. Lig ht should not
light.
13. Pu sh "set speed" all the way in and h old . Test l ight
s hould light on the brown wir e and on the yellow wire,
Te st light shou ld nOt light on the green wire.
14. Release "set speed"
switch button.
15. Move slide s witch 10 "re sume" po sitio n and hold.
Touch the test light le ad in turn. to the brown wire,
the
yellow wire and th en to the gr een wire. Te st light
should light.
NOTE: If Steps 1 thru 7 do not check out and Steps 8 thru
15 do c he ck out, replace wiring harness. If steps 8 thru 15
do not check out, repla ce the engagement switc h.
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BRAKE RELEASE
CHECK
1. Disconnect multiple connector from regulator (a ll
other connections are made),
2. Touch one test light lead to blue wire and other test
light lead to ground. Bulb shou ld not light.
3. Depress brake pedal; test light and brake lights should
go on when pedal is depre ssed and off when pedal is
reJeased.
NOTE: Excessive brake pedal tra ve I necessary to acti v ate
test light may result in vehicle braking befare release of
Cruise Contral System. If thi s is objectio nable adjust brake
light
switch .
4.
If above sequence fails - c he ck for brake light switch
adjustment, defective switch, or defective brake
light
circuit fuse.
VACUUM CHECK
Make sure vaCuum h ases are properly connected and care·
fully rout ed.
WARNING: If hase connected 10 servo is collapsed or
kinked , servo may keep throttle open even though brake
is applied,
REGULA TOR SPEED
ADJUSTMENT
20
If vehicle accelerates or decel erates more than 2 mph upon
operating set speed button, a regulator s peed adju stment
ma y be necessary,
CAUTION: This should be ac compli shed by EXTREMEL y
fine adjustments ,
TO VACUUM ~URCE
TO SERVO
FIGURE l ADJUSTING
KRE'fI'
1. If vehicle accelerates more than 2 mph after depressing
set speed bulton, turn speed adjusting screw " C" s Ji ghtly
toward S,
2, If vehicle decelerates more than 2 mph after depressing
set speed buttan, turn speed adjusting screw "C" s li ghtly
toward F.
CIRCUIT DIAGRAM
lll i LH.. k! ;. ~
1L""' Y[ I ' , J ;"~
-.
Pl"SH ~ r ;: o .~
SI. II);. 51:1 : C"
f- --,---- .-- --j ~~~ ~ ~ ~ ~
.-
CL U S[D
C LJ S:'O
OPE'· -
CL{I<aO
(1.O ~ F.t1
c.' ('J S~ D
.
s.nTeH eJ."
CLOS!;D
Op Et-
n Os eD
~ ~
s -
r
C. ., ... l 'tt, ', !
:,; '.'1 1" 1: 1,
,
~~:,
1.,1-
.~
.,
y ;: 1. 1,0 ;"
t ,
, l
G RE~
l "
--
----.J
E r
l
RE LA'
' l 'SH
BlIno:;
SL ID(
Sl:IT Ch
- ~OR."V.l ...... orr
--·O I:P RE SS EO - o~
_ .. /!.ES,
:-O O H:
R!"LA y I.:lLL
CH
~OT
Dt:R I~C o r f.RA n U::-
;
~f o " 'I"
,..,
,u'r f
B LACK
f-
IIlilTE
l.5
'"
n;SE
~
L
\ I OLH
ICS l1 1 0:-0 S I.:! TCH
, -I
"c c.
S 1:) (
V~!d C L~
1SF,..:. i- ,;.
$ .... 1': e l;
VEHl(] l
B RAP
Fn ,E
I If-l
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22
TROUBLE SHOOTING GUIDE
DESCRIPTION
The regul ator is dr ive n by a flexible dr ive cable from the
transmission. The spee dometer is driven by another fle xible
dri ve cab le from th e regulat or. The engagement switch
electrically cont rols the regulator which in turn contrals
the vacuum from the inlake manifold to the servo w hich
actuates the thronle. Electri cal co nnect ions are pr ovi ded
for attachment to the existing b rake li ght switch to ca use
disengag eme nt of the unit when brakes are applied. Fo r
your con venien ee and safety th e slide switch will di sengage
the entire s yste m wh en pushed to the "off" pos ition.
CO NDITL ON PQSSIBLE CAUS E
AEM EQY
Blowing fu'es
Sh Ort or ground in Cruise Contral
Perform el ectriCal ch eck s
w i ri ng circuit
Replace only wit h 1.5 am p 1use
Cruise Contra I does not .ngage Cr ul s. Controi ha rness fuse burnt
Replace fu se ( 1.5 amp on ly)
out
Brake li ght switc h on
Adjust or replace braka li ght switc h
Faulty brak.e l ight swit ch
Rc!p1ace b rake l ight switch
No current tO brown wire
R epair w ,r ing na rness or check for
l oose con ne ction
Vacuum le ak
Repai r l eak
Sad ground
Chec k regulator for ground
E t.ctrical
See e lectrica l check
No ground
Ad d wire from regu la tO r tO gro und
f au l ty con n ett ions
T .ght en conne ctions
Brake light fuse burnt out Aeploce fuse
B r ake lamp bulb burn ! out Replllce bulb
Engaging sw itch inoperative R ep l ace eng39,n9 switch
S.e el ettrica l c he c ks -
Ste ps 8 th TU 15
Cr ui se Controi does
lmproper b rake light sw itC h Adj ust brake I.ght SWI tc h
not d'Sllngage
adjunm .nt
whe n brake i5
Defective bra ka light switc h
Rep l ace brake lig ht sWI tch
app lied
Co llapsed tube from Servo to
R ep la ce tube
r egulat or
Re-engages wnen brake is rel eased
F aulty engagement sw itch Aepl<lce engage m en t swi tch
V eh.cle·s b<l uerv di lc ha rge d I
mprOp er wire connections Selec! Correc! po we r SOUTce
See Ins t<lllati on In st ructions
Vehicle's banerv d i sch a' ged
Def.ct'v. rel av in C ruise Contr oi Replace w iron g tu rness -
& Cruise ContrOi switch l ett " on "
wiring har n en
l mportant · Aep lac e C ruls e Con tr o i
1use on l v w i th a 1.5 amp fu se
Engine do es not
Impr ope r Cruise Contro i Ser vo Adju5t C ru ise Contro i servo
return to normal
linkage ad ju u ment linkage
idle
lmp.oper accelerator linkage A djv Sl acce lerator lin kage
adju stm ent
Weak or disconnected Replace o r connec t spr ing
thrOttle return spri ng
Pvlsating accelerator pe d al
Speedome ler ca ble o r L u bricat e cables li g htl Y .• ncluding
d, i ve cab le kinked o r la ck of tips, or repla ce cab le if necessarv
lub ri cat io n
Spe e do me te r
Speedom eter cable not C heck for broken cab le or
inop.rati .... e & Crvi se Controi
driving s peedomeler 10 0se connection s
op erates
Faulty reg ula tOr R eplace Regulator
Neitner sp ee do meter
Trans miss Io n cable not Ch .ck. fo r b rok. en cable
nor Cr ui se ContrO i o perates
driving r egu la to r or loos.e connec tions
Fa ulty r egulat or Rep la ce R egu l ator
Ve hl c re accelerate s or
Regu l ator out 01 adju stment
Re f er to Aegu l ar Speed
dece lera tes more ,h an 2 MPH
Ad just men t , page 18
upo n depressing of engagement
switch
Engine acce \erates wh en sTarte d V a
cuum lu bes re versed at
Check instruct lo n s sheel fo r
r
egulator
prOp er connections
SYSt e rn dise ng ag es
Loose wiring co nne c t ions or
T ig ht en connec ti ons and
o n l eve l rOad wi th ou t
poo r ground
c h eck grov nd
applvi ng brake
Loos e t ub es
Check tvtoe connecti ons
Ser .... o link.age chain broken
Re pai r cha in or tig hten clam p
o r t h
rOtt le c l am p slipped
Errat ic ope ration
F au Ity v acuum servo or Re place servo o r va cuum tube
of C ru i se Controi
vacuum tube
Fa u h y r egulato r R ep la ce regu lator
23

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CUT
OUT
ON
LIN!:.
4 -
SIDES
• •
VOLVO
6-CYL. 1974 & 1975
CUT
OUT
&
PLACE
OVER
EXISTING
HOLE
1.25
k
\----}\---
LOCATE
ON
RIGHT
WHEEL
WELL
RIB
DRILL
11/64
HO~~S
P~~H
l:Jj
Si
o--l
~
H
Z
(fl
o--l
'Tj
H
~ ~
r-' r-'
59B-01540 Rev . A

BUTT
AGAINST
fIRi':WALL
PlIEL
CANISTER
TEMPLATE
VOLVO 6
CYL.
1975
IlUTT
AGAINST
RIE
ON
lUGHT
FRONT FENDER
FRONT
l
,
DRILL
OR PUNCH
•
3/16
DIA.
HOLES
(2)
,
1.38)
rlIT
()]IT
nN
J
TNF
,-..
.......
I'"