Volvo 164, 1970 User manual

SERVICE
MANUAL
VOLVO 164 1970

FOREWORD
This Manua ,1 contains servicing i l ns~ructions for the
Volvo 164, 1970 model.
The book is divided up into 9 parts as indicated
by the register opposite. The pages and figure
illustrations in each part are numbered in such a
way that ,t he first group shows the number of the
part concerned while th.e second group shows the
number of the page or figure illu strat ion in , that
particular part, for example , under the heading
"Electrical system and instruments"; 3-1, 3-2, etc.
A
convenient way of finding the particular section
you are looking for is to bend the right side of the
Manual back so that the arrows in the register
point to the index marks on the first page of each
section.
The various parts are divided up as follows:
Tools
Desoription
Repair Instructions
The specifications are to be found in Part O,
General.
The instrvctions given in this book general ly as-
sume that special100ls are used and a, re 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
achiev ,e the best results in the shortest possible
time.
AB VOLVO
Göteborg - Sweden
Reprinling permitted if source quoted.
o General
1 Servicing and maintenance
2 Engine
3 Electrical system and instruments
4 Power transmission, rear axle
5 Brakes
& Front end and steering gear
7 Frame, suspension, wheels
a Body

Part O
GENERAL

l
.

GROUP 01
TYPE DES IGNATl ONS
This Manual deals with the Volvo 164 car of the following types: *
Type designation
164-134
164-155
164-156
164-137
Engi1
ne
B30A
B30A
B30A
B30A
Gearbox
M 400
M410
BW35
BW35
Rear ax le
3.73:l
3.73:l
3.31 :l
3.31:l
* App ' licable in Sweden
TYPE PLATES
l. Vehicle type designation,
chassis number and code
number for colour and
upholstery.
2. Body number.
3. T ype designation and
chassis number (stamped
on the front right-hand
door pillar).
GROUP 03
•
DIMENSIONS AND WEIGHT
Leng,th ." " . . . ",.' . . , . . ", .. ,."" . .. , . . ' . . , .. , .. ... .... , .
W·idth .. ..... , .. . .. ........... , .. ... ,' ... .. , ....... . ...... , .
Height .. .. , .... , .... . .. . .. . ...... .. ...... . , .. ... , . ..... " .,
Wheelbase ..... ... ... . ..... . ........ , ........ , ........ . ' ..
Ground c1earance .. ,. , . ..... ' . . , . ... . , , , . ... .. .. .. ....... .. .
Track,
front . ....... " ." . .... . . .. ... , ........ . .. . . , ..... . .. .
rear .. . .... . . .. ... . .... .. ...... . ... . . . ....... . .. , .. .
Turning ci:rde
......... ... ..... . .......... . .. ... . .. . , ...... .
Curb weight ........ , ... ........ .. .. . , . . ". . . ..... .. approx.
47'15 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 typ.e de$lignation,
part number and manu-
facturing seria ·1 number.
5. Gearbox type des . igna-
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: l

LUBRICATION
ENGINE
Lubricant, type ... . . . . . . .. . . .
grade ., ... .. . . . . .... .. ... . .
viscosity, a ll year 'round . . . . .. . .. ... . . . .
below _ 10 ° C ( 14 ° F) ... .. .. . .......... .
be,tween - 10° and +3 0° C (1 4 and 90 ° F)
above +30
0 C (900 F) . . . . . . .
... . ... . . . .. .
O il capac ity, exclud in g o il fil ter .. . . . . ... . .. . . . ... ... . . . . .
in clu d in g o il f il ter. . . . . . . ... . .. . .. . . .... ... . .
O il for carburettor damping cy l: in der .. . .. . . .. . .. . . . . . .
GEARBOX (WITHOUT OVERDRIVE )
Lubr icant, type . .
viscosity
at continous air temperatune below -10° C
Engine oil
Service MS
Multi
grade O il SAE 10 W- 30
SAE lO W
SAE2 0/ 20 W
SAE 30
5. 2 li ,tres ( 9.1 5 Imp.pint s= 10. 97 US p' in ts )
6. 0 litres (10. 56 Im p.pint s= 12 . 66 U -S pints)
Automa ti c Tran sm i ss ion F lui d, Type A
Gear oil
SAE 70
(14 ° F) .. .. .... .. . . .. .. .. .. .. .... . .. .. .. . SAE 80
AI,temative lubricant, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6ng in e o il
vi scosi,ty, a ll y ear roun'd . . . . .. . . . .. . ... . SAE 40
Oil capac ity . . . . . . . . .. . . ... . ... .. ... .
GEARBOX WITH OVERDRIVE
Lubricant, type . . .. .. . .. . . .. . . . . .. ... .. . . .. ........ ... ..... .
grade . . . .. .. . .... . . . . . . .. . .. . .. .. . . . . .. . . ...... . .
vi scosity, a ll year round . .. . . . . . . . . .. . ... .... . . . . .
a lt ernat iv e .. .... ... . .. . . . . . . . .. . . ..... . .
O il capacit y, gear box and ov erdr ive . .. . . ... ..... . . .. . . . .. . .
AUTOMA TIC TRANS MI SSION
Lub ricant, .type . . .. . . . . . . . . . . .. . .. .. . . .. . . . . ..... ..... . .
Normal oper ·ating tCr.1p . of oil .. .. . . . . . . .. . . ... .. . . . .. .. . . . .
Oil capacity .. . . .. ... ..... .. .. .. . . . . . . . . . . .. .. .. .. . . ... .. .. .
FINAL DRIVE
Lubricant, type, without differen,tial brake . . . . . . . . .. . . .... .. . .
with differential brake
.. . ... . ... . . . . ...... . . .
viscosity, above -
10 ° C (14 ° F) .... ...... . ... . .. . . .
below - 10 ° C (14 ° F) .... ... .. .... .. ... . .
Oill capacity .. ..... ... .... . .. . . . ... . . . . .... . . . . . .... . . . . .. . .
MECHANICAL STEERING GEAR
Lubricant, ty.pe .. .. . .. . .. . .. ...... . . . . . . . . . ... ... ... .. . ... . .
viscosity .
.... . . .. . . ..... . . .... .... .. . . ...... . . .. .
oil capacity . . . . . . . .. . . .. ... . . . . . . ... .. . . . .. . . .. . .
SERVO STEERING
Lubri 'cant, type . . . . . .... ..... .. . ... . .. ...... .. .. . . . . .. .. . . . .
Oil capacity . . . . .. . . .. . . .. . . .. . . . .. .. . . .. ..... .... .. approx.
ENGINE
GENERAL
Type designation . . . . .. .. . ....... . . .... . ... .. . . .. . . . . ... . ... .
Output, h.p. at r.p.m. (SAE) ... . . ..... . . . . .. . . . . .. .. . . ... . . .. .
(DIN) .. .. . . . .. . ..... . .. ... . ... ... .... . .
Max. torque, kgm (Ib.ft.) at r.p.m. (SAE) . . . . .. . . .. . .. . ... . . . . .
(DIN) ........ .. . . ... . . . . . . .
0 :2
.6 li tre ( 1. 1 Imp.pi nts= 1.3 US pints)
Eng
in e oil
Ser vi ce MS
SAE 30
Multig:r
ad e O il SAE 20 W -40
1 .4 li kes (2 .4 6 Imp .pints= 2. 95 US pi n. ts)
Automatic Transmission Fluid, Type F
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
SAE90
SAE80
1.6 litres (2 . 82 Imp .pints=3.38 US pints)
Hy.poi ,d oil
SAE 80
.6litre (1 .1 Imp.pints=1.3 US pints)
Automatic Transmission Fluid, Type A
1.2 litres (
2.11 Imp.pints=2.53 US pints)
B30 A
145/5500
130/5000
22.5 (163)/3000
21 (152)/2500

Compression pressure (warm engine) when turned over with
staroter motor, 250-300 r.p.m. ... .. . ........ . .. . ..... . ... . .
Compr-essio.n ratio .. .......... . . ......... . ........... . .. ... .
Number of cylinde1 rs . .. . ... ... . ... . .. . . .. . ................ .
Bore
.... . . .... . ..... . ......... .
Stroke . ............ . . .. .. ................. . . . .. ... . ...... . .
Displacement .. . .. ..... .. . . . ........ .. . . .. . . ....... . . . . ... . .
Weig ht, incll!ding electrical eq u ipment a nd gearbox . . ... . . . . .
We i ght exclud in g g· earbox , starter motor, o il a nd water
CYLINDER BLOCK
Mater i'a l .... . . . . . . .. . . .
Bore,
standard . .. . ... .
oversi
ze .030" ..... . .
PISTONS
Mateni'al . . . ... ... .. . .. .. ... ... ... ... . . . . .. . . . .. . ... . .
We ight, st andard .... . . . . . . .. . . ...... . .. .. ... . . . ...... . . ... .
P,ermi ssib le weight de vi aflion be1t ween pistons in same eng ine
Height,
to ta,1 ... ... . .. ... . .. .. .... . .. . . . ... . ... . . .... .
Height from
pi ston pin ce n tre to piston crown . . . ... .... . .... .
Pi st on cleara n ce . ....... .. ........ .... .... . ..... . .. ... .... .
PISTON RINGS
Piston ring gap, me as ured in ,ring openin g .. .... . . ... . .... .
Oversi ze on piston rings . .... . . . . . . .. .. . . .... . .......... .
COMPRESSION RINGS
Marked "TOP ". Upper ring chrome.d.
Number on each piston .. . .. ....... ............ .. ......... .
Height ... . .... ... .. . .... . .... . .. . . ....... . ..... . .... . .. . .. .
Compression ring clearance in groove . . . .. . ... . .... . .. .. . . . .
Oll SCRAPER RINGS
Number on each piston . . ... ....... . ........ . .. . ...... . .... .
Helig,ht . .
.. . ........ . . .. ....... . . ...... . . . .. ... .. .... . . . . .. .
Scraper ring clearance in groove .... ..... . ... .. . ... ...... . . .
GUDGEON PINS
Floating fit. Circlips at both ends in pistan.
Fit:
In conneoting rod .... . . . . ...... . ........... .... .
In piston ..................... . .... .. ...... . . . .......... . .
Diameter, standard . . ............... . .. . .. .... ... ..... . .... .
overs ·iz es . 05 "
CYLINDER HEAD
Height, rrieasured from cylinder head contact face to face for
bolt heads . ..... .. . .. .. .... . . . . ... . .. ... . ..... .. .......... .
Distance from t·
op side of head to over-flow pipe upper end
(pipe pl ' aced ul nder thermos tat) ... . ............... . .. .. .. . .. .
Cylinder h.e-ad gasket, thickness standard ( unioaded) .. .. ..... .
CRANKSHAFT
Crankshaft , end float ...... ..... ..... .. .... .. . . .. . .. .. .. . .
Main
bearings, radia 'l clearance . .. . . . . ... .. .
Big-end
bearings, radial clearance . . . . .. . .. . ... .. ..... .
11-13 kg/cm2 (156-185 Ib/sq.in)
9.3:1
6
88.90 mm (3.50")
80
mm (3.15")
2.98 litres
241 kg (530 I h. )
192 kg (422 Ib.)
Sp
ec ia l a ll oy cast iron
8 8. 90 mm (3.499")
89.66 mm (3.523")
Light o
ll oy
50 7±5 gmmmes (17.75±.18 oz.)
10 gra mm es (.35 oz .)
71
mm (2.79")
46
mm (1.81")
.0 2-.04 mm (.0 00 8-.0016" )
.4 0 -.55 mm (.016 -. 0 22 ")
.030"
2
1.98 mm (. 078")
.045
-. 072 mm (.0017 -. 0028")
1
4.74 mm (. 186")
.045- .072 mm (.0017-.0028")
Close running fit
Push fit
22 .00 mm (.866")
22.05 mm (.868")
86.7 mm (3.41")
35
mm (1.38")
.8
mm (.031")
(Ioaded .7 mm = .028")
.047-.138 mm (. 0019- .0054")
.028-.079 mm (.0011 -. 0031 ")
.029-
.071 mm (.0012-.0028")
0 : 3

MAIN BEARINGS
Main bearing journals
Diameter, standard ...... .
undersize
.01 O"
.020 /1 ...
Width on crankshaM for pi l ot bear ing shell
Standard .. .. . . ....... . .......... ......... ... .
Oversi
ze 1 (un dersi ze she ll .010 /1)
2 ( /I .020/1) .. .....
Main bearing shelIs
Th ickness, standard
undersize .01 0/1
.020/1 . . . ........ .. ..................... .
BIG-END BEARINGS
Big-end bearing journals
Wi·dth of bearing recess ................... ...... . .. .. .. . .. .
Di 'ameter, standard . ........ ... ......... .. .. . .. . ...... .... . .
u,nde:rsi
ze .01 0/1 . ........... . ......... .. ..... .... . .
.020" . . . . . ... .... ........ ............ . . .
Big-end bearing shelIs
Th ickness, standard .... ... . ... .. ...... .... .......... .
undersize
.01 0/1 ... ... ...... . ................ .
.020/1 ....... . .. .. . .... . ... . ...... ... .. . .
CONNECTING RODS
End float on crankshaft . . .. .... .. ............ . ... .. ...... . .
Len9'th, centre-centre
.. . ... .... . . .. ............ . . ....... .
Max. permissible weight deviation between connectings rods
in
same engine ................... ... . ...... ............. . .. . .
FLYWHEEL
Permissible axial throw, max .. .
Ring gear (chamfer forwards) ..
CAMSHAFT
Marking .. .... . ........ .. . ..... . . .. . . ... . .. . ........ " .. .
Number
of bearings .. . . ... . ..... ... . ..... . . . ..... .
Joumal, di ' ameter ...... . . . ... ...... .. .... . . ... ........ .
Radial
clearance ..... . . .. ... ....... . . .. ......... .... ..... . . .
End float .... . .................................. .. ...... . . .
Valve
dearance for controi of camshaft setting (cold engine)
Inlet valve shoul'd then open at .. . . . ........ . ...... . . ....... .
CAMSHAFT BEARING
Bearing diameter ... .. . .. . . .... ... . .. . .... ... ........ . . . . . . .
TIMING GEARS
Cr'ankshaft drive, number of teeth ... .. . . .. . . ...... . . . . ... . .
Crankshaft gear (fibre), number of teeth .. . . .... ... .......... .
Baokl ,ash ........... .... . .... .. ............. ..... .... ... .. . .
End Hoat, camshaft .... ... .. ... . . . .......... . . .... . ........ .
0:4
63.451-63.464 mm ( 2.4981-2.4986/1 )
63.197-63.210 mm (2.4881 -2.48 86")
62.943-62.956 mm (2.4781-2.4786")
38.930-38.970 mm (1 .5327-1.5342 ")
39.031 -3 9.072 mm (1 .5366-1.53 83")
39.133-39.173 mm (1 .54 07-1.5422")
1.985 - 1.991 mm ( .0782-.0784/1 )
2 .11 2-2.118 mm (.08 32-.0 8 34 /1)
2.239-2.245 mm (. 0882 -.0 884/1)
31.950-32.050 mm (1 .2579-1.2618")
54.099-54.112
mm (2.1299-2.1304")
53.845-53.858 mm (2.1199-2.1204")
53.591-53.604 mm (2.1099-2.1104")
1.833 - 1.841 mm (.0722-.0725/1)
1.960-1.968 mm (.0772-.0775")
2. 08 7-2 .09 5 mm (. 0822 - .082 3 /1)
. 15 -.3 5 mm (.006 -. 014/1)
145±.1 mm (5.71 ± . 004/1)
6 grammes (.21 oz.)
. 05 mm (.002 ") at a diameter of 150 mm (5.9/1)
153 te,eth
C
4
46.975-47.000 mm (1 .8494-1.8504")
.020-.075 mm (.0008-. 0030/1)
.020-.060 m.m (.0008-.0024")
1,45 mm (.057/1)
00 (T.D.C)
47 . 020-47 . 050 mm (1 . 8512-1.8524/1)
21
42
.04-.08 mm (.0016-.0032")
.02-.06 mm (. 008- . 0024"

VALVE SYSTEM
VALVES
Inlet
Disc di ameter
Stem d i'ame'ter . , . . ..... .. . .
Valve face angle .. . .... . ....... .. . ........ . . . . ... . . .
Valve seat ang le . . ..... . . .. ... . . .. . . . .... .. . . .... .. .
Seat wi dth i.n cy li nder head . . . ..... . ... . . . ... ..... .. . .
Cl earance, bot h wmm and cold eng i ne . . . . ... . ..... . .
Exhaust
Disc di ame ter . . . . . . .. . .. .. . . .. . . . .
St ,e m diame ter . ... . . . . .... . ....... .
Va lv e face ang le . ... . . . .. . . .. . . ..... . . . .
Valve se at ang le . . .. . .. .. . .... . .. . . ..... . ... .
Se at wid ~ h in cylinde.r he ad . ...... . ... .. . . . .... .. . .. .. . . .. . . .
Cle ar ance, both wmm and col de ,ngine .. . ..... . .. .
VALVE GU I DES
Length, in l et va lve . . . . .
e xhaust va lve . . .. . . .
Inner di ameter . . ...... ... ... . . . ... . ... . .. .. .. . . ..... .. ... .
Height
above uppe 'r face of cy li nder head .......... . ...... .
Cl earance, va lve stem- va lve gui de, illl et va lv,e . . . . . . . .
exha ust
va lve ..... .
VA LV E S PRI NGS
Len gt h, unio ad ed, ap pr ox. . . . . . . .. . ... .. . . .. . . .. . . . ... .. . . . . .
with a
loa ·ding of 25.5± 2. 0 kg {5 6±4,4 Ib) ......... . .
wi .th a l oading , of 66.0 ±3 .5 kg (14 5±7.7 Ib) . . . . .. . . . .
LUBRICATING SYSTEM
Oil capacity, including oil f.ilter .. ......... .. .... . . .. .... . .. .
excluding oil filter ..... ... . ..... ... . . . .... .. . .
Oil pressure , at 2000 r.p.m. (with wa : rm engine and new oil filte r)
Oll FilTER
Type .. . .. .. . . . . .... . ... . . . . ...... . ... . .. . . .. . . . ... .. .. . . . . .
Oll PUMP
Oi'l pump, type . . . . .. ... .. . ... . .... . . .. .. . .. . . . . . .. .. . . . . . . .
nu:mber of te eth on each gea 'r wheel . . ... . . . . . . .. .
end float . ..... .. ... .. .. . . ... ..... .. . . ... ... .. .. .
radial clearance . . . ... . . . . . . .. .. ... .. .... .... .. . .
backla sh . . . ... .... . ... ... .. . .. .. . ... . . ... . .. . . . . .
RELIEF VAlVE SPRING (IN Oll PUMP )
Length, unloaded .. . .. . .. . . . . . . '.' . . . .. . .. . ... . . . .. .. approx .
I, oaded wi ,th 5.0±,4 kg (11.0±88 , Ib.) . . . . .... . . .... . . . .
FUEL SYSTEM
FUEl PUMP
7.0± .8 kg (15,4 ± 1.7lb .) .. . .. .. . .. .. . .. . . .
Diaphragm type pump . . . .. . ... . . ....... . . . .. . .. . ... . . .. . . . .
Fuel pressure, measuredat sam.e levelas pump at 1000 r.p.m.
42 mm (1.654")
7
.9 55-7 .970 mm ( .3 1 32-.3 13 8" )
44.50
45 °
2.0
mm (.080")
.50-.55
mm (.020 -. 022")
35 mm (1.378")
7 . 925 ~ 7.940 mm (.3120 -. 3126")
44.50
45 °
2.0
mm (. 020-.022" )
.50-
.55 mm (.020 -. 022" )
52 mm (2.047")
59 mm (2.323")
8.000-8 .022 mm (.32 - .321")
17.5
mm (.689")
.030 -. 067 mm (.0012-.0026")
.0 60- .097 mm (. 0024- .0038")
45 mm (1.77 ")
39 mm (1 .5 4")
30 .5 mm (1.20")
6.0 litres
(10 . 56 lm.p .pints=12.66 US pints)
5.2 ,litres (9.15 Imp.pints=10.97
US pints)
2.5-6.0 kg/cm2 (36-85 Ib/sq. in.)
Full-flow type
Gear
9
.02-.10 mm (.0008-.0039")
.08
-. 014 mm (.0032-.0055")
.15-.35 m:m (.0060 -. 0140")
39.0
mm (1.54")
26 . 25 mm (1.03")
21.0
mm (.83")
Pierburg PV 3025
min . .15 kg/cm2 (2.1Ib/sq .' in)
max. .25 kg/cm2 (3 .5 Ib/sqJ in)
0 : 5

CARBURETTORS
Type . . ... .... .. . .... .. .. . ... . .. . .. . . . . ... . .. .... .... .
Ma, ke and deSligna.tion ................... . ..... .. ... . . . .... .
N
um ber .. .. . ... .. .... ... . . . .. . . .. . . .. . .. ... .. . . . . . .. . . . . .. .
Air intake diamet er . ... . ... . . .. .... . .. ... . . . . . . . . ... . . .. .. .
Idli1ng spe ed ...... . ... . .... .. . ... ... ...... ... . ... .. . . . . . . . .
For cars with automatic transmission .... .. .. . .. . . . .... . .... .
Metering
needl~ designation .. . .... . ......... . .. . . . . .. ..... .
Oil for damping cylin, der .............. ... .. . . . .... ... .
COOLlNG SYS TEM
Type .... .. . . ... . . . . . ...... . ..... . .. .. .. ..... . . .... .
Roadia.tor cap valVle opens at . . . . .. .. . ..... .
Oapacity ... .. ... .. .. . . .. . . . .......... . . ... . . .
Fan belt, designati'on
.. . . .. .. ...... . ...... . . . .......... . .. .. .
Fan belt tension: for a force of 7- 9 kg (15-20 Ib.) on the
he lrts between the pu ll eys obtained with a depression of . .... .
T
HERM OSTAT
Type .... . . .. ..... . . .. . . .... . , . .. . . .. ... .. ....... .. . . . . . .. . .
Marked .... . .. . .. , . .... . . . . . . . , . . , . ... . .. . . , ....... . .. .... .
Beg
in s to open ot . .. .. ... .. . .. . .... , . .... . . . . .. , .. . . . . .. . . .
Fully open at .. .. . . . . . . .. . ... . .. ... .... . ...... . . . .. . .. . .. . .
TIGHTENING TORQUE S
Cylinder head ... ".. . . .. ... ... .... .. .. .... , . . .. .. . .
Main
bearings ....... . . . .... . .... . .. . . . .............. . ... .. .
Big -end herings . . , . ........... . ... . . ....... . . .... . . . . .... . .
Flywheel .. ..... . . ... , ..... . ..... . . , .. . . .... .. . , .. .. ...... .
Spark plugs . ......... .. .......... . . .... .. ... .. . . ... ... . .. . .
Camshaft nut . ... . ........ .. .... . . .. . . . ..... . .. . ....... . .. .
Bolt for cra lnkshaft helt pulley .................... , . . .... . . .
Nipple for oil filter ....... . .. ... .............. . ... ... ..... .
Sump bolts
... .. ....... . ... . ... . . .. . . ....... , ... . ... . . . . .. .
Altemator bolt (%") . ............. . ...... ...... .. ..... .. ... .
WEAR TOLERANCES
CYLINDERS
To be rebored when wear amounts to (if engine has abnormal
Horizonf.al carburettor
Zenith-Stromherg 175CD-2SE
2
41. 3 mm (1.6 3 ")
800 r.p.m.
700 r.p.m.
Bl AM
Automatic Transmission Fluid, Type A
Sea le d system
.7 kg/cm2 (10.0 Ib/sq.in.)
approx 12.4 litres=2.73 Imp.galls/3.27 US galls.
(expansion tank of wich 1.5 litres=2.6 Imp.
p' ints=3.2 US pints)
7MX875
10 mm (. 39")
Wax
82°
81-83" C (177 -182° F)
90° C (1 94° 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
.8-1.1
7.1-8.6
Lb.ft.
61---69
87 -94
38-42
36-40
25-30
94-108
51-58
32-40
6-8
50-60
oil consl,lmption) ................ . . . . . . .. . .... .......... . . . .. .25 mm (. 01 O")
CRANKSHAFT
Permissible out-of-round on ni 'ain bea ' ri'ng journals, max. . .. .
Permissible out-of-ound on big-end bea 'ring journals, max .. .. .
Crankshaft end float, max. . . . ......... . .... . ........ .. ... .
VALVES
Permissible clearance between valve stems and valve guides,
.05 mm (.0020 ")
.07 mm (.0028")
.15 mm {.0060")
max. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 mm (.0060")
V'alve stems, permissible
we ' ar, max. .. . .. ... ..... . ........ . . . 02 mm (.0008")
CAMSHAFT
Permissible out-of-round (with new berings) max .. . ... . .. . . . . .
Bea'rings, permissible
wear . . . ... , .. . ....... . ....... .. . . . . . . .
TIMING GEARS
Permissible backlash, max.
0:6
.07 mm (.0028")
.02 mm (.0008 ")
.12 mm .0048")

12
8 4 5 9
13
11 7 3 2 6
10 14
Y E?Fi~'t
Ti gh t'ening seq u, ence for cyli nder h ead bo lts (tigh tened in 2
stages ). ht s~age: 2. 5--3.0 kgm (1 8- 22 Ib.ft.); 2nd stage : 8.5-
9.5 kgm (61
-69 Ib.ft.)
ELECTRICAL SYSTEM
BATTERY
Type .... . ... ... .. .. .. . . . .. .. ... .. . . . . .. . ...... . . .. . . ... . . .
Gl10u n ded .. . .. . . . . ..... ... . . . . .. . . . . . . ... .. . .. ..... .. .. .
Sy
stem vo l tag ·e . . . .. .. . .... .. . . .. .... . .. . . . ... . .. .. . . . ... . .
Battery , oapac ity . . .. . ... . ..... . ... .. . . . . . ... . .. . . . . .. . . . . . . .
Spe6 fic g r av ity of el eo t ro ly te:
F ul · ly cha rg ed b atte ry . .. . ... . . . . . . .. . . . .... . . ... .. . ... . . .
Whe ,n re charging is ne:eess ary . ........ . ... . . .. . . ... .. . .
Re c omm e nded c harg ring cU l1 rent . .. . . . . .. .. . ...... . .. ..... . .
ALTERNATOR
Type .. .. . . . . . . . .. . . .. . . . .... . . ... . .. .. .. . . . .. . . . . . . . ... .. .
Output . . .. . . . . ... . ..... .. .. .. ... . .. . . . . ... . .. . ... ..... ... .
Max.
amperag ·e .. .. . . . . . . . .. . .... .. ..... .. . . . . .. ... . . ... .. .
Max . spe · ed .... ..... ...... .... . . .. . . ... ... . . .. . . . . . . .. ... . .
Di r ection of rotation . . . . .. ..... .. . .. .. . ............. .. . . . .
Ratio,
engine -· alternator .. ...... .. ... ... . . ... .... . .. . . .. . .. .
Brushes, minimum len9'th .
.. . ..... ... .. .. . . . .. .. . . .. ... .. .. . .
Tigh~ening torques:
ANaching screws ...... ... .......... . . . . . ...... .. .. . .... .
Pulley nut .. .. . . .. .. . . . . . . . . .. . ... . .... ..... ... .. . . ... . . . .
TEST VALUES
Field winding resistance . . . . .. ... . .. .. . . . . . . . . ....... . ..... .
Voltage drop acrossi rnsulation diode . . .. .. . . . . .. .. . . ... .... .
Rated test . .... .. . . . . . . .. .... . . . . . .. .. . ... . .. . .. . . . . . . .. .. .
V OLTAGE REGULATOR
Typ.e . ... .. . . . .... . .. . . . . . ... ... .. . . . .. .. . .. . .. ... .. . ... . . . .
Contml vol~age, cold regula~or ... .. .. . . .. . . .. . .. . . . . . .... .. .
a~ter running 45 minutes . . . . .. . . . . ......... .
ST AR TE RM OTOR
Type .. . . ....... . ... . .. ... . .. . ... . ... .. ..... . . ... .... ... .. .
V· oHage . . . .. . ..... ... . . .... .. . . .. . . .... .. ... . .... ... . . ... . .
Grounded ... ... .. . . . ... . ... . . . . . . . . .. ..... . . . . ... . . ... . ... .
Direction
of rotation . . .. . . .. .. . .. ... .......... . . . .. ... .. . . . .
Output . . .. . .. .. . . . . .. ...... ... .. .. . . . . .... .. ... .... . . .. . . .
Brushes,
number . . .. . . . . . ... . ...... . . . . . .. . . .. ... . . . ... . . .. .
Tu
dor 6 Ex 4 F op or equ i va l en ,t
N
egat i ve term i na ·1
12 V
60 Ah
l.28
1.21
5.5 A
S.E.V.Motorola
14 V-34833
770 W
55A
15000 r.p.m.
Op~ional
1-2
5 mm (. 20")
.28- .30 kpm (2.0-2 .2 IbJt.)
4 kpm (29 IbJt)
3.7 ohms
.8-.9 V
48 A {min. · at 3000 r.p.m. and , approx. 14 V)
S.E.V. Motorol ·a 14 V-33544
13.
1-14.4 V
13.85--14.25 V
Bosch GF 12 V 1 PS
12 V
Negative terminal
Clockwise
Approx. 1 h.p.
4
0:7

TEST VAlUES
Mechanical
~otor end float
Br ush spr ing tension .. ....... . . .. . . . . . ... ..... . .... . ... . . .
Di
sta n ce from p ini on to r in g gear ... . ... ... . ..... . . . . . .. .
Fricti ooOl I torqu e of roto'r br ak e . .. . . . . . . .. . ..... . . .. . .. . .
Pi
n' ion idl ing to rqve .. .. . . . . . ..... . . . . .. ... . ....... . . .. .. .
Ba ,cklash .. .. . . .. . .. . . . . . . . . . . . .. . .... " .. . . ... . . .... , . . .
Mini
mum di ameter of commufaror .... . ... .. ... . . . . . .... . .
Mini
mum l engt h of el ec . brush es . . .. . .. . . . ... ..... .. ... .. .
Electrical
Un l oaded starter motor:
12.0 V '
and 40 -50 A
Loaded s
tarter motor:
9
Van d 18 5- 200A
Lock ed s ~arter motor:
6
Vand 300-350 A
CONTROl SOLENOlD
.05-.3 mm ( .002-.012" )
1.1
50- 1. 300 kg ( 2.53-2 .86 I b. )
1.2 -4.4 mm ( .04 7- .1 73")
2. 5- 4.0 kgcm (2.1 7-3 .81 Ib.in.)
1.3- 1.8 kg cm {1.13 -1.56 Ib .i n. )
. 35-.45 mm (. 14-.018")
33 mm (1 .3 ")
14 mm ( .6 ")
69 00- 81 00 r.p.m.
1050-1350 r.p. m.
o r.p.m.
Cut-in
voltag 'e ... . . ... ... .. . .. . . . . .... .... . . . . . . . . .. . . . . .. Mi n. 8 V
IGN I TION SYSTEM
Fining order . . .... ... .. . ... . . . . . . .. . .. .. . . ... ... .... .. . . .. . .
Ign ifi. on .t iming
( aif" 600 -800 r.p.m. wi th v ac uu m go ve rn or di sco n n.ec t ed ) . .. .
Spar k plugs, type .. . .. . . ... . .... . ...... . . . .. . .. . ...... . .. . .
thread .. . ... .. . .. . . ... . .. . . .. ... . . . . ... . . . ... .
s park plug gap .. . ... .... .. ..... . ... .. . ... . .. . .
tightening
torque . ..... ... ... .. . ... ...... . . .. . .
Pr e-enga ·ging resistance to ignition coil . . . .. . . .. . ... . .. . . . .. .
DI STRIBUTOR
'Type . . . . ... . .. .. . . . . . . . . . . .. .. . .. .. .... .. . .. . ........ .. . . .
Direction
of rotaif"ion . ... .. ..... .. . . .. .. .. ...... .. . . .. .. ... . .
Br e aker poin,ts, g, ap .. . . . . . . .. . .. .. . ... . . .. .. . . . . . . .... .. . . .
contact pressure
.. .. . . . . . . .. . . . .. ... .. .... . .
dwell ang ' le . . . . ... . . . . .. .. . . . . .. .. ... .. .. . .
Capacitor
Centrif l,l gal gove rn or:
Advance range, total . . . .. .. . ... . . . . .. . .. . ... ... .. ..... .. .
Advance begi,
ns at . . . . . .. . ... ... . .. . .... .... . .. .. .. . . .. . .
Values, 5°
.. . . . . . . .. .. . .. . .. .. .. . .. ... . . . ... . .. . . . . . .. . .
10° . . . . . . . . . .. . . . . . .. . . . . .. .. .... .. .. .. . . . . . . .. . .
Advance finishes at . . . . . .. . ....... .. ... . ... . . . .. . .. .. . . . .
Vacuum gover no r:
Pos itive co ntroi
Advance range, total .... .. . . .. . . ....... . .. . .. . ..... . .. .. .
Ad",anoe begins at . ..... .. . . .. . .. . . .. ... . . . ... .. .. . . .. . . . .
Valu'e, 2.5° .
... .. ... .. . .... . ... ..... ... ...... . . . . .. . ... .. .
Advance finishes
ot .. . . . .. . . . , ... .. . . .. .. , . . .... . ... .. .. .
Vac uum governor:
Negat ive co ntroi
Drop, total .. . ,.,., ., ... ... .... . . . ,. , ... . " . .. .. " . . . . . . . .
Drop begins
at . ..... . , .. , ..... " .. . .. . . . , .. ... .... . . .. .. .
VI O'lues 2° . . . ...... , .. . .. . .. . , .. . . . . . . ... . , .. . . . .. . .. . .. . .
Drop
fi ·nishes at . . .. . . . , ... . .. , .. .. , . . .... . . . .. .. ...... ... .
0 :8
1 -5-3 -6-2-4
10° before T.D. C.
Bo s ch W 200 T 35 or equival,ent
14
mm
.7 -. 8 mm (.28 -.032")
3.5-4.0 kgm (25 .3- 29.0 Ib .ft.)
.9± . 05 ohm
Bosch
JFUR 6
Anti-clockwise
Mi ' n. .25 mm (.01 O")
500-630 grammes (1.10 -1.40 Ib.)
40±30
.2 fl- F-25 %
12 ± 1° (distr. gradua ,tion)
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° (distr. graduation)
6-10 cm Hg
9.5-14 cm Hg
14.5-16 cm Hg
3± .5 ° (distr. graduation)
16-25 cm Hg
23-31 cni Hg
28-32.5 cm Hg

LAMP BULBS
He adlights ....... .. .... ... .............. . . ..... ........... . .
Fog lights
... . . .. .. .. . ......... . ... . .. . . ........ . . . . .
Park ing li ghts, front ... . . .... . .. . . . .......... . . . . .. . ... . . . . .
rear .. . . .. . . .. . . . .. .. . .. . .. . . . . ... .. ... .. .. . .
Flashers . . .
... . .. . . . . . . .. .. ... . . ... . ..... . . . . . . .. . . ... .. . . . .
S top l ig:ht s . .... . ... . .. . ... . ..... . .. ...... ........ ... . ... .. .
Reversing lights . . . .
... .. ...... ...... .... . ... .. ... ..... .. . . . .
Numb er pl ate li ght . . ... . . .. .. . . . .. . . ... . . ... .. .. . .. .... . . .
S ide marker lamps . .. . . .. . .. ... .. ...... . ... .. . .. .... .. .... . .
Int. erior ii ghtmg : .. . .. ... . . . ... . .... .. . . . . .. .... . . .. ... . . . . . .
Glove
compartment li ght .. . .... .. .. .. .. . ...... .. . . . . . ..... . .
E
ngine and l uggag e compartm ents . . . . . . . .. . . . . . . . .... ... . . .
Ins~rument li ght ing . ...... . . . . ..... . .... ... .. . . . . .. .. . . .. . . . .
Lightf' ing heater contro ls ... ..... ..... ... . .. . .. .. . . . ..... . ... .
C on~ro l lamp , in strument pa 'nel . . . . .. . ... .. . ... .... . .. .. . .. . .
Co ' ntro ·1 l amp, ov er drive .. .. . . . . ......... . . . . ..... . . ... ... . .
C ontro i I' amp, el:e c. heat ed re ar win do w . . . . . . . .. . . . . . . .. . . .. .
Hazard warning signal flashers . . . ....... ..... .. . . . .. ..... .. .
FUSES
Rated cu rrent 16 A
R, ated current 8 A
Rated curre nt 5 A
EL ECT R ICAL LY HEATED REAR WINDOW
Outpu t, at first position of s wi tc h . . ........ . . .. .. . .. . . . . . . .
Outpu rt, at second position of switch . ........ . .......... .. . .
INSTRUM ' ENTS
SPEEDOMETER GEARS
Tyre 165 SR 15
G earbo x I Ftnal drive
red.
ra tio
M 400 3.73:1
M 410 3.73:1
BW 35
3.31 :1
I Small
S-gear
I
Part No. I Teeth
380168 18
380754 18
380649 16
Watts
45/40
55
5 (4 cp)
5 (4 cp)
32 CP
25 (32 cp)
15 (32
cp )
5
5
10
2
18
3
1.2
1.2
1.2
1.2
1
.2
Numb er
4
4
App r ox . 40 W
Approx. 150 W
Larg'e
S-gear
Part No . I T eeth
381033 6
380682 6
235810 6
Socket Number
p 45 t 2
P 14,5 s 2
Ba 15 s 2
Ba 15 s 2
Ba 15 s 4
Ba 15 s 2
Ba 15 s 2
SV 8.5 2
Ba 15 s 4
SV 8.5 1
Ba 9 S 1
SV 8.5 2
W 2.2 d 2
W 1.8 d 3
W 1.8 d 5
W 1.8 d 1
W 1.8 d 1
W 1.8 d i
I
R.a ti o I
Er ror
%
3.0:1
+0.43
3.0:1
+0.4 3
2.66 :1
+0 .38
The pe ,rcen,t age error ,in the ao bov 'e t able is calculated fo r a rolling radius of 308 mm (12.1 " ), whioh is the value
of the figure es t ablished by AB Vo lvo fo r tyres at a vehicle speed of abou t 80 km .p.h. (50 m.p.h.).
Number of speedomete r cable r evolutions per km (mile) r egistered : 640 (1024).
TYRE 6. 85-15
G earbox
I
Fi nal drive I Small S-
gear
I Large S-
gear
I
Ra tio I Error
red.
ratio
Part No . I Te·
eth Part No . I Teeth %
M 400 3.73: 1 380168 18 381033 6 3.0: 1 -1
M 410 3.73:1 380754 18 380682 6 3.0:1
-1
BW 35
3.31 :1 380649 16 235810 6 2.66 :1
-0.75
The per , centag 'e error , in the above table is calcula t' ed fo 'r a r.olling r adius of 312 mm (12.3"), which is the value
of the figu' re established by AB Volvo for tyr es ata vehicle spe ' ed ofabou t 80km .p.h. (50 m.p.h.).
Numbe r ofspeedom et er cable revolu,tions per km (mile) reg isf ered : 640 (1024).
0 :9

POWER TRANSMISSION, REAR AXLE
CLUTCH
C1utch, type . . ... .. . . . . . . ... . ........ . .......... .. ... . ... . . .
Size
........ . ..... . ..... . .... .. ...... . ...... ... .......... . . .
C1 uk h fricti on area , tota l .. ..... .. . ........ .. ... ... .. . .. . .. .
Re l 'ease lev er pl ay , vehicle wi th left-hand steer i·ng ... . .. .. .. . .
vehicle with right-hand s
te ering . .. .. .. .. .
GEARBOX
M 400
R ed uction r at i os :
1
st spee d . . .. . .......... . . . ... .. .. . .... . . .. .. . ... . ... . . .. .
2nd s
pe ed .. ... .. . . .. . . .... .. . . .. . ...... ... . . " . . .. .. . . . . .
3rd sp
ee d .... ...... .. .. . . ... ... . .. . . ..... .... ........ . . . .
4th
speed .. . ........ . ... . ... . ... . .... . .... . ... .. ... .. ... .
Re v erse . ...... . ...... . ...... . .... .. . .......... ... .. .. . . . .
Flan
ge n ut t ighten in g to rqu e . . . ... .......... .. ........ .... . .
Lu bri oa nt . ... ... ........... .. .. . . ..... .... ... . . ... . .. . . .. .. .
vi scosity .... .. .......... ... . .. .......... .. ....... . .
at continuous a'ir temp er ature helow
-100 C
(1 4° F) ... ... . ........ ...... . . . ... .
A lt erna tive lubric ant ... . . .. ....... .. . . .. . ... . .. . .. ... ...... .
vi scosity .. . . . ... ... ... ....... . ... . .. . . .
O il c ap ocity . ........ . .. ... ... .. ... . .... . . . ....... . . ... . . . . .
M 410 (GEARBOX M 400 WITH OVERDRIVE)
ReduotiOlnmtio, overdrive .. . . .... . .... . . .. .. . .. .. . ........ .
Oil pressure, di' rect drive . . .. . . . ..... . .. .. .. ...... . .. . .. .. .. .
ov , erdrive . .......... . ...... . .. . . .. . . .. . ... . . . .
Nut for driVling flange . . . . .. . .. .. ...... . . .. .... . ...... .. . . . .
Lubriaant,
....... . .... . . . . . ... .. ... . ... ... .. . ............ .. .
viscosity .
..... . .. . ....... ..... . . ... .. . .. .. .. . ... .
qual 'ity ........... . ... . ... ..... ........ .. ...... .. .
Oil capacity, gearbox and overdrive . . . . . ... . . .. . . ... . . . ... . .
A UT OMATIC TRANS MI SS I ON
Make and type ... . . . . . . . .. .. . . ... . . .... . . .. ....... . ... . ... .
Type
designa ,tion . . .... .... .. ... . . .... ... .... ... . . . .. . . .
Colour of rtype plate . .. . . .. . .... . .. . . . ...... . .. . .. . ... . . .
Reductioill r' atios: . ... . ..... ... . .. . ..... . ..... . .. .. .... . . . . . .
1st
gea 'r .... .... .. . . . .. . ... . ... . .. .. . .... ... . ....... . . . .. .
2nd gear . .. ... ... . . ... . .... ... . . . .. . .. . .... . .. ... . .. .. . .
3rd g' ear ·. . . .... .. .. . . . .. .. . . .. . ... . . . ....... .. ........ . .. .
Reverse ... .. . . . . . .... . ... . .. ....... .... .. .... . .. ... ... . . .
Number of teeth, front sun gear ..... . . ...... . .. .. . .. . .. .. . .
rear sun gear ..... ... .. . .. .... .. .... . . .. .
planet gear, short .. ..... . . .... ..... . . . . . .
planet ge ' ar,l l olng . . . . . .. ..... ... .... .. ... .
ring
gear .. . . . . .. .. ....... . .. .......... . .
Size
of converter ..... . .. . . ... .. . .. ........ .. ... . ... ... ..... .
T
orque roNo , in convertrer . . ...... . .... .. .. .. .. . .. . ... .. .. . .. .
Norma151tall speed . .. .. .. . . . .. . . .. ... ... . .. . .. . . .. ........ . .
Weights:
G, earbox ... .... . .. . ..... ... . .. .... . .. ....... ............ .
Converte 'r aase .. . ..... . ... . . .. . . . ... . .. .. .... ... .. ...... .
Converter ...... .. .. ... ... . .. . .. .. ... . . .... . .. . . . .. ... ... .
Total, without fluid .. . ...... . ... . . ....... .. .... .... . .... .
Weight of fluid .... .. .... .. . .... ... ...... .. . .. .... . .... . . .
To~a , l, with fluid .. .... .. ... ..... . ..... . . ..... .... . . . . ... .
Fluid,
type .... .. . ... ........ .......... . ... . ... . . . . .... . . . . .
Fluid
capacity . .. . . . . . . . .... . ..... . ... . .. ....... ... ..... . . . .
Norma ll opemting , temperature of fluid . . .. .......... .. ..... .
O: 10
Single, dry-pl
ate, di, aphragm spring
9"
468 cm
2 (72.5 sq
.i n.)
4 -5 mm (.16 -.2 0")
2- 3 mm (. 08 -. 12 ")
3.14 :l
1.97:1
1.34:1
1:1
3.54:1
11.0-14.0 kgm (80 - 101 Ib .ft.)
Ge ar oil
S
AE 90
SAE 80
Engine oil
SAE 30 'Or
SAE20 W -40
ap pro x. .6 litre (1.1 Imp..pint s= 1. 3 US pints)
0.797:1
Approx. 1.5 kg/cm2 (21 Ib/sq.in.)
36-39 kg/cm2 (510-550 ·Ib/sq.in.)
11.0-14.0 ·kgm (80-101 Ib.ft.)
Eng ,ine oil
SAE or SAE 20 W-40
Service
ML , or higher
approx. 1.4 litres (2.46 Imp.pints=2.95 US pints)
Borg-Warner, type 35
AS 5-35 EN
Blue
2.39: 1 l
1.45:1 )'
1 :1 X Converter ratios
2.09:1
32
28
16
17
67
11" (28 cm)
2:1-1 :1
2100 r.p.m.
Ib. kg
82 37.2
7 3.2
30 13.6
119 54.0
17 7.7
136 61.7
Automatic Transmission Fluid, Type F
14 pints (8.2 litres)
approx. 212-240° F (110-115° C)

Approximative shift speeds
I 1- 2 shift I 2
-3 shift I
3-2 shift I
km.p.h. I
m.p.,h.
km.p.h. I m.p.h. km.p.h. I m.p.h.
Full throttle I 48
I
30
I
87
I
54
I
66
I
41
I
Ki,ck·down
63 39
112
70
100
62
SPRINGS FOR CONTROl SYSTEM
Spring Effect
iv e number
ApPl10x imate l engt h
1-2 shift va lv e
Convel1f:er eXihausting va lve ........ . .
Rear pump check
V'a lve . o ......... .
Primary reg ul , ator valve ooo. ooooooo.
Servo onific econtro l vlO'lve .. oooo .. oo
Modul'
ator valv oe ooooooo. o. ooo .... o' .
Seao n, dary regulator va.lv e . oo .. .... .
2-3 shift va lve (i nner spring)
Throttle valve
(in ner spr i,ng)
1.094"
27.8 mm
.70"
17.13 mm
.617" 15.7 mm
2 .850"
72.4 mm
1.005"
25.5 mm
1.069"
27.2 mm
2.593 "
65.9 mm
1.59" 40.4 mm
. 807"
20.5 mm
Thro~He valve ( outer spring) l .174-1 .185" 29.8-30.1 mm
TIGHTENING TORQUES
Application
Torque converter -drive pla,te . ooooooo .. . ooooooo. oooo o' ooo
Transmissi'on
case - conver~er housing . oo. , o, , . o. .. . .. oooooo
Extension housing -tr,ansmission
ca 'se . . . . . . . o ... . o. oooooo
Oil pan -transmission case oooooo ... o ... oo .. o .. ooo. ooooooo.
Front
serVlo -transmission case oo. oo. . o .. o .. ... .. ... o .. oo ..
Rear servo -transmission case oooooo. . o ... o. . ... .. o. .. . oooo.
Pump adaptor -front pump body oo .. o. ..... o. ooo .... ooo. o.
Slotted screws oooooooooooooo. oo .. .. o. . . ooo .. ooo .. ooo. ooooo
Pump adaptor -transmissi'on case o ....... ooo .... . o. oooo. .. .
Re J ar pump -transmission ca se ooo .. ooooo .... . . ooooooooooooo
Slotted screws . oo. o .... oooooooooo. ooo ... ... ... .. .. oo .. o. oo
Centre support -transmission case .. . . o. . oo .. . ooo. oo. o. . .. oo
Outer I' ever -manual voO'lve shaft oo. oo. . . o. o. ... oo. oo ...... o
Pressure pOlint o. o. .... . o. o .. oo. oooo .. .. . o. ... .... oo .... ooo
Oil pan drain plug ooooo. . ooo. ooooo. . o ... .. o. . oooo o. o. oo. o. oo
Oil tube oolledor -lower body . . ..... ooo .. o ... oooooo. .. . . .
Governor li ,ne plate -lower body . o. oo. . oooooo .... oooo ... ooo
I.:ower body end plote -lower body o. o. ooo. oo .. . o ... ooo. . . o
Upper body lend plate frOlnt or rear - upper body ... . ooo ... oo
Upper body -lower body . . o. o o. oooooo. ooo .. o ..... . ooo. oo ..
Valve bodies assembly -transmission case o .. ... ooo ... o. oo. .
Fr , ont pump str.ainer -lower body oooo. oooo. o .. oo. . .. o .. o ...
Downshift valve cam brackeif -valve body ooooo. oo. . oo. o .. oo
Governor
Inspection cover - ,extension housing . o. o .. . ....... . .. ooo .. oo
Cover . pl l ate - governor body oooo .. ooo ..... .. o. . .... o .. oooo
Drake band adjustment
Adjus,ting screw nut -front servo lever ooooo ... oo. .... o .. o. ..
Adjusting screw locking nut, rear servo - case oooo. o .... oo. o
Special threaded parts
Start, er inhibitor switch locknut
Downshift v:alve
cable adap~or -transmission case o .... o. . . .
Coupling flange -driven shaft ooooo. o. ooooo .... . oo .. o. oo. .. .
Lb.ft.
25-30
8- 13
8- 13
8- 13
8- 13
13 - 27
17 - 22
2-3
8-18.5
4-7
1.7-3.0
10-18
7-9
4-5
8-10
1.7-2.5
1.7-2.5
1.7-2.5
1.7-2.5
1.7-2.5
4.5-9
1.7-2 .5
1.7-2.5
4-5
1.7-4.0
15-20
25-30
4-6
8-9
35-50
of 1>urns
1 31 /2
12
3
141 /4
17
19
18
221 /2
28
191 /2
2-1
shift
km.p.h. I m.p.h.
14
I 9
51 32
Wi re di ' ameter
.024"
.018 "
.019"
.054 "
.024 "
.028"
.056 "
.036"
. 018"
.032"
Kgm
3.5-4.1
1.1 - 1.8
1.1 - 1.8
1 .1- 1.8
l.1-1.8
1.8-3.7
2.4-3 .0
.3-.4
1.1-2.6
.6- 1.0
.25-.41
1
.4- 2.5
1.0-1.2
.6-.7
1.1-1.4
.25-.35
.25-.35
.25-.35
.25- ~ 35
.25-.35
.6-1.2
.25-.35
. 25-.35
. 6-.7
.25-.55
2.1-2.8
3.5-4.1
.6-.8
1.1-1.2
4. 8-6.9
.61 mm
.46 mm
.49 mm
1.37 mm
.61 mm
.71 mm
1.42 mm
.91 mm
.46 mm
.81 mm
o. 11

PROPELLER SHAFT
Type ... . .. . . .. ....... ..... ... . . . . . . ... .... .. . ... .. . . . ... . . .
Univers
al joints ....... . ...... . .. .. .. . ... ... ... .. ... . .... . . . .
Lubri
ca nt, sliding joint (when asse mbling) . . .. . . . ... . . . . .. . .
unive rs al joint .... . .. ... ..... . . ... . . . . . . .... .. . .. .
REAR AXLE
Rear axle, type . . . . . ... .. . . . .. . . . .. ... .. .. . . .. . . ..... .. . .. .
Tl1a 'ck ..... .. . . . . .. . . . . . . . . .. ..... ...... . . .. .. . ... .. ... . . . . .
F I NA~ DR I VE
Type .. ....... . .. . . . .... .... . .. . .. .... .. . . ........ .
Reduction
ratio . . . . . . . . ... . ... ... . .. .. . . ... .... . ... . .. . . . .
Ba ,cklash . . ... . . ... : .. . . . . . . . . .. . . . . ... .. . .... . ........ . ... .
Pre-I' oading on pinion bearings, new bearings . . . . . . ... . . .. . . .
run-
in beari , ngs . .... . . .. ... . .
Pre-I oading on differentia l bearings ... . . . . . ... ... . ..... .. . .. .
Lubricant,
.. ...... ..... . . ... . . . . " ..... . .. . . .. .. ... ...... . ... .
viscosity
.. . . .. ... .. . .... . ... .. . .. . ... . . .. .... ... . .
OH oapa6ty ........ . . . .. .. . .. .... . ..... . . .. . ... ......... .. .
TIGHTENI NG TORQUES
FI . ange . .. ..... . ... . . . .. .. . . . . . .... . . .... .. .... . . . . . . .
Gaps .. . .. . . . .. .. . . . .... . .... . ... ........ . . .. . ..... .. . .. .. . .
Crown wheel . .. .... . . ... ..... .. . . .. ... . . ... . . . . ... . . .... .. .
BRAKES
FRONT WHEEL BRAKES
Type . . . . .. ... ..... . . ... . . . . ... . .. . . .. . ... . .. . . ............ .
Brake
discs:
Outside diameter .. . . .. ... ..... . . .......... . . ..... . .. . . . .
Thickness,
new ...... ...... . . .. ...... . . .. .. .. ...... . ..... .
reconditioned ... ..... ... . . ..... . ... . ... . ..... . . .
W, arp . . ..... .. .... . .. . . ..... . . .......... '. . ... . . . . . .. . .... . .
Brak'e linings :
Number per wheel .... .. ..... . ........ .. .. . . . .. ..... .. .. . .
Thickness, new . . .. ..... . .. . .... .. ..... . ... . . ............ .
6Hective area .. . . . .. ..... ... .. ... . ... . ... . ...... .. ... . .. . .
Whe ,el Imit cylinders: '
Number per wheel .. . ..... . .. .... . .. .. . . . . .. . . . ... . .. . .. . .
Diameter . ... . .. . .. ... ..... .. ... . ... . .. . . . . . .... . .. . . ... . .
REAR WHEEL BRAKES
Type .. .. . .... . .. . .... .... ... .. .. .. .... ... .. . .. . . . .... . ... .
Brake discs:
Outside diameter .. .. . . .. ... . ... .. .. .. . . . .. ....... .. .. , . ,
Thickness,
new . . .... .. . .. . .. . ... . ... . . . .. ... ..... . ..... , .
recon 1 ditioned .. .. .... . . ........ . ........ .. .. .. . .
Warp .... ...... .... . ... .... ...... . ... .. .. . . .. ..... .. ... . .
Brake linings:
Number per whe ·el .. .... . ... . ... . . . . .. ....... ....... . ... . .
Thiokness,
new . . .. .... . . .... ...... . . . . ...... .... ....... . . .
Effective a
rea ..... ... .... ; . . . . . . . . . . . . . . ..... .. .. .. . .. . . .
Wheel unit cylinders :
Num-be'r
per wheel .... . . .. ....... . ..... .. ..... . . .. .. .. . .. .
Diameter . . .... .. .. ... .... . ... . . ... .... . . .. . .. " . . .... . .. .
O: 12
Tubul ar, divided , three un iversal joints,
sup
port bear in gs
Fitted with n ee dl 'e b ea rings
Molybdenum disulphid e ,chass is gr ea se
Further addi ,tion not required
Semi-Hoating
1350
mm (53.15")
Sp i Ta l bevel (hypoid)
3.31 :l (13: 43) or 3.73:l (11: 41 )
.13-.20
mm (.005-.008")
11 - 23 kgcm (9.55-20 Ib.in.)
6- 11 kg cm (5.21 -9.55 l.b.-in.)
.13-.20 mm (.005-008")
Hypo id oil
SAE 90
1.6 li tres (2.82 Imp.pints=3.38 US pints)
Kgm
28 -30
5.
0-7.0
6.5-9.0
Disc brakes
272.2 mm (10.7")
LbJt.
20 0- 220
35-50
45-65
12.7-12.8 mm (.500-.504")
Min. 11 .6 mm (.457")
Max .. 10 mm (.004")
2
10 mm (.394")
172 cm
2 (26.7 sq.in.)
4
36.12 mm (1.422")
Disc brakes with A.S. B. devioe
294.6 mm (11.6")
9.6 mm (.378")
8.4 mm (.331")
max .. 15 mm (.006")
2
10 mm (.39,4")
100
cm
2 (15.5 sq.Iin.)
2
38.15 mm (1.5")

MASTER CYLINDER
Nominal diamet , er , , ,
Bo~e " " ', ' "
Pi
ston d iam elfer
BRAKE LINE
Outer diame.fer
BRAKE VALVE
Make" " ,
Operating pr ,essu're '"
SERVO CYLINDER
Mak 'e .... . , . "
Designat.ion .,. , . , ' . . " ... ,
TIGHJENING TORQUES
Attaching bo ,lts, front broke cal'iper .' . .. . ....... . ..... . . . . .
Atta 'ching bo lts, reor brake ca ' li per , . . ... ', .. .. , . ' .. , .. . . ... .
Whee l nu.ts . ..... , .. . . ......... . ... , . . ... , . .. . ..... , ...... . .
Stop screw , master cy li nder . . ...... , , . . . .. , ... . , . .. , ..
Attoc hing nuts , master cy li nde 'r .... , . . , ...... , , ........... , ..
Ve nN ng :n i pp l es . . , .... " . . .. , . ' .. . . , ' . . .. , ..... ' ., . . . . . .. " .
Bra ke h oses .... ...... . . ... ,., . .. , ......... . ..... . . . " .. ... .
W,a rning va
lv e, s wi tch .. . .. ,.,., .. ........ ' .. .. . ... .. . . . . , ..
Bl ra ke pip es . . .. .. .... . . ... . , . .. ..... . . .. . . . .. , . . .... . . .... .
Plug, br ak e va lv e .. .............. .. ... ... .. , ....... , . . .... . , .
Lock nut,
broke valve ........ . . ' ,' .... , ..... , . , .. .. ... . . ,
23.81 mm (. 94" )
Max. 23.92 mm (.95")
Min. 23.66 mm ( .93" )
3/16"
Ate
50 ±2 kg/cm2 (711 ±28,4 Ib/sq.i n. )
Ate
Bromsgerät T 51
Kgm
9- 10
6-7
1 0- 14
.5-.8
1.2 - 1.5
.4-.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- 1 00
3.6-5 .8
8.7 -10.8
3. 0 -4.5
12 - 15
10 -15
8- 11
70 - 85
18-25
FRONT END AND STEERING GEAR
WHEEL ALlGNMENT (UNLOADED VEHICLE )
( , aster ..... . ....... . ... .. . . ...... . ...... . .. ... ............. .
(amber ........ . . . .. . .... . . . .. .. ... .... ......... . ......... .
King
p.in indina ti'on at :a camb er of 0° .. . ............ . ..... .
T, oe - in .. . .... .. . ... . ... . .. .. . . ... .. ...... . .. .... .. .. .. .. .. . .
Tuming an ' gles :
alt a 20 ° -t um of the outer wheel the inner wheel should be
tum , ed 21 .5° to 23.5 °.
Shims, thickness . .. .. , . . , ... , . .... . ...... , ...... .... ...... . .
MECt-IANICAL STEERING GEAR
Steering wheel diame f. er ............. ..... . .. .... ... . . .. . .. .
Number of tums from stop to stop in vehide . . .. .. .. .. . . .. . .
Steering g,e, ar:
Make . ..... . . .. . . . . . , ... ......... .. .... . ................ .
Type ... . . .... .. ... . , .... .. ... ,., .. .. . .......... . .. , .. .. . .
Reduction
rati ' o, ce ntre position .. .. . ......... . .... . ....... .
(Iearance , steering shaft-bush, new part . , . .. . . ... . . .. . .. .
Ball di' ameter , bearings
ball nut
wear limit ..... .. ....... .. .
o to +1°
O
to +0.5°
7.5 °
Oto 4 mm (O to 0. 16/1)
. 15 mm (. 006 /1 )
.50 mm {.020/l)
1.0 mm (. 039 /1 )
3.0 mm (. 118/1)
6.0 mm (.236 /1 )
423 mm (16 . 6")
4.8
Burman
( l
am and ball nut
18 .3:1
. 025 - .063 mm (.001 0- .0025/1)
. 18 mm (.007")
7.14 mm (.28 /1 )
7.93 mm (.31 /1 )
o:13

Shims . . .. ...... . . . . . . . . ... . . .
Lubricant .... . ...... . ....... . ... .
Oil capacity ....... .
SERVO STEERING
Steer in g wheel diameter . . . . .. . ........ . .... . .. . .
Number of tums from stop to stop rn vehicle .. .
St' eer ing g' ear:
Make and type .. . . . . .. . . ...... .
Reduction
ratio .. . ..... .
Servo pump:
Make ond type . . . . . . .. . .. ... . .... . . . . .
Max.
pressure . . . .. .. .. . .. . ... . .. . ..... . ........ ... ...... .
Theore !ti'cal capac ity at 500 r.p.m. . .. . . .. .. .. ... . .. . ....... .
Min. capLlcity, 500 r.p.m., 50 kg/cm2 (7 11 I b. /sq.in.), 80° C
(176° F)
.. .......... .. ...... .. .
Regul' ated capac ity .
Drive . . ........ . ....... . .. .
Ratio,
engine-pump
O il type ...... ... .. . . .
Oi l changing quantity .... . . . . .
TIGHTENING TORQUES
Atta 'ching balt for upper wishbone shaft . . .. . . ... . . . . . .. . . . .
I\Jut for steering wheel .... . .. ... . ...... .... .... . . . ...... .. . .
Nut for pitman mm . .. . . . .. .. .... .. . .. ..... ... . .... . ...... .
Locknut
for tie rod .. . .. ....... . ...... . .. . .. .. ..... ... ..... .
Mechoni' ca I steering 9'ear:
Sarew for steering box screw cover .. ............. .. . .. . .. .
Sarew for stop pl ' ate .. . ... .. ......... . . ... .. . . . . .. . ...... .
th = .0.5 mm (.002")
th=.127 mm (.005")
th = .254 mm (.010")
Hypo id o il
.6 litre (1.1 Imp.pint = 1.3 US pints)
423
mm (16.6")
3.7
ZF, ball and nut
15.7:l
ZF, vane pump
75 ±5 kg/cm2 (106 6±7l Ib/sq.in.)
6.65 11m (1 2 Imp.pints =14 US pints/minute)
4.5 l/m
(8 Imp.pints=9.5 US pintslminute)
5-8 l/m (9 Imp.p,ints= 10.5 US pints -14 Imp.
pints = 17 US pints/minute)
With
belt
l :l
Oil appro v ed as "Automatic Transmission Fluid,
Type
AU
Approx . 1 .2 litr es (2.11 Imp.pints=2.53 US pints)
Kgm
Lb.ft.
5.5-7 .0
40-50
3-4 20-30
17.5-20
125-145
7.5-9
55-65
1.7-2.1
12-15
1.7 -2 .1
12-15
SUSPENSION, WHEELS
SPRINGS
FRONT SPRINGS
Type .. .. .. .. ... ... ..... ... ... . . . . .
Wire diamet 'e'r .. .... .. ....... . ....... ... ..... . ... . ......... .
Ex , temal di, ame , ter ... . . . . . . . . . . . . . . . . . . ... ... .. . .
No. of eHective turns . ... ... . . . . . . . .. . .. . . .... . ... . ........ .
Test
values:
loading ~or a aompression of l cm (25/64") (measured within
a spr.ing length
of 185-205 mm = 79/
22
-8'/'6) ..... .. . ....... .
Length, fully
compressed . .. .. ..... . . . . ...... ... . .. .
Length,
when loaded with 600-630 kg (1320- 1386 Ib .)
REAR SPRINGS
Type . .... . .. .. . ....... .
Wir ,e , diamefe 'r ... ... ... . .
Ex , temal di' ameter . . . .. .. . .
No.
of eHective tums ...... .
Test
values :
Loading (for a
compression of 1 cm = 25/64") . .... . .. .
Length, fully compressed . . . . . .... . ... .
Lo : ad/spr .ing length .. . . . ... . ........... .. . ... ... ... . . . . . .. .
o:14
Helical spring
15.5
mm (.61")
125.7
mm (4 .95")
65h
61.9 -65 .9 kg (136-145 Ib.)
max. 127 mm (5.0")
195 mm (7. 6")
Helical spring
12.1 mm (.48")
127.1 mm (5 .0")
8 .9
15.88-16.88 kg (35 -37 Ib.)
max. 114.9 mm (4 .5 2")
211 -225 kg/297 mm (464 -495 Ib./11.7")

SH OCK ABSORBERS
Type .. ,.......... . .... . ... . .. . .... . . .. . .. . . .. .... . .. . ... .
T
otall lengif'h:
f.ront shock absorbers, compressed .... . .. ... .... . .. .... .
unloaded ...... .. .. ........ . .. . ... .
front shock absorbers, compressed . ...... . .... .. . .
WH'EELS
WHEEL RIMS.
unloaded ... . . ............ ... .
Designation
... ..... ... .. . ..... .. .. . .. .... . ... ..... . . .... ... .
Type
.... .... . .. . . .. . . .. . . . ..... . . ... . ..... ... . ..... .. ..... .
Ra , di ·al throw ......... . .. .. ..... .. . .... .... . ... ........ . ... .
War p ....... .. . ... ... . . ....... . .... . .... ..... . .. .. . . .. . ... .
Imbalance, com.plete wheel .... ........... . ..... . .... . . . .... .
Tightening torque
for wheel nuts .... .. ...... ... ........ . .. . .
TYRES
Type .. ... .... ... . ....... ... . ...... . . .. .................. .. .
Size ... .. ............ ... .. ........ . ... ...... . ... . . .. .. ..... .
Double-act.ing, hydraulic, telescopic
approx.
223 mm (8.78")
approx ..340 mm (1 3.39")
approx. 279 mm (10.98")
approx. 443 mm (.17.44")
4.5 JX 15 L
Dise
max. 1.6 mm (.063")
max. 1.6 mm (.063")
900 gem (7.8 Ib . in.)
10-l4 kgm (72 - 101 Ib.ft.)
Tubeless
l 65 SR 15-4 PR
6.85-15-4 UR {U SA )
o:15