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