Volvo 164 1969 User manual

SERVIC_
M NAL

FOREWORD
This Manual contai ns servicing instructions for the
Vo l vo 164.
The
book is di vided up in to 10 parts as i ndicated
by th e regist er op pos it e. The pages and figure
illustr ation s in each part are n um bered in such a
way that the fir st group shows the numb er of the
part concerned while the se c ond group s how s,the
number of the pag e or figure illustration in that
particular part, for example, under the heading
"Electrical system"; 3-1, 3-2, etc. A convenient
way of finding the particular section you are look-
ing for is to bend the right side of the Manual
back so that the arrows in the register point to the
index marks on the first page of each section.
The
various parts are divided up as follows:
Tools
Description
Repair Instructions
The specifications are to be found in Part O,
General.
The instructions given in this book generally as-
sume
that special tools are used and are based on
experience
gained from method studies. The same
results may be obtained with other working me-
thods,
but we are convinced that by following the
instructions given in this
Manual you will always
achieve the best results in the shortest possible
time.
AB VOLVO
Göteborg -Sweden
Reprinting
permitted if source quoted .
o
1
2
3
4
5
&
7
a
9
General
Servicing and
maintenance
Engine
Electrical system
we. t iul s •• i ss iulI ,
rear axle
Brake s
Front end and
steering gear
Frame, suspension,
wheels
Body
Instruments, accessories
and other equipment

Part O
GENERAL

j

GROUP 01
TYPE DESIGNATlONS
This Manual deals with the Volvo 164 car of the fol lowing types: *
Type designation Engine
Gearbox Rear axle
164-134
B30 A M 4 00 3.73: l
164- 1 55
B 30A M 410 3.73: l
164 -156
B3 0A BW 35 3.31: 1
164-137
f33 0 A
BW 35 3.31: l
* App li cable in Sweden
TYPE PLATES
l. Vehicle type designation,
chassis number and code
number for colour and
upholstery.
2. Body number.
3. Type designation and
chassis number (stamped
on the front right-hand
door pillar).
GROUP 03
•
DIMENSIONS AND WEIGHT
Length
Width
Height
.. . ........ ... ...... ... ................... .... ..... . .
Wheelbase ...... . ...... ..... ....... . .......... . . .. .... . .. .
Ground c1earance .. . .. .. . ... .... . .. ..... . .. ..... ..... ..... .
Track, front
.......................................... . .... .
rear . . ............................................ , ..
Turning circle ........... . .......... . . , . ............... .... .
Curb weight ........ ............ . . .. ..... . ..... . ... approx.
4715 mm (186")
1735 mm (68.3")
1440 mm (56.7")
2700 mm (106.3")
180 mm (7.0")
1350 mm (53.2")
1350 mm (53.2")
9600 mm (31.6 ft.)
1360 mm (2992 Ib.)
4. Engine type designation,
part number and manu-
facturing serial number.
5. Gearbox type designa-
tion,
part number and
manufacturing serial
num-
ber.
6. Plate on lower part of
inspection cover showing
number of teeth and re-
duction ratio of final
drive.
o:1

LU BRICAT I ON
ENGI NE
.Lubricant, type . .. .. .. . ...... ..... .. . . .. . .. ... ... ". . .. . ... . . . .
grade
.... . . .. .. . .... .. .. . . .. . . .. . .. . . ... ..... .... .
viscosity, all
year round .... . . . .. . . .. .. .. .. . . .. . . .
below _
10 ° C (14° F) . . .. .. . .... . . .... . . .
between _ 10° and + 30° C ( 14 and 90° F)
abbove + 30° C ( 90° F) . .. . .. . . .. . .. . . .. .
Oil capacity, excluding oi l f il ter . . ..... .. . . ... . . . . .. ...... . .
including
oi l f ilt er ...... .. . ... . .... . . . .... . ... .
CO il for carburettor damping cy li nder . . ... ... .. . . . . . . . ...... .
GEARBOX (WITHOUT OVERDR I VE )
~ . L Ll!lbricant, type . .. .. . . . . . . ... . .. . ....... . .... . . . . . ..... . . . . .
vi sc osity ............ . . .. . .... . .. ... ....... . ..... .
at continous air temperature below - 10° C
(14° F) ... .. ... . .... . .. ... ... . .... . .. . . . .
.,Alternative lubricant, type . . .. .. . ... . ...... . . . .. . . .. .... . .. .
viscositY !i- 1f OII year round ...... . ... . . .. . .
a
lt ernat iv e . .... . ... . . . .... . ... . ...... .
~ .oil. capacity
': ' GEARBOX WITH OVERDR IV E
;l. lJ wnricant, type . . ... .. .. . . . . .. .. ..... . . ... .. . . ..... . ... ... . .
g,
rade ....... . .... .. ..... . ..... . . . .. .. .......... .
viscosity, a
ll year round .. .... . ..... . ............ .
alt~rnat iv e . . .. . ....................... .
O il capacity, gearbox and overdrive
AUTOMATIC TRANSMISSION
Lubricant, type . .. . .. .... ........ ... . .. ... .. .... . ..... ... . . .
Normaloperating temp. of oil . .. ......... ......... .... ... .
Oil capacity .... . ............ ... .. . . .. . .... ..... .. ..... . .. .
FINAL DRIVE
Lubricant, type, without differential brake .................. .
with differential brake . . .
.. .... . ....... ... .
viscosity,
above _ 10° C (14° F) .............. .. .. .
below -10° C (14° F) . ... .. . .... . ..... . .
Oil capacity .. .... ... . . ................... . .. . ...... ... ... .
MECHANICAL STEERING GEAR
Lubricant, type ..... .. . ... . . . .. . .. .... .. . ... . .. ........ . .. . .
viscosity . .
... ... . ... . ..... . .. . .. . . .. .. ........ .. .
Oil capacify .. .... . .. . .. .. . .......... ... .. . ........ . ... .. . . .
SERVO STEERING
Lubricant, type ... . ... . .................. . ....... . ......... .
Oil capacity .. . .. .. . ............ . .. . . ... ...... .. . .. approx.
ENGINE
GENERAl
Type desiglnation .... ....... .. ... ... .. .... ... . . ....... . .... .
Output, h.p. at r.p.m. (SAE) ......... ....... . . . . .. . . .... . .. .
(DIN) ... . . .. ..... . ............ .. ... . .
Max. torque, kgrm {lbJt.) at r.p.m. (SAE) ................... .
(DIN) .... .... ... .... . ... .
0:2
Eng in e o il
Se rvi ce MS
Multigrade O il SAE 10 W -3 0
SAE 10W
SAE 20 / 20 W
SAE 30
5.2 li tres ( 9.15 Imp.pints= 10.97 US pints)
6.0 litres (1 0. 56 Imp .pints= 12.66 US pints)
O il for Automatic Transmissions, Type A
Gear oil
S
AE 90
SAE 80
Engine oil
SAE 30
Multigrade oil SAE 20 W- 40
0.6 litre ( 1.1 Imp.pints = 1.3 US pints)
Engine oil
Service
MS
SAE 30
Multigra.de Oil SAE 20 W-40
1.4 litres (2. 46 Imp.pints= 2.95 US pints)
Oil for Automatic Transmissions, Type A
100-115° C (212-239° F)
8.2 litres (14.43 Imp.pints = 17.30 US pints)
Hypoid oil
Oil according to MIL-L-2105 or MIL-L - 2105 B,
provided with additive for differential brake
SAE 90
SAE 80
1.6 I.itres (2.82 Imp.pints = 3.38 US pints)
Hypoid oil
SAE 80
0.6 litre (1.1 Imp.pints= 1.3 US pints)
Oil for Automatic Transmissions, Type A
1.2 litres (2.11 Imp.pints=2.53 US pints)
B 30 A
145/5500
130/5000
22.5 (63}/3000
21 (152)/2500

C omp ression pressure ( warm engine) wh en tu rned over with
st arter moto r, 25 0 -3 00 r.p.m. . . . . . .. . . . . .. . . ... ..... ..... . .
C
ompre ss ion ratio . . . . ... . . . . . . . ............ ... ... . . .. . . . . .
Nu
mber of c yli nders ... . . . . ... . . . . . . ... . .... . . . .... . . . . .. . .
Bore . .
.. .... ... . . . . . .. ... . . . .. .. . ... . . . . .. . .. . . ... . . ... .. .
S trok e . . . ... . . . . . . . . . .. .. .... . . . . ... . . . .. .. .. .. . . . . . . . .. . . .
D-isplacement . . . . . . . . . . .. . ...... . .. . .. .... ... . ... . .. . .. . . . . .
We ight, included elec tri c al e quipm e nt and gearbox . . .. . . . .
We ight exclud'ing gearbox, s tarter motor, oi l and water . . . . . .
CYLINDER BLOCK
Mater ial .. . . .... ... . . . . .. . . .. . .. .. . . .. . ... . .. . . .. . ... . . . .. .
Bore,
standard .. ... . . .... . . .. . . . . . . . . . . . . . . . . . . .. . . .. . .. . . .
oversiz e .030"
PISTONS
Material ...... .. . ... . . . ... ..... ... ............. .. .. . . . . ... .
We i ght , s tandard . . .. . .. . . . ...... .. . .. .. ... . . .. . .. . ... . . . . . .
Permi ss i ble we i ght dev i at ion betwe en pi stons in same engine
Heig h t, tota l . . ... .. ..... . . .. ... . . . .... .. . . . .. . ... .. . . .. . . . .
Height f rom piston pin centre to piston cr own . . . . ... . . . . .. .
Piston cl e aran ce . .. . . . .. . . . . .. . . ..... . . .. .. . . . . .. . . ....... .
PISTON RINGS
Pist on ring gap , meas ur ed in ring opening . .. . . . .. . .. . . . . . . .
Oversize on piston rings
.. . . ... . . . .. ... ... . .. . . .. .. . . . . . . . .
CO MPRES S ION RIN GS
Marked " TOP" . Upper ring·chr omed .
Number on e,ach piston . ... .. .. .. ... .. .... . . . . .. . . ... . .... .
Height .. ... . ...... . . . .. ... .... ... . ... . . . .. . .. . . . .. ... .. .. . .
Pis ton ringl clearance in groov e .. .. ..... ... .... ....... .. . . .
Oll S CRAPER RINGS
Number on each piston . . .. . ........ .. . .... .. ... .. . .. .. .. . .
Height .. .. . .. . ... . . ... . . . . . . ... .. .... . . . . .. .. . .. . . . . . .. .. . .
Piston ring clearance in g. roove . . ... . . ... . . . . ... . .. .. . ... .. .
G UDGE ON PINS
Floating fit. Circlips at both ends in piston.
Fit:
In connecting rod .. . . ... ..... .. . .. ... .. .. ... ... . ...... . . .
In piston .. . .. .. . . . . .. ... .. . ....... . . .
Diamet e r, standard .. . . . . . . .. . .. . . . .... ... .. . . . . . .. . . .. ... . .
oversiz
es .05" .... .... . .. ... ......... .. . ..... ... ..
.10" .. .. .. . .... . .... . . . . .. . ..... . . . . . . . .
.20" ... . . . .. . . . ... ... .. . . . .. . . . ... . . . . . .
CYLINDER HEAD
Height, measured from c. ylinder contact face to face for bclt
heads ... . .. . . . . .. : . . .. . . .... . . . . . .. .. . .. . .. . . . . .. . ..... .. .
Cylinder heod gasket .. . ... . . . . . . . .. .. ....... . . ... . ..... .. .
CRANKSHAFT
Crankshaft, end float ... ... .. . . . .. . . . ..... . . . . ... . . . . . . .... .
Main bearings, radial clearance . . . .. . . . .. . .. .. . . ... .. . . .. . .
Big
i- end bearings , radial clearance . . . . . ... . ...... . . .. . . ... . .
11 - 13 kg/ cm
2 (
156 , 185 Ib/ sq. in)
9.2: 1
6
88 .90 mm (3. 50 ")
80 mm (3.15 ")
2.98 litr es
2 41 kg (530 I b. )
192 kg ( 42 2 Ib.)
Special all
oy cast iron
88 .90 mm (3.499 ")
89.66 m m. (3.523")
Light a lloy
5 00 . d;:5 gramm es (1 7.5± .18 o z. )
10 'grammes (.35 o z. )
71 mm (2.79 ")
46 mm (1.81")
. 02 - .0 4 mm (.0008 -. 0016")
.40-.55
mm (.016-.022 ")
.030"
2
1.98 mm (.078")
. 04 5-. 072 mm (.0017 -. 0028")
1
4.74 mm (. 186")
.04 5- .072 mm (.0017 -. 0028")
Close running fit
Push fit
22 . 00 mm {.866")
22.05 mm (.868")
22.10 mm (.870")
22.20 mm (.874")
86.7
mm ( 3.41 ")
.7
mm (.028 ")
.
047-.138 mm (.0019 -. 0054")
.038
-. 089 mm (.001 5- .0035")
.039-.081
mm (.0016 -.0032")
0
:3

MAIN BEARINGS
Main bearing journals
Diamet er , sta nd ard
unde rs ize .
010"
. 020"
. 030"
.040"
.050"
Wid th on crankshaft for pilot bearing she"
Standard ....... . ... . .... .. ................. .. .. . ....... .
Oversize l (undersize she" .010") . .. . ... .. .. .. . . . ..... . . .. . .
2 ( .020") ... .... ... . . . ... . .. .. .. . .. .
3 (
.030 ") .. . .. . ... . .. ... ........ .. . .
4 ( .040" ) ... .. .. .... . . ... ..... . .. . . .
5 ( .050") . . ...... . .. .. .......... ... .
Main bearing shelIs
Thickness, standard . . ... .. ... . . .. . .... ........ ... .. . .. .... . .
undersize .010" . . . . . ... . . . .. . . . . . ..... ....... . .. .
.020" .. ... . ... . ... . . ........ . . .... . . . . .
. 030" . .... . ..... . ...... .. .. . . . . . .. . .. . .
.040" . . .. .... . . . . ..... .. .. . ... . ... .. . . .
.050" . . . . .. . .. . . .. ..... . .. ... . . .. .. . . . .
BIG-END BEAR I NGS
Big-end bearing journals
Width of bearing recess .. . .. . ...... ... .. ........ ... .. .. . .
Diameter,
standard ... .. . ... .. .. ... ... .. . . .. . .. ....... .... . .
undersize . 010" .. ... .. . ... ..... . ...... . .. .. . .. . . .
Thickness,
standard
undersize
.020" .......... . . .... . ...... . . .. ..... . .
.030 " ... . ... . . . .. . . . .. ... . .. .... . . .. . . .
.040" . ............... .. . ... ... .... . ... .
. 050" . ..... . . ... . . ....... ... .. .. . .. .. . .
.010"
.020"
. 030"
.040"
.050 "
CONNECTING RODS
End float on crankshaft .. ... .... . . .. ... . . . . . . .. .... . .. .. . . .
Length, centre-centre ... . . . .. . .. . .. . .. .. . ........ .. ...... . .
Max. permissihle we·ight deviation
between connectings fO'ds in
same engine
FLYWHEEL
Permissible axial throw, max.
Ring gear (chamfer forwards)
CAMSHAFT
Marking . . .. ........... ... ...... . . . . . ..... . ............. . . .
Number of bearings . . ... ... . . . . . ...... ... .. ....... . ... . . . .
Journal, diameter
......................................... .
Radial clearance ................. ... ........ ... .... . ..... . .
End float . .. . . .... .. . ..... .... .. . ... ...................... .
Valve clearance for controi
of camshaft ~etting (cold engine)
Inlet valve should then open at . .... ........... . .. .... . ... .
0 :4
63.44 1 -63.454 mm (2.4 9 77-2.4 982 ")
63. 187 -6 3. 200 mm (2 .4876 - 2.4882")
62 . 933 - 62 . 946 mm (2.4777 -2.4782")
62.679-62.692 mm (2.4677 -2.4682")
62.425-62.438
mm (2.4577 -2.4581")
62.171 - 62.184 mm (2.4477 - 2.4482")
38 .930-38.970 mm (1.5327 - 1.5342")
39.031 - 39.072 m m. (1 . 5366 -1.5383")
39.133-39. 173 mm (1.5407 -1.5422")
39.235-39.275
mm (1.5447 -1.5463")
39.336-39.376 mm (1.5487 -1.5502")
39.438-39.478 mm (1.5528 - 1.5542")
1.98 5- l.991 mm (. 0782 -.0784")
2.112-2.118 mm. (.0832-.0834")
2. 239 - 2.245 mm ( .0882 -.0884")
2.366 - 2.372 mm (.0931-.0934")
2.493-2.499 mm (.0981 - .0984")
2.620-2.626 mm (1 . 0315-1 .0339")
3l.950-32.050 mm (1.2579-l.2618")
54 .089 -54 .102 mm (2 .1295-2.1300")
53.835-53.848 mm (2.1195-2.1200")
53.581-53.594 mm (2.1095-2.1100")
53.327-53.340 mm (2.0994-2.1000")
53.073-53.086 mm (2.0895-2.0900")
53.819-52.832 mm (2.1189-2.0800")
1.833-1.841 mm (.0722-.0725")
1.960-1.968 mm (.0772-.0775")
2.087-2.095
mm (.0822 -.0823")
2.214-2.222 mm (.0872-.0875")
2.341-2.349 mm (.0922-.0925")
2.468-2.476 mm (.0972-.0975")
.15- .35 mm (.006 -. 014")
145 ±. 1 mm (5.71 ±.004")
6 grammes (.21 oz.)
.05 mm (.002") at a diameter of 150 mm (5.9")
153 teeth
C
4
46.975-47.000 mm (l.8494-1.8504")
.020-.075 mm (.0008 -.0030")
.020 - .060 mm (.0008 -. 0024")
1.45 mm (.057")
0° (T .D.C)

CAMSHAFT BEARING
Bearing diameter .... . ... . .. .. . . .. . . . .. .................... 47.020-47.050 mm (1.8512-1.8524")
TIMING GEARS
Crankshaft drive, numher of teeth . . ... ......... . ... . ...... .
Cra nk sh aft gea r (fi bre ), nu mber of teeth . . . .. . .. . . ..... . . . . .
Backlash
... . . .. . ..... .. ... . .. . . ......... . . .. . . .... .. . .... . .
End
float , camsh aft . . ...... . .............. ..... ... .... .... .
VALVE SYSTEM
VALVES
Inlet
Disc di ameter .......... .. . ... .. . .... . . . . . ............. . . . .
Stem diameter .. ... ..... ........ . . .. .... ... ...... . ........ .
Val ve seat ang l. e ... ..... .. . . . . .. . .. .. ... .. ..... ... ....... .
Seat ang le in cy li nder head ........ . ... ... ... . ........ .. .. . .
Seat width in cyli nder head .... . ... .. . .. . . .. ............. .. .
Cl
earance, both warm and cold eng ine . . .. .. .. . ..... .. ... .
Exhaust
Disc diameter
Stem di ameter . . . . . . .. . . .... .. . ... . . . . . ... ...... ... .. .. .. . .
Valve seat ang le ..... . . ......... . ..... . ... ... .. . .. . . . . ... .
Seat angle in cylind er h ead . ... .. .. . . . . ... .. .. ... . ... . . . .. .
Seat width in cylind er h ea d . ............ . . .... . . . .. ... . ... .
Cle
aran ce, bo th w ar m and cold engine . . . ... .. .. . . .. .. . . . .
VAlVE GUIDES
Length, inlet valve . . ... . ..... ... . ........... . .... . .. . . .. . . .
exhaust valve .... ... . . . .. . . .. ... . .. . . . . .... . .... . . .
Inner diameter ....... .. ........... .... . .. . . . ... . ........ . . .
Height
above upper face of cylinder he ad . ... ........ ... . . .
C
learan ce, valvestem-valve guide, inlet valve ..... .. ... .
exhaust valve . ... . . .. . . .
VAlVE SPRINGS
Length, unioaded, approx .. .. . . . . . . . . . ... .. . .. .. .. ... . . . . .. .
with a
loading of 25.5±2.0 kg (5 6±4.4 Ib) ........... .
with a
loading of 66. 0±3 .5 kg. (145±7.7 Ib) ... . ... ... .
LUBRICATING SYSTEM
Oil capacity, including oil filter ... . . . .. . .... .. .. . ...... . .. .
excluding oil filter
.. .. .. . .. ... ..... . .. . .... .. .
Oil pressure at 2000 r.p.m. (with warm engine and new oil filter)
Lubricant
.. . ....... . . .... ... . .. . . . . ......... .... ... .. . . . . . .
viscosity all
year round
or
viscosity, above + 30° C (8r F) .... .. . . ... ... .. . . .
between - 10°C and +30 ° C (14 ° and
87° F) . .. . ..... . . . . . . .. .. . .. .. . . . . .. . .. .
below _10° C (14° F) . .. ... ... . ........ .
l) When cold-s1ar1ing difficul1ies are 10 be expec1ed (below _20
0
(=_4
0
F)
mul1igrade oil SAE 5 W-20 can be used .
Oll FilTER
21
42
.04-.08 mm (.0016 -. 0032")
.
02- . 06 mm (.008 -. 0024 ")
42 mm (1.654")
7.955-7.970 mm (.313 2-.3 138")
44.5°
45°
2.0
mm (.080")
.50-.55 mm (. 020- .022")
35 mm (1.378" )
7.925-7.940 mm ( .3120-.3126" )
44.5°
45°
2 mm (.0 80" )
.50-.55 mm (. 020- . 022 ")
52 mm (2.047")
59 mm (2.323")
8.000-8.022 mm ( .32- . 32 1 ")
17.5 mm (. 689 ")
.030-.067 mm (.0012 -. 0026")
.060- .097 mm (.002 4-. 0038 ")
45 mm (1.77")
39 mm
(1.54 ")
30.5 mm (1.20")
6.0 litres (10. 56 Imp.pints= 12 . 66 US pints)
5.2 litres
(9.1 5 Imp.pints = 10.97 US pints)
2.s---:6.0 kg/cm2 (36 -85 Ib/sq.in.)
Engine oil.
for Service MS
Multigl rade oil SAE 10 W-301)
SAE 30
SAE 20/20 W
SAE 10W
T ype . . .... .... . ... . ... .... .. . .. ........... . .. . ....... . ... . Ful.l-flow type
0 :5

Oll PU MP
Oil pump, type ... . . . .. ................. ... . ..... .. . . .. ... .
number of teeth on each gear wheel . . ... . . . ... .
end flo a.t . . . . .... . . .... . ... ....... .. . . .. .. . . .. .. .
radial clearance ... . ... ..... . ............ . ...... .
backlash ... . . . . . . . ........ . . . .............. . . . . .
RELIEF VAlVE SPRING ( IN Oll PUMP )
Length, un l oaded .. . .. .. ...... . . . . .... . .. . .. . .. . . .. approx.
l oaded with 5.0±.4 kg ( 11.0±88 I b. ) . .... . . . .. . . . . . .
FUEL SYSTEM
FUEL PUMP
7.0±.8 kg ( 15.4±1.7 Ib .... ......... .. ..
Di aphragm type pump .. . ... . ... . ...... .. . . ......... ... . . . .
Fuel pressure, measured at same level as pump at 1000 r.p.m.
CARBURETTORS
Type .. . .. . . ................... . ... . . .. . .. ..... .. .. . ... .. . .
Make and designat ion . ..... . . .. ... .. .. . .. . ... .. ... .. . ... . .
Num
ber ....... ... ... ........... . ..... . . . .. . .. . . . . . . . .... . .
Air i
ntake d i' ameter . ..... ... .. . . . .. . .... . .. . . ..... . . . ... . . .
Id li ng speed .. .. . . . .. .. ..... . ..... .. . ..... . .. . . .. . . .. .. . . . .
M
ete ring n eed le des ign at ion ... . . ... . . . .. ... ..... . ........ .
O il for da mping cylin de r .. .. . . . .. .. . . ..... ... .. . .. . ... .... .
COOLlNG SYSTE M
Type .. .. . .. ...... .. . . ... . . . . . . . . . . ... .. ... . . . ..... . .. ..... . .
Radiator cap valve opens at .... . ..... . ...... . . . .... . . . .. . .
Capacity ..... ... ... . . .. .. ....... ... . ..... .. ... . . .. . . . . . . . .
Fan belt,
designation ....... . . . .. .. . .. . ... . .. ... . . .. .... .. . .
The fan
belt is tensioned so that the friction torque of the fan
pulley in the dhe:ction of rotation wi ll be .. ...... .. . . . . . . . . . .
THERMOSTAT ~
Type ... ....... ... .. .. : .. .. . . .. . . . . .. . ..... . .. . . . ... .. .. . . .
Marked .. . .. . ... . . . . . . . . . . . . . ........ .... . .. .. .. . . .. ..... .
Begins
to open at ........ . .. . .. ... ... . . . . . . .. . .. .. . . . . . . .. .
Fully open at . ..... ... . ....... . . . . .. . . . . .. .. . ... .. ... .. .. . .
TIGHTENING TORQUES
Cylinder head . .. .. ........ .... .. . . . ..... . .. . .... .. . . . .. . . .
Main
bearing 's . .. .... . . . . . ......... . . . . .. ... ... ..... .... . . .
Big-end
bearings .. .. .. .. . . . . .. . . .. . .. . .. .. .. . . . ..... . ..... .
Flywheel ... . .. .. .. . .. . . . .. . ....... . . . .. . . ... . . . . . . .. . .... .
Spark plugs . . . ... . ..... . ...... . . . . .... . . . . . ... ....... . . . . .
Camshaft nut .. ... . . . . . .... .. ........ . ... . ...... .. ... .. . .. .
Bolt for crankshaft belt pulley . ... .. ... .. .. ... .... . ........ .
Nipple for oil fi l ter ... . .. . .. . ... ... ... ... .... .... . . . . ..... .
Sump bolts ....... . ... . .... ... .. . ..... . .. ... .. .... ...... . . .
WEAR TOLERANCES
CY LI NDERS
To be rebored when wear amounts to (if engine has abnormal
G ear
9
. 20-.10 mm (.0008 -.0040 ")
.08-.014 mm ( .0032-.0055 ")
.15-.35 mm (.0060-.0140")
39.0
mm (1.54")
26 .25 mm {1.03 ")
21.0 mm (.83")
Pierburg
PV 3025
min .. 15 kg / cm
2 (
2.1 Ib/sq.in)
max .. 25 kg / cm
2 (3.5
Ib /sq.in.)
Hori
zo n ta l carb u rettor
Zenith-Stromberg 175CD-2SE
2
41.3 mm (1.63 ")
750 r.p.m.
Bl R
O il a pp rov ed as oil f or Automa ti c
Trans mi ssions, Type A
Sealed system
.7 kg/
cm ? (10 .0 Ib/sq.in.)
approx 12.4 litres=2.73 Imp.galls/3.27 US gdls .
(expansion tank of which 1.5 litres=2.6 Imp.
pints=3 .2 US pints)
HC 38x875
1.2-1.7 kgm (8 .6- 12.3 Ib.ft.)
Wax
82°
81-83° C (177 - 18T F)
90° C (194° F)
Kgm
8. 5- 9.5
12-13
5.2-5.8
5.0--5.5
3.5-4.0
13--15
7-8
4.5-5.5
1. 0-1.2
Lb.ft.
61 -69
87-94
38-42
36-40
25-30
94- 108
51-58
32 -40
7. 3-8.7
oil consumption) . . . ..... .. ..... .... ... . . .. . . ... . .. ... ... . . . .25 mm ( .mo "'):
0 :6

CRANKSHAFT
Permissible out - of-round on main bearing journal s, max. . ...
Permissible out - of-round on big-end bearing journals, max. '"
C rankshaft end float, max. . . .... .. ...... . .......... ..... . . .
VALVES
Perm issible clearance between va l ve stems and va l ve gJu i des ,
max ...... . . . . .. ... .. . .. ... . .... . ............. . ........... .
Va lv e stems , permiss ible wear, max ..... . .. . ....... . ..... . . .
CAMSHAFT
.05 mm {.0020")
.07 mm :(.0028")
.15 mm (.0060")
.15 mm '(.0060 ")
.02 mm (.0008")
Per missible ou t-of-round (with new bear i ngs ) max. ....... . .. .07 mm (.0028 ")
Bearings , permissib le wear . . .. . .. . . .. .... . ..... .... .. . . . . .. .02 mm (.0008")
TIMING GEARS
Permissible backlash, max. . .... . . ... .. ............. . ....... .12 mm (.0048")
12
8 4
Tight ening s equen ce for c ylinder he ad bolt s {tightened in 2
s
tages). 1 st s tag e: 2. 5- 3.6 kgm (1 8- 22 Ib.ft.}; 2nd stage : 8. 5-
9.5 kgm (6~ Ib J t.)
5 9
13
ELECTRICAL SYSTEM
BATTERY
Type . .. . . . . ........ ... . . .. .. .. .... .. . .. .. .... ... . . . .. ... . .
Grounded .. ........ .. .. .. . .. .. . .. ... . .. ........ . ... . . .. . . .
System voltage ... .. .. . .... ... . .. ... ...... . . . . .... .... ..... .
Battery, capacity . ... . . .. . .. . . . . .. . . .. . . .. .. ... .... .. .... .. .
Specific gravity of electrolyte :
Fully charged battery . ..... ......... .... ........ ... . .. .. .
When recharg ·ing is necessary ....... . ....... . .. . ........ .
Recommended charg iing current ... ....... . ..... . . .. . ...... .
ALTERNATOR
Type .. . ............ ... . ... . .. .. . ......... .... .... . ... . .. . .
Wattage . ....... . .. .. .. .. ... .... ... . . ...... . .... . .. . ... . .. .
Max. continuous current ... . .... . . ..... ... . ..... . ..... . .. . . .
Max. spe ' ed .. .. .. ... ... . .. . . .. .. . . . .. .. .. . ... ..... ..... . . . .
Direction of rotation .... . ... ... ....... . ......... . ........ . .
Ratio,
eng , in.e - alternator . ... ...... . . .... .. . ....... . .. .. . . ... .
Brushes, minimum
length ... . . . . . . .... . .. ..... .... ...... ... .
Tighten ing torque · s:
Attaching screws ......... .. .............. . ... . ... ... .... .
Pulley nut . ... . .......... . ............. . .. .. ... .. .. ... .. .
Tudor 6 Ex 4 F op or e quivalent
Neg , ative terminal
12V
60 Ah
1.28
1.21
5.5A
S.E.V.Motorola 14 V-26641
420 W
30A
15000 r.p.m.
Optional
1 .- 2.15
5 mm (.20")
.28-.30 kgm (2.0-2 .2 Ib.ft.)
4 kgm (29 IbJt.)
0
:7

TEST VALUES
Fie ld winding resistance . . . . . . .. . . .. .......... . . ..... ... ... .
V olt age drop acr oss i ns ul at ion di ode .... . .. ... . .. .. . . . . . . . . .
Roted
tes t . . . ... . . .. . . . . . . . .... . . .. . .. .. .. . ... ... .. .. . .. .. .
VOLTAGE REGULATOR
Type . . . . ... .. .. ... . . .. . . .... ..... . . ... . . .... . . . ... . ..... . .
Controi
voltage, cold regulator ... ... ... .. . . . ...... ... . .. . . .
af ter running 45 minutes . .... . ...... . . . . .. .
STARTER MOTOR
Type . . ... . .... . . . . ... .. . .. . . . ... .. . .. . ...... ... ... . . .. .. . .
Voltage . .... . . . . . . . . .. ..... .. . . . ..... . . ........ .... . . .. . . .
Grounded .. . . . . . . . .... . . .... . .. ... .... .. .... . . .. ... . .... . .
Direction
of rotation . .... .. .. .. . . ...... .. . . .. . . . . . . ... . .. . .
Output ... .... . . . .. ..... ......... ... .... . . . . .. . . . ... .. . . .. .
Brushes,
number .. . . .. . . ... . . . . . . .. .. . . .. . . ... .. .. .... . ... .
TEST VAL UES
M ec ha ni ca l
Rotor end float
Brush spr in g tension . .. . . ........... . .. . .... . ....... . . . . .
Di
stance from pinion to ring gear ... . . .... .. .. .. . . ... . .. .
Fr ictional torque of rotor brake .. ... ...... .... ... .. . . ... .
Pinion idling torque .... . ... . ... . ... ... ... . .. . .... ... .... .
Backlash
... . .... .. ............. . ... . .. . ................. .
Minimum
diameter of commutator ........ . ... . . . . ....... .
Minimum length
of elec. brushes .... . .................... .
Electrical
Unloaded starter motor:
5. 2± .2 ohms
.8 -. 9 V
30 A (min. a,t 3
00 0 r.p.m. and approx. 13 V)
S.
E.V. Motorola ' 14 V-33525
13.1 -14.4 V
13.85-14.25 V
Bosch GF 12 V 1 PS
12 V
Negative terminal
Cl
ockw ise
Approx . 1 h.p.
4
.05-.3 mm (.002-.012")
1.150-1.300 kgl (2.53-2.86 Ib.)
1.2-4.4 mm (.047- .173")
2. 5-4.0 kgcm (2.1 7-3 .81 Ib.in.)
1 .3- 1.8 kg,cm (1.13- 1.56 Ib . in .)
.3 5-.45 mm (.014-.018")
33 mm (1.3")
14 mm
(.6")
12.0 Vand 40-50 A ..... .. ....... . ..... . ....... . ... . ... . . 6900-8100 r.p.m.
Loaded starter motor:
9 Vand 185-200 A
Locked
starter motor:
6 Vand 300-350 A
CONTROL SOLENOlD
1050-1350 r.p.m.
Cut-in
voltag ,e .......... . .. . . . . . . .. ... . .- . . ... . ............ Max. 8 V
IGNITION SYSTEM
Firing order . ... .. . . . . . ... . . ... .... . .. ... ... .. .... .. . . . . ... .
Ignition timingl
(at 600-800 r.p.m. with vacuum governor disconnected) . .. .
Spark plugs, type .. . .. . . ... ... .. . .... . .. .... . ... . ... . .. . . . .
thread ...... . .... . ............. . .... . ..... . .. .
spark plug gap ... . ..... . ... . . . .. .. . . . ........ .
tightening torque .. ... .. ... ...... . . .. . .. . .. ... .
Pre-engaging resistance to ignition coil . . . . ...... . ... .. .. .. .
DISTRIBUTOR
Type . . . ... .... . ...... . ....... . . .. ... ..... . . . ............. .
Di rektion of rotation ..... .... . ... . . .... ... . .. . ... . ... . . . . . .
Breaker points, gap . .... ..... .............. ... . . ... .. . . ... .
contact pressure ......... . .. .. . . ..... .. .... .
dwell
angle ............ . . . .... ... ......... .
Capacitor
0:8
1-5-3-6-2-4
10° before T.D.C.
Bosch W 175 T 35
or equivalent
14 mm
.7-.8 mm (.028-.032")
3.5-4.0 kgm (25.3-29.0 Ib.ft.)
.9 ±.05 ohm
Bosch JFURG
Anti-clockwise
Min
.. 25 mm (.010")
500-630 grammes (1.10-1.40 Ib.)
40±30
.2 fL F- 25 %

Centrifugal governor:
Advance range, total . . ... .. . . ........ .. . ... .... . .. . .... . .
Advance begins
at .......... . . .. ............. . ..... . .. .. .
Values, 5° .............. . ....... . ... ... . .......... . ... . . .
10° .......... . .. ... ..... .. ... ... . . ...... ... ...... .
Advance finishes at .... ..... ...... . ...... .... .......... . .
Vacuum governor:
Positive controi
Advance range, total .. . ................. ... . .. ... ... . .. .
Advance begins at .. . ... ... ......... ... . . ... .. ......... . .
Value, 2.5 °
Advance finishes at .... . .. .. ...... . .. . .. . .. ........... . . .
Vacuum governor:
Negative controi
Drop, total . . . .. . . .. ..... . ..... ... ..... .... . .. . ...... . .. .
Drop begins
at ... . ... . . ..... ...... ... .. ... . ... .. . ...... .
Values 2° ....... . . . . ................. . . . .. .. .... .. ..... . .
Drop finishes
at .. .. .... . . . .... .......... .. . . ........ .. .. .
LAMP BULBS
Headligh ts .. ....... . . .... . . . . . . ... . .. . . ... . .. .. . . . .. .. . . . . .
Parking lights ..... .. ....... . . . . .. ..... .. . .. . . ............. .
Flashers . . . . . . ......... . ............. .. .. .. . . .. ..... . . .... .
Rear li ghts ....... ... ........ ... . ....... . . .... ...... . ..... .
Stop lights . ..... ... .. ..... ... . ...... ... ............ . .. . .. . .
Re vers in g li ghts . ..... ... ........... . . . ... ... ... .. . . .. .. . . . .
Number plate light .
...... . ... . ................ .. .. . . .. ... .
Interior lighting .. .. ...... . ... .. ........ .... ..... . . ...... .. .
GI ;ove compartment light ..... . .. . ..... . . .. . .. . .. . .. ... .. . . .
Engine and lugg; age compartments . . .. ...... ............. .. .
Instrument lighting ...... . ...... . ..... .. ... . . . .. . .. .. .... .. .
Lighting
heater controls .. . . .... . ... . .. .... ..... .. ..... . .. . .
Controi lamp, instrument panel ..... .. . .. ..... .. .. . .. . . . ... . .
Controi lamp, overdrive . ... ... .. . .... ...... . ...... . .... . . . .
Controi lamp, elec. heated rear window ... .... .... ....... . .
FUSES
Rated current 16 A
Rated current 8 A
Rated current 5 A
ELECTRICALLY HEATED REAR WINDOW
Output, at first position of switch . .. ... . ... ... . ..... ... . .. .
Output,
at second position of switch ........ .. .. . . . . .. . .. . . .
12±1 ° (distr. graduation)
425-525 r.p.m. (distr.)
625-725 r.p.m. (distr.)
1150-1000 r.p.m. (distr.)
1850 r.p.m. (distr.)
5±
1° (di str. graduation)
6-10 cm Hg
9.5-14 cm Hg
1 4.5- 16 cm Hg
3±.So (distr. graduation)
16 -25 cm Hg
2~31 cm Hg
28-32.5 cm Hg
Watts
45 / 40
5 (4 cp)
32 CP
5 (4 cp)
25 (32 cp)
15 (32 cp)
5
10
2
18
3
1.2
1.2
1 .2
1.2
Number
1
3
5
Approx. 40 W
Approx.
150 W
Socket
p 45 t
Ba 15 s
Ba 15 s
Ba 15 s
Ba 15 s
Ba 15 s
SV 8.5
SV 8.5
Ba 9 S
SV 8 .5
W2.2d
W 1.8d
Wl.8d
W 1.8d
W 1.8d
POWER TRANSMISSION, REAR AXLE
CLUTCH
Clutch, type ....... ... .... ......... .. . .. .. ............. ... .
Size . . .... ................ ..... . . ... ........ . .. .. ... ...... .
Clutch friction area, total ..... .. ...... ... .......... ... . ... . .
Relea'se lever play, vehicle with leH-hand steering .. . ... . . . .
vehicle wit right-hand steering . . ... .... .
Single, dry-plate, diaphragm spring
9"
468 cm.2 (72.5 sq.in.)
4-5 mm {.16-.20")
2-3 mm (.08-.12")
Number
2
2
4
2
2
2
2
1
l
2
2
3
l
1
1
0:9

GEARBOX
M 400
. Reduction ratios :
l st speed .. .. . . . . .............. . ........ . ..... . ... . . . .
.. 2nd speed .. . . .. . . .... . ........... . ... . .. ... ............ .
: 3rd
speed ........ . . . ....... . ..... . . . .. . ..... .. ......... .
4th
speed .................. . .. ..... . ............ .. ..... .
Reverse
.......... .. ....................... ... ..... ..... .
Fl
ange nut tightening torque ... ......... ... ..... . ... .. . .. .. .
Lubricant
................... . .......... .... ..... ... ... .. .. .
viscosity
............. ........ . ............. . .... .
at continuous air temperature be l ow
-100 C (1 40 F) ........... .. . . ......... . .
Alternative lubricant . . ,
...... . . .... ... ..... ... .......... .. . .
viscosity
........ .. .. . ..... . .......... . .
Oil capacity
M 410 ( GEARBOX M 400 WITH OVERDRIVE )
Reduction ratio, overdrive . .. . .... . ....... . ... .. ... . . . . .... .
Oil pressure ·, direct dr iv e . .. ..... . .... . .. .. ......... ... .... .
overdr iv e ... .. .. . ... .. ......... . .. . .... . .... .
Nut for driving fl ange . .. .. .. .................... .. . . ..... .
Lubricant,
................ ..... .. ... .. . .. .. . . .. .. .. ........ .
viscosity .
... .. ....... . ...... . .. . .. .............. .
qua iity .... ... ..... ...... ........... . .. .. ....... .
Oil capacity, gearbox and overdrive .. . . . . . ..... . .. . ....... .
PROPELLER SHAFT
Type ................ ..... . . . .. . ..... .. .... ... ... ......... .
Universal joints
.. .. . . ... .. . ... . .... ..... . .... ..... ........ .
Lubricant, sliding joint (when assembling)
................... .
REAR AXLE
Rear axle, type ... . . .. . ......... ... . . ... ...... ..... ....... .
Track
...... ........ . . . ......... .. .. . .... ................. . .
FINAL DRIVE
Type .............................. . . ..... ... ... .......... .
Reduction
ratio ...... . ... .......... . . . . .. ...... . ..... ..... . .
Backlash
.......... .. .. . ..... . ... .... . . ......... . .......... .
Pre-Ioading on pinion bearing 's, new bearings ........ . ..... .
run-in
bearing ,s .. .... .. .... .
Pre-Ioading on differential bearingls .......... . ....... ... .. .
Lubricant,
.. ...... .... . ...... .... .. ........................ .
viscosity
....... .. .. .. ..... . ..................... .
Oil capacity ...... . ... ........... .. . . . .... .. .. .. . . ... .. . . . .
TIGHTENING TORQUES
Flange . ..... .... . .. ... . .. ........ . .. . ............. ... . .. .. .
Caps .. ..... . .. . . . .... .. ......... . .... .. . . ... .. ......... .. .
Crown
wheel . .. ..... ............ ... .... ...... . .... ... .... .
O: 10
3.14: l
1.97:l
1.34: l
l :l
3.54: l
11.0--14.0 kgm (80--101 Ib.ft.)
Gear oil
SAE90
SAE 80
Engine oil
SAE 30 or
SAE20W-40
approx .. 6 litre (1. 1 Imp.pints=1.3 US pints)
0.797: l
Approx. 1.5 kg/ cm2 ( 21 Ib/sq.in.)
36-39 kg/cmf! {510--55O Ib/sq.in.}
11.0--14.0 kgm (80--101 IbJt.)
Eng, in e oil
SAE or SAE 20 W-40
Service ML or higher
approx. 1.4 litr es (2 .46 Imp.pints=2.95 US pints)
Tubular, divided,
three universal joints,
support bearings
Fitted with needle bearings
Molybdenum disulphide chassis grease
Further addition not required
Semi-floating
1350 mm (53.15")
Spiral bevel (hypoid)
3.31:1 (13:43}
or 3.73:1 (11 :41)
.13-.20 mm (.005-.008")
11-23 kgcm (9.55-20 Ib.in.)
6-11 kg:cm (5.21-9.55 Ib.in.)
.13-.20 mm (.005--008")
Hypoid oil
SAE 90
1.6 litres (2.82 Imp.pints= 3.38 US pints)
Kgm
28-30
5.0-7.0
6.5-9.0
LbJt.
200-220
35-50
45-65

BRAKES
FRO · NT WH EEL BRAKES
Type .... ...... . ... ................... . .. ........ .. ....... .
Brake discs:
Outs i de diameter ........... .... ........................ .
Thickness,
new . . . . ... . .. . . . .... ..... ..... . .. . . . . ..... . .. .
reconditioned . ....... . .. ... ... .. . ... . .. . . ... .. .
Warp . . .. . .... . ....... . . .. .. . ... . .... . ... .. . . .... . .. . .. .. .
Brake
li nings:
Nu
mber per wh ee l ... ... .... . . .. . . ........ ... ... . ... . ... . .
T
hi ckness, new . . .. . . ...... ... .... .. .. .... ..... . . . ..... . . .
Effecti
ve area . ... . . .. . . . .. . .... . .. . .. . . ........ . .. .. . .. .
Wheel un it c yli nders:
Number per wh ee l .. .. ...... . .. . .... . . .. ..... .... ... ... . . .
Diameter .. . ...... . ........... . ... . .. . .................. .
REAR WH EEL BRAKES
Type . . .. . .... . . . . . . . ....... . . .. . . . ... .. . ........ . . . ... .. . . .
Brake discs:
Outs i de diameter . .. .. .. .. . ........ .. . .. . . .. .... . .
Thickness,
new .. . .... . . ... ...... .. .. .. . .. . . .. . . ......... .
reconditioned .. . .. . . . . . ... ... . . .. . . .. ......... .
Warp .................. . ...... . ................... . .. . .. .
Brake linings:
Nu mber per wh ee l ...... . .. . . . . . ...... . . ... ... . .. ... .. . . .
T
hi ckness, new .... .. .... . ............. . ............ . .... .
Effect
iv e area . .. .... ... ... . . .... .. . ...... . ... . ... . .. .. . . .
Whe el unit cylinders:
N umber p er wheel . .... .. . .. . ..... . ..... . . .. . .. . ... . .... .
D
iameter .. . ... . .... .. ....... . .... . .. . ... ..... . ..... ..... .
MASTER CYLINDER
Nominal diam eter . . ... . .... . ... . . . ...... . ...... ... .... . ... .
Bore
... .. .. . . . . ..... .. .. . .. . ... ... ... . .. ...... .. ...... .. . . .
Piston
diameter
BRAKE LINE
Outer diameter
BRAKE VALVE
Disc brakes
272.2 mm (10.7")
12.7-12.8 mm (.500-.504" )
Min. 12.2 mm (.480")
Max . .10 mm (.004")
2
10 mm (.394 ")
174 cm~ (27.0 sq.i n. )
4
36.12
mm (1.422")
Disc
brakes with AS.B. device
294.6 mm ( 1l.6 ")
9.6 mm (.378")
mi
n. 9.1 mm (.358")
max
.. 15 mm (. 006")
2
10 mm (.394 ")
93 cm2 (1 4.4 sq .in .)
2
36 .12 mm (1 .422 ")
23.81 mm (9 4")
Max . 23.92 mm (.95")
Min. 23.66 mm (.93")
3/16"
Make. . ... ..... .. .. . .. . .. . ... .. ... .... . . ... . .. . .... . .. .. . . . Ate
Operating pressure ... . . .. . . . . . . . . .... ........... ... .... ... 50±2 kg/cm2 (711 ±28.4 Ib/sq.in.)
SERVO CYLINDER
Make. .. . . . .. . .. .. .. . .. ... .. . . . .. .. . ..... ... .... . . .... ... .. Ate
Designation ... . .... . .. . . ... ....................... . . ... .... Bromsgerät T 51
TJGHTEN ·ING TORQUES
Attaching bolts, front brake caliper . . . ...... . ...... . . . . .. . .
Attaching bolts,
rear brake caliper . . . .. . ... . . . .. . . . . ..... . . .
Wheel nuts . . .... . ..... .... . . .. . ... . . .. . . .. . . . . ... .. .. . . . .
Stop screw,
master cylinder . . .... . ....... .. ......... . . . . ... .
Attaching nuts, master cylinder . .. . .. .. .... . .. . .... . . .. .. . . . .
Venting nipples
... ...... .. .... .. . . .. ....... . .... .. . ....... .
Brake
hoses ... ... .. . ...... .. .. .. ... . .... .... . ... . ... .. .. . . .
Warning valve, switch . ... . . ...... ... .. ... . .. . . . . . . . . .. . . . . .
Brake
pipes . ...... . .. . ............ . .. .... .... . ... .. .. ..... .
Plug, brake valve . .. . ..... .. .... . . .... . .. . ... . ... ... .. .... .
Lock nut,
brake valve . . .. .. . . . .. . . . . . . . . ..... ...... .. ... . . .
Kgm
9- 10
6- 7
10-l4
.5---.8
1.
2-1.5
0. 4--0 .6
1.6-2 .0
1.4- 2.0
1.1-1.5
10-12
2.5---3.5
Lb.ft.
65---70
45-50
70-100
3.6-5.8
8.7-10.8
3. 0-4.5
12-15
10-15
8- 11
70-85
18 - 25
o: 11

FRONT END AND STEERING GEAR
WH E EL ALl GNMENT ( UNLOADED VEHI C LE)
Caster .. ... ... .... .. . . ... .. .... .... . .. . .. . .. . ....... ..... . .
Camber .... .. . . . . . . . .. . . .. ... . .. ~ .. ...... . . . . .. . . '" ... . .. .
King pin inclination at a camber of 00 ••• .•• . ••• • • • ••• • • ••••
Toe-in . . . .. . .. ... ....... . ..... .... . : .. . .. .. . . ... ... ....... .
Turning a ngl es :
at a 20
0 turn of the outer wheel the
inn er wh ee l should be
t urn ed 21.5
0 to
23.5
0•
S hi ms , thickness . . ... . ........ . .... . ... .. .... . . . .......... . .
MECHANICAL STEERING GEAR
Steer in g wh ee l diameter . .... .... .. . . ..... .. . ..... .. ... . .. .
Number of turns from stop to stop in vehicle .. . . . . . . .... .. . .
Steer
ing gear:
Make . . ..... . ... . . . .. . ..................... ... .. . ....... .
Type . .. .... .. .. .. . .. . .. . . .......... . ... .. . ... . . . ....... .
Reduction ratio, centre position . . ... . .. . ... .. .. ...... . .. .
Cl earance , steer in g shaft-bus hin g, new part . .. ... . ....... .
wear limi t ............. .
Ball diameter, bearings . .. . . ... ....... . ... . . . ........ ... . . .
ball nut ................. . . .. . ..... ... . . .. . . .
S
him s . .... . ...... ... ......... ... . .. ... . .. .... .. .. .. .... . .. .
Lubricant ... . .... .... ........ .. ... . . .. ... . .. . .. .. . .... ... . .
Oil capacity .. ... .... . ....... . ..... . . .. ............ .. . ... . .
SERVO STEERING
Steering wheel diameter . . .. ... ... .... .... .......... ....... .
Number of turns from stop to stop in vehicle ... . . . .. .. ... .. .
Steering
gear:
Make and type ... . ... . .... .. ... . ...... . ...... .. ...... . . .
Reduction ratio
.... .... . . . . .. . . .. . . ....... ... ..... . .... . .
Servo pump:
Make and type .... .. ..... .. . . . . .... .. . ........ ........ . .
Max. pressure .
.... .... . ..... . ...... .......... ... .. . .. . ... .
Theoretical capacity at 500 r.p.m. .... ... ...... ............ .
Min. capacity, 500 r.p.m., 50 kg/cm2 (711 Ib./sq.in .}, 80
0 C
,( 176
0
F) ..... . ....... . ... ... ... .. . ............... . ..... .. .
Regulated capacity ..... . ............ ... .. . .. .... .. . .... . .
Drive .
.... . .. . ....................... ..... .... . . . .. ..... .
Ratio, engine-pump .... . ... .. ........ ..... . . . . ..... . .. . .
Oil type . ...... .. . ... . .............. ... . ................ . . .
Oil changing quantity . . ... . . .. ................ . ... .. ...... .
TIGHTENING TORQUES
Attaching bolt for upper wishbone shaft ..... ..... .. ....... .
Nut for upper wishbone shaft .......... ... .. . .... . ... . .. .. .
Nut for steering' wheel .... .. ... ... ..... .. ..... .. ... ..... . . .
Nut for pitman arm . .. . ... . .......... .. ................... .
Lock nut for tie rod ........................ ... .... . .. . .... .
Mechanical steering
gear:
Screw for steerin9' box screw cover .. .......... . ... ..... .
Screw for stop plate ........ . . .. .. ............. . .. . ..... .
o: 12
oto +1°
Oto +0.50
7.5
0
Oto 4 mm (O to 0.16")
.15 mm ( .006 ")
.50 mm. (.0 20")
1.0 mm (.039")
3.0 mm (.11 8 ")
6.0 mm ( .236" )
423 mm (1 6.6")
4.8
Burman
Cam and ba l ,l nut
18 .3:1
.025--.063 mm ( .001 0-.0025" )
.18 mm (.007")
7.14 mm (.28")
7. 93 mm (. 3 1")
th = .05 mm (.002")
th = .127 mm (.00 5 ")
th = .254 mm (.010")
Hypoid oil
.6 litre (1.1 Imp.pint= 1.3 US pints)
423 mm (16.6")
3.7
ZF, ball nut
15.7: 1
ZF, vane pump
75±5 kg/cm.
2 (1066±71 Ib/sq.in.)
6.65 l/m (12 Imp.pints=14 US pints/minute)
4.5 l/m (8 Imp.pints= 9.5 US pints/minute)
5--8 l/m (9 Imp.pints= 10.5 US pints - 14 Imp.
pints = 17 US pints/minute)
With belt
1:1
Oil approved as "Oil for Automatic
Transmissions, Type
A"
Approx. 1.2 litres (2 . 11 Imp.pints=2.53 US pints)
Kgm
4.8-5.5
5.5--6.2
3-4
17.5--20
7.5--9
1.7-2.1
1.7-2.1
Footpound
(ft . lb.)
35--40
40-45
20-30
125--145
55.-65
12-15
12-15

I SUSPENSION,
WHEELS
SPR ING S
FRONT SPRINGS
Type .... . .... . ... . . ..... . . ... . . ... ... . .. . . .... . .. .... ... . .
Wire diameter ..... ... . .. .. ...... .. . .. . . . . . . .. .. . . .. ... . . . .
Externai
diameter .. ... . ... . . .. . .. . . ... . .. . . .. . .. . .... .. .. . .
No.
of effect iv e turns . . . .. ... .. . . .. . .. .. . .... . . ... . . ... .. . .
Test
va lu es :
Load ing for a compress i on of 1 cm (25 / 641/) (meas u red within
a
spr ing l ength of 1 85-205 mm = 79/22-8'/ '6) ..... ........ .
Le ng,th, fully co mpressed . . .. . . ... . . . . . .. ... .. ...... . .. . . .
Le n gt h, wh en loaded with 600-630 kg (1320- 1386 Ib.) . .. .
REAR SPR INGS
Type . ... .. ... . ..... ... .. ... .. .. . . .. . . ... . ......... . .. . .... .
Wire di ame t er . .. .. ... .. . .. ... .. . . _ .. . . . .... . ... .. .. .. .. . . .
Ex te rn a i dia m eter .. ... ... . . .... ... .. . .... . . .. ... .. .. ... ... .
No.
of effect i ve turns . . .... . . .. . . . . . ... . .... .. . . .. . ....... .
Test va·1u
es:
Lo ad in g (for a compress i on of 1 cm = 25/ 641/ ) .... .. . . . .. . . .
Len
gt h, fu ll y compressed . ... ... . .... . .... ... ... .. . .. . . . . .
Lo a d/ ~ pr ing l eng th . .... .. . . . . .. . . ... . . ...... .. .. ... ... .. .
SH OC KAB SORBE RS
Type . ... .. ..... ........... . . . . . . .. . . . . .. .. . . .... .. .. . .... .
Totallength :
front shock abs orb ers, compressed .. .. . . ... .. . .. . .. . .. . .. .
unloaded .... .... ... ..... .. ...... .
rear sho ck absorbers, compressed . . . .... .. . . . . . .... .. . . . .
WHEELS
WHEEL RIMS
unloaded ..... . . . ...... . ........ . . .
Type . .. . .. ... .. .. .... ... . .. . ... . .... . .. .......... .. . ... . . .
Designation . ..... . .............. . .............. . .......... .
Radial throw ... .. . .... . .. . .. .. . ........ .. ... . . . . . .. . .. . .. .
Warp ... .. . . .. ... .. .. ...... . . . .. .. ... .... . ....... .. .. . .. . .. .
Imbalance, com.pl,ete wheel .. .. ... . .... . . . ... .. ............ .
Tightening torque for wheel nuts .. ... . ..... .. ... . ... ..... .
TY RES
Type .. . . .. . . . .. ..... ... . . . . .. ... .. .. .. . . . . . .... . .. ....... . .
Size . ..... . .. .. .. ... . ... . .. . . . . . . ... ........... . ...... . .. . .
Helical spring
15.5 mm (.611/ )
125.7
mm (4.95 1/)
65/6
61 .9- 65.9 kg:(136-145 Ib.)
max. 127 mm (5.01/ )
195
mm (7. 61/ )
Helical spring
12.0 mm ( ,471/)
127.0 mm ( 4.91/ )
82/3
15.7-16.7 kg (34.5---36.7 Ib .)
max . 114 mm. (4. 51/ )
201 - 216 kg/283 mm (442 -4 75 I b. )v'l1,4 1/)
D oubl e-a cting, hy dra ul ic, te l escop ic
appro x. 223 mm (8.781/)
approx. 340 mm (1 3. 391/)
approx. 279 mm (10 .98")
approx. 443 mm (17.44")
Disc
4.5 J X 15 L
max.
1.6 mm (.063")
max. 1.6
mm (.0631/)
900 g. Cln {7.8 Ib.in.)
10--14 kgm (72 - 101 Ib.ft.)
Tubeless
165 SR 15-4 PR
6.85-15-4 PR (USA)
165 S 15-4 PR
o:13

Part 1
SERVICING AND MAINTENANCE

CONTENTS
Instru ct ions for oil level checking and changi ng .. . . .. . .. .. . . . l: l
Engine . . ... . . ... . . .. . .. .. ....... ... . .. .. . .... . . .. .. . . . . .. l : l
Gear bo x ( wi t hou t ov er driv e) . . . . . ... ... . . .. . . ...... . . . l : l
G earbox ( wi th ov e rdriv e) . .. . . .. . ... .. . ... ... . .. l : 2
Auto m ati c transmission . . ... . ... .... .. . ...... . . .... ... . . . . l : 2
Final drive . . . . ...... ....... .. . . .. .. .. ..... .. . ... . .. . . . .. l: 3
St e ering bo x, me chanical steering . .. . . . . . . . .. . . l : 3
Servo steering . ... .. . . . .. .. .. . .. . ..... . .. . . . .... . .. . . . . . . l : 3
Checking the brake fluid level .. ..... ... .. . .. l : 4
Instructions for l ubricating ...... . . . . . ... ... .... . . l : 4
Di stributor .. . .. .. .. ...... .. . . . . . . . . . . . . . . .. . . l : 4
Body .. ...... . . .. . . . . . . . . . .. .... .... . . . . .. . . . . .. . .. ... . . . l: 4
Lu
bricating chart