Volvo 164 User manual

owner's manual
VOLVO 164

Operating Instructions
Description
Servicing
Reproduction permitted if source quoted

FOREWORD
This owner's manual deals with all the va-
riations of the Volvo 164 with model year
designation W.
Before you start driving your new Volvo
please read through this manual carefully.
I t contains all the information you need to
be able to drive and service your vehicle
i n the best possible way. By following the
i nstructions given in this manual you will
find that your Volvo will come up to all the
expectations concerning economical ope-
2
ration and excellent performance that you
have every right to expect of a top-quality
vehicle.
This is not intended to be a comprehen-
sive technical manual and does not claim
to make the reader a perfect car mecha-
nic. It will, however, show you how to look
after your vehicle so that trouble in the fu-
ture can be avoided. The better you know
your Volvo, the better service it can give
you. Even for an experienced motorist it
can contain some valuable information.
For a more detailed mechanical descrip-
tion and repair procedures, we refer you
to the special Service Manual for the car
which can be purchased from the dealer.

CONTENTS
FOREWORD
I NTRODUCTION
Volvo Service Organization

4
Warranty and Service Booklet

4
Service Inspections

4
Type Designations

5
OPERATING INSTRUCTIONS
I nstruments and controls

6
I nterior and body

14
Starting and driving

20
Running-in

20
Starting the engine

21
Gear-changing

22
Towing

25
Braking

25
TECHNICAL DESCRIPTION
Engine compartment

26
Engine

28
Power transmission

30
Front end and steering

33
Heating system

33
Electrical system

34
Brakes

38
SERVICING
General

39
Maintenance scheme

40
Lubrication

42
Oil changes

43
Engine

46
Electrical system

51
Power transmission

56
Brakes

56
Front end

56
Wheels and tyres

57
Body

59
Long-distance trip

61
Cold weather

61
Lubricating chart

68
FAULT TRACING
When the engine stalls

63
SPECIFICATIONS
Measurements and weights

64
Engine

64
Electrical system

66
Power transmission

66
Front wheel alignment

67
Wheels and tyres

67
Capacities

67
Tools

67
I NDEX

70
WHEN FILLING THE TANK

72
3

I
NTRODUCTION
Volvo Service Organization
To get the most out of the invested capital
represented by a car, it must be looked
after
and serviced regularly. Volvo has
gone to a great deal of trouble in the de-
sign and selection of material to ensure
that the car in question only requires a mi-
nimum of servicing. We rely, however, on
your co-operating with regard to the future
maintenance of your vehicle. To help you
with this, Volvo has built up a world-wide
service organization. All
Volvo dealers
have specially trained personnel and re-
ceive a continuous supply of technical in-
formation from the Volvo Service Organi-
zation
concerning repairs and adjust-
ments. They have also special tools, de-
signed at the Volvo factory. Moreover, all
Volvo dealers have a comprehensive stock
of parts which is a guarantee that the part
you get is genuine Volvo. That is why our
4
dealers are in the best possible position to
give your vehicle first-class service con-
cerning both maintenance operations and
repairs. You should also refer to your
dealer for any information about your Vol-
vo that is not included in this manual.
Volvo not only has a workshop within easy
reach in your own country, it also has a
widely distributed service network in other
countries.
Warranty and Service Booklet
A warranty and service booklet accom-
panies each vehicle when it is delivered.
This booklet contains a coupon entitling
you to a service inspection after 1 500
miles (2 500 km). If possible, let the dealer
who supplied the vehicle carry out this
service inspection.
Any of our dealers,
however, can do this if required.
I f
our six-month guarantee is to apply, we
make one absolute condition and that is
that the above-mentioned inspection is car-
ried out at roughly the mileage shown and
that the vehicle has been looked after in
accordance with the instructions given in
this book.
Service Inspections
After the 1 500 miles (2 500 km) service in-
spection has been carried out, you should
come to some arrangement with your
dealer concerning continued, regular serv-
i ce inspections in accordance with the
suggestions
made in our Service Book.
Thorough and regular servicing is of vital
i mportance for the performance and length
of life of the vehicle.
Always use genuine Volvo parts.

I NTRODUCTION
Type designations
I
n
all
correspondence concerning your
vehicle with the dealer and when order-
i ng parts, the type designation, chassis
and engine number should always be
quoted.
1. Vehicle type designation, code number
for colour and upholstery: on bulkhead.
2. Body number.
3. Type and model year designation (W)
as well as chassis number: stamped
on right door pillar and also on the
floor plate behind the petrol tank.
4. Type designation, serial number and
part number of engine: stamped on en-
gine left-hand side. The final figures of
the part number are stamped on a plate.
The serial number then follows with all
i ts figures stamped on the block.
5. Type designation, serial number and
part number of gearbox: underneath
gearbox.
6. Final drive reduction ratio, part number
and serial number: on a plate on left-
hand side of final drive.
5

OPERATING INSTRUCTIONS

I NSTRUMENTS AND CONTROLS
1. Windscreen wiper and washer switch
2. Choke control (not B30E)
3. Light switch
4. Instrument panel
5. Turn indicator switch, dimmer and
headlight flasher
6. Horn ring
7. Ignition switch and steering wheel lock
8. Fan switch
9. Cigarette lighter
10. Heater and ventilation controls
11. Ashtray
12.
Foldable panel for fusebox (fuse
change, see page 55)
13. Place for radio
14.
Grab handle
15. Parking brake
16. Fresh-air intake vents
17.
Bonnet release
18. Clutch pedal
19. Brake pedal
20. Accelerator pedal
21. Switch for foglights
22. Switch for elec. heated rear window
23. Gear lever
24. Clock
25.
Switch for emergency warning flashers
26. Glove locker
27.
Fresh-air intake vents
OPERATING INSTRUCTIONS
The instrument and controls are described
i n
more detail in the following pages with
a reference to the numbers in the picture
opposite. Note that variations may occur
between different markets.
1 Windscreen wiper and
washer switch
The windscreen wipers are operated elec-
trically and can be adjusted to two speeds.
Normal speed is attained by pulling the
switch out to the first position. This speed
i s recommended for normal driving in rainy
weather or snow. When the switch is pull-
ed out fully, the wipers operate at full
speed. Full speed is only recommended
when driving in heavy rain or when driving
at high speed in the rain.
When the switch is pressed fully in, the
wiper blades stop in their parking position.
The windscreen washers are operated by
turning the switch clockwise. The switch
automatically returns to its initial position
on being released. The fluid container for
the washers is located in the engine com-
partment and holds about 1'/2 litres (2
3
/4
I
mp.pints = 3'/2 US pints).
2 Choke control
The choke control is used when the en-
gine is started from cold. When the control
i
s pulled out about 10-15 mm ('/2"), the
i dling speed is increased. Pulling the con-
trol out further enriches the fuel-air mix-
ture. The warning lamp (4J) on the in-
strument panel lights when the choke is
pulled out.
3 Lighting switch
The headlights are operated by means of
a push-pull type switch on the dashboard
as well as a lever (5) on the steering
column.
All the lights are extinguished when the
li ghting switch is pushed fully in. Pulling it
out to the half-way position, switches on
the parking lights, and when it is fully out,
the full or dipped headlights are switched
on, depending on the position of the lever
(5).
Since the lighting system is not connected
across the ignition switch, the lights will
function irrespective of whether the igni-
tion key is in position or not.
7

OPERATING INSTRUCTIONS
A Panel light switch
Turning the knob clockwise or anticlock-
wise increases or dims the lighting on the
i nstrument panel.
B Fuel gauge
The fuel gauge is graduated "full", "half",
"reserve" and "empty". The red field be-
tween "reserve" and "empty" is a remind-
er that the tank should be filled. When the
gauge pointer is on "reserve", there are
approx. 8 litres (2 Imp. galls = 2'/2 US
galls) in the tank. The gauge pointer re-
gisters
when the ignition is switched on.
E Warning light, charging
This lights red when the battery is dis-
charging. Should it light during driving,
either there is some fault in the electrical
system or the fan belt is not sufficiently
tensioned and is thus slipping on the al-
ternator pulley, causing poor charging.
D Coolant temperature
gauge
The temperature gauge shows the tem-
perature of the coolant and thus indicates
the working temperature of the engine. The
gauge pointer should normally remain
within the green sector.
During town driving and idling when the
weather is particularly warm, the tempe-
rature gauge pointer may enter the field
marked with oblique red dash lines.
Should the pointer repeatedly point to the
completely red field, the coolant and fan
belt tension should be checked.
4 Instrument panel
Panel light switch
Fuel gauge
Speedometer
Coolant temperature gauge
Warning light, charging
Warning lamp, overdrive
Warning lamp, turn indicators
Warning light, parking brake and
brake circuits
Warning lamp, fullbeam headlights
Warning lamp, choke
Warning lamp, oil pressure
Mileometer
Speed warning indicator
Trip meter
Trip meter reset knob
8

OPERATING INSTRUCTIONS
F Warning lamp, overdrive
The lamp gives a steady green light when
the overdrive is engaged. Concerning en-
gaging and disengaging overdrive, see
page 22.
H Parking brake warning light
(functions also as warning
light for both service
brake circuits)
This lights red when the parking brake is
applied and the ignition is on.
The light also functions as a warning light
should a failure arise in one of the brake
circuits. If the light goes on during driv-
i ng, the car should be driven without delay
to a workshop for a check on the brake
system. Observe due care when driving
under such conditions.
K Oil pressure warning light
This lights red when the engine oil pres-
sure is too low. When the ignition is
switched on, the light should go on and
then go out again when the engine starts.
Never start driving until the light goes out.
I f the light goes on during driving, stop the
engine and find out the reason for this. In
most cases it means that the oil level is
too low. After hard driving it may happen
that the warning light comes on when the
engine is idling. This is normal providing
it goes out again when engine speed is
i ncreased.
J Warning lamp, choke
The lamp gives a steady amber light when
the choke control is pulled out. Drive as
short a distance as possible with the
choke out.
Vehicles with the B 30 E engine do not
have this warning lamp.
L Mileometer
The mileometer shows the total distance
covered in miles. After 999999 miles it re-
turns to zero and starts to go round again.
M Speed warning indicator
The speed warning indicator
i s mounted on the speedo-
meter and consists of a manually adjust-
able sliding arrow. Its purpose is to remind
the driver of the particular maximum per-
missible speed in connection with speed
limit regulations.
N Trip meter
The trip meter measures distances of up
to
maximum 999 miles. The window fur-
thest to the right shows tenths of a mile
and is therefore useful for measuring short
distances.
0 Trip meter reset knob
The trip meter is set to zero by pushing
i n the knob.
9

OPERATING INSTRUCTIONS
5 Turn indicator switch lever, dimmer
and headlight flasher
The switch lever on the left-hand side of
the steering column just below the steer-
i ng wheel controls the turn indicators, dip-
ped headlights and headlight flasher. The
switch has a so-called
"stop point" for
changing lanes. In other words, when
changing lanes or passing, move the
switch up or down to the stop point and
hold it there with the hand. The res-
pective indicator should start blinking.
When the lever is released, if automatical-
l y returns to neutral. When making a turn,
move the lever past the stop point as
far as it can go. It will return to neutral
when the steering wheel straightens out
the car again. To switch from main beam
to dipped beam and vice versa, move the
10
l
ever towards the steering wheel and then
release. Here the lighting switch (3) should
be pulled fully out.
The lever is also used for flashing with
mainbeams when the headlights are not
switched on. The headlight flasher is
switched on by moving the lever towards
the steering wheel and it remains switch-
ed on until the lever is released.
With the key in the Intermediate position,
the steering wheel is unlocked and cer-
tain electrical
components are switched
on.
To start the engine, turn the key to the
Starting position and this engages the
starter motor. As soon as the engine starts,
release the key which automatically re-
turns to the Driving position.
If the car is parked in such a way as to
make it difficult to unlock the steering
wheel, unlocking can be made easier by
slightly turning the steering wheel one way
and then the other.
7 Combined ignition switch and
steering wheel lock
The switch has four positions: (0) Lock-
i ng position, (1) Intermediate position, (II)
Driving position and (III) Starting position.
The key can be taken out of the lock only
i n the Locking position. Removing the key
automatically locks the steering wheel.

OPERATING INSTRUCTIONS
8 Fan switch
The fan is operated by means of a push-
pull switch which can be set at two dif-
ferent positions. Pushing the switch fully
i n stops the fan, pulling it out to the first
position operates the fan at full speed and
when pulled fully out, the fan operates at
half speed.
The overpressure in the air intake is rela-
tively small. Therefore, at speeds below 80
kmph (50 mph), the fan should be allowed
to operate at full speed if maximum air
capacity is desired. On the other hand,
however, the fan should not be used if
cooling air is required on a hot summer's
day. Instead, open both the fresh-air con-
trols (16, 27), the defroster control "DEFR"
and the ventilation control "FLOOR".
9 Cigarette lighter
To use the cigarette lighter, push it in. The
lighter releases automatically when it at-
tains sufficient heat.
10 Heater/ventilation
controls
The control on the left, TEMP, regulates
the temperature of the air in the car. The
middle control, DEER, regulates the air
flow to the windscreen. And the control to
the right, FLOOR, regulates the air flow to
the front seat and rear seat floor.
The temperature, also the air flow, is in-
creased by moving the controls downwards
whereby a red strip marked down the
middle of the control in question indicates
the size of the opening. Note that when
altering the temperature control, there will
be a slight delay before the desired tem-
perature is reached.
To avoid or remove mist on the windows,
set the fan and defroster controls at max-
i
mum output. However, the fresh-air con-
trols (16, 27) should be closed. Try to
avoid water on the floor and under the
mats as this increases the humidity and
thereby misting, particularly during the
wintertime.
15 Parking brake
The parking brake lever is on the outside
of the driving seat and operates on the
rear wheels only. When the parking brake
i s applied and the ignition is on, a red
warning light (4, H) shows on the instru-
ment panel.
Remember that the footbrake warning sy-
stem is also connected to this light. Should
the light show when the parking brake is
not on, this may be due to a failure in one
of the brake circuits. If this is the case,
drive immediately (but with due care) to a
workshop for a check.
16, 27 Fresh-air controls
Pushing the control forwards opens
fresh-air intake vents on the driver's or
passenger's side. Note that the fan should
not be operating if cool air is desired
through these vents.
11

OPERATING INSTRUCTIONS
17 Bonnet release handle
The bonnet lock is released by pulling out
the handle situated to the extreme left un-
der the dashboard. This will release the
bonnet which is still retained by the sa-
fety catch.
The bonnet is opened by inserting the fin-
gers under the front edge and pressing up
the catch as shown in the picture. Check
that the bonnet locks properly when clos-
ed.
The location of the bonnet when closed
can be adjusted if necessary by screwing
i
n or out the rubber plugs underneath the
bonnet at the front end and on the mud-
guards below the windscreen.
21
Switch for foglights
The foglights are switched on by pushing
i
n the switch, providing that the parking
or dipped headlights are on.
The foglights are switched off by pushing
i n the switch again.
Because of regulations on certain markets,
the foglights are connected across the
parking and fullbeam headlight or only
across the parking lights.
12

OPERATING INSTRUCTIONS
22 Switch for electrically
heated rear window
I n order to obtain a clear view through the
rear window during cold and damp wea-
ther, your Volvo is fitted with an electrical-
l y heated rear window.
Heating is by means of wires on the inside
of the rear window.
Avoid placing anything on the rear shelf
which could damage these wires.
The heating for the rear window is switch-
ed on by pushing in the switch. This lights
a warning lamp in the switch.
Pushing in the switch again switches off
the heating.
Switch off the heating when the rear win-
dow is free from mist and ice in order not
to overload the battery unduly.
24 Clock
The clock is operated electrically. To reset
i t, push in the re-setting knob and turn the
hands.
The clock is not fitted on certain variants.
25 Switch for emergency
warning flashers
All the four warning lights start flashing
simultaneously when the switch is pushed
i n.
A warning lamp mounted in the switch
blinks in unison. The warning lights are
connected across the ignition and these
operate irrespective of whether the ignition
i
s switched on or not.
Pushing in the switch again will switch off
the warning flashers.
These warning lights should be used only
when you have to stop the car where is
possible danger to other traffic. Note that
regulations governing the use of these
lights
may vary in different countries.
1 3

OPERATING INSTRUCTIONS
I NTERIOR AND BODY
Front seats
Lumbar support
The front seats are provided with an ad-
j ustable lumbar support. This is operated
by means of the knob on the right side of
the backrest. To tension the lumbar sup-
port, and thus exert more pressure against
the small of the back, turn the knob clock-
wise, "FIRM", and to relieve the pressure
against the small of the back, turn the
knob anti-clockwise, "SOFT".
Bench-type front seats have the knob
mounted on each side of the seat.
14
Backrest adjustment
The front seat backrest is adjusted with
the lever on the outside of the backrest
(see picture). Lift up the lever, adjust to
the desired angle, and lock the backrest
there by pushing down the lever.
The backrest can be folded backwards to
a comfortable rest or repose angle.
Length and height adjustment
driver's seat
The driver's seat can be adjusted for-
wards-backwards by lifting catch A up-
wards. Exert leverage with your feet on the
floor and slide the seat to the desired po-
sition.
Adjustment is made vertically by lifting
catch B upwards and then setting the seat
to one of the four height positions. If ne-
cessary, the seat can then be adjusted
l ongitudinally.

OPERATING INSTRUCTIONS
Length and height adjustment
front passenger's seat
The front passenger's seat can be adjust-
ed forward-backwards by pressing down
l atch C on the outside of the seat. Verti-
cally the seat is adjustable to three dif-
ferent positions. Remove the seat cushion
to get to the bolts in the seating bracket.
Remove the two bolts holding the seating
frame to the seating brackets. Place the
frame in the desired position and refit the
bolts in the suitable holes.
I n connection with this adjustment, it may
be desirable or necessary to adjust the
i nclination angle of the entire seat. This is
done with the eyelet bolt at the front under
the seat frame. Remove the bolt which
goes through the eyelet screw and fold the
seat backwards. Then release the locknut
i n the floor of the car and adjust the eye-
l et screw to the desired position. Re-lock
securely the eyelet screw with the locknut.
Head restraints
The front seats are provided with adjust-
able head restraints. If the head restraint
i s to fulfil its function properly, it is im-
portant that it is correctly adjusted, that is,
i t supports against the head and not only
against the neck. After adjusting lock the
head restraints by turning the plastic nuts
clockwise.
1 5

OPERATING INSTRUCTIONS
Safety belts
Always use the safety belt for all types of
driving. Remember that it is possible even
i n slow city traffic to incur serious injury
from sudden, unexpected stopping.
Automatically retracting inertia safety
belts
The Volvo 164 is equipped with automati-
cally retracting inertia safety belts.
To fit the belt, pull out the webbing slowly.
I f the webbing is pulled out too quickly,
the emergency-locking retractor reacts and
l ocks the belt. Normally the safety belt re-
tractor is "unlocked". Locking takes place
when the webbing is pulled out rapidly or
when the car is braked suddenly.
16
Should the webbing lock when being pul-
l ed out, slacken off slightly and then con-
tinue pulling out more slowly. Place one
strap round the waist and the other across
the shoulder - chest and secure the belt
by pushing the buckle tongue into the
l ocking slot in the lock between the seats.
An audible clicking sound is a sign that
the belt is locked.
Make sure that the webbing fits comfort-
ably across the body and is not twisted.
The belt is released by pulling up the lever
i n the locking device. Make a habit of lett-
i ng the roller roll up the webbing on re-
moving the belt.
Safety belts in rear seat
As standard, the car has attachments for
safety belts in the rear seat. The belts are
fastened by pushing the buckle tongue on
the strap into the lock in the other. The
belts are released by pulling back the
spring loaded sleeve and separating the
straps.
When not being used, the side belts should
be attached to the hooks on the rear win-
dow, see picture next page.

OPERATING INSTRUCTIONS
I f the belt requires lengthening, first
slacken the upper section of the belt and
take hold of the adjusting piece with one
hand and pull out the lap strap to the
desired length. Tidy up belt slackness by
pulling in the upper part of the double
section.
To shorten the belt, pull in the upper sec-
tion of the lap belt.
Remember
Do not let the belt lie on the floor other-
wise it will get entangled and dirty as well
as hinder getting in and out of the ve-
hicle.
Now and again check that the bolts an-
choring the belts are properly tightened
and that the belt is otherwise in good
condition. Water mixed with some syn-
thetic washing agent can be used for
cleaning the belt. If the belt is exposed to
violent stretching, for example, in connec-
tion with a collision, it should be replaced
even though it may appear to be undamag-
ed. Also replace the belt if well worn or
damaged.
Never modify or repair the belt on your
own, but have this done by a Volvo work-
shop.
17

OPERATING INSTRUCTIONS
The door locks have been designed with
a view to providing maximum possible
protection against freezing during the win-
tertime. As an extra measure, however,
you should lubricate the locks regularly
during very cold weather with a suitable
anti-freeze agent. If the lock is already
frozen, be careful not to break the key in
the lock. Instead, heat the key and imme-
diately place it in the lock. This should
unfreeze the lock. Should you lose the car
keys, contact your nearest Volvo dealer
for new ones and quote the code number
of the keys which have been lost.
Doors and locks
The car is fitted with a lock and keyhole
on each of the front doors.
All the doors can be locked on the inside
by pushing down the lock button on the
window ledge. On the front doors this lock
button lifts automatically when the door is
opened from the inside. On the rear doors,
however, the lock button must first be
pulled up before the doors can be opened
from the inside. This is an advantage if
children are in the back seat.
The front doors can be locked from the
outside by pushing the lock button on the
window ledge down and shutting the door
while keeping the outside handle pulled
out as shown in the picture. To lock the
rear doors it is not necessary to keep the
door handle pulled out.
Do not leave the keys in the car.
Rearview mirror
The inside rearview mirror can be switch-
ed to anti-dazzle by pushing back the
knob.
18

OPERATING INSTRUCTIONS
I nterior lighting
1.
The light comes on when either front
door is opened.
2. The light is always off.
3. The light is always on.
Luggage compartment
The luggage compartment is locked with
the same key as that used for the doors.
The lid is opened by turning the handle
clockwise and lifting the lid up at the same
ti me. Note that the key must be removed
from the lock in order to turn lock knob.
The lid is balanced and will remain sta-
tionary in its opened position. The spare
wheel is securely held in position to the
right in the compartment. The jack and
tool kit are fastened to the spare wheel.
Under the floor of the compartment to the
l
eft there is sufficient space for an extra
spare wheel, for stowing tools or a re-
serve fuel can.
Sun-roof
Certain models are fitted with a sun-roof.
The sun-roof is opened and closed by a
winding handle.
When not in use, the
handle is folded in the recess in the roof
between both the sun visors.
To close the sun-roof, wind it forwards
fully, then wind back the handle a little and
fold it into the recess in the roof.
19