Volvo PV 544 User manual

Description
Description Type designations
In all correspondence concerning your vehicle with the dealer or with the Volvo
factory and when ordering spare parts, the type designation and chassis or
engine number should always be quoted.
The vehicle type and chassis number are stamped on a
nameplate attached to the right under the hood. The
nameplate also indicates code numbers for color and
upholstery. ,
| This instruction book deals with vehicles having the following :
type designati Volvo Special P544-11141B
Volvo Special de Luxe P 544-11142 B
Volvo Sport de Luxe P 544-11244 B
The Volvo PV 544 is a two-door, five seater car. It has an integral body so that
there is no chassis frame. The front and rear ends together with engine and
transmission are fitted directly into the body.
The body is synthetically enamelled and provided with a rust-preventive primer.
The car is made thief-proof by the ignition switch and coil being connected • with
an armored cable.
There are three types of this car:
Volvo Special, equipped with 60 h.p. engine (B16A), 3-speed transmission and
with a rear axle ratio of 4.56:1.
The engine type designation and part number are
given on the left-hand side of the cylinder block.
The engine number, that is to say, the
manufacturing serial number, is stamped on a tab
above the part number. For identifying the
engine, both the part number and serial number
should be quoted, for example 495387-89237.
Volvo Special de Luxe, equipped with 60 h.p. engine (B 16 A), 3-speed
transmission and with a rear axle ratio of 4.56:1. The rear side windows can be
opened and in addition the car has chromium-plated trim strips.
Volvo Sport de Luxe, equipped with 85 h.p. engine (B16 B), 4-speed trans-
mission and with a rear axle ratio of 4.56:1. The equipment otherwise is the same
as for the Volvo Special with the exception of the wheels which on this model are
provided with chromium-plated trim rings.

1. Float chamber
2. Air cleaner
3. Front carburetor
4. Equalizing tube
5. Oil cleaner
6. Carburetor
7. Container for wind-
shield washer B. Oil
filling tap 9. Charging
control
10. Windshield washer
motor
11. Throttle control
12. Air cleaner
13. Battery U.
Distributor
15. Coil
16. Hoses for heating lyite
17. Fusebox
18. Heater
11
19. Fan motor
20. Fan for heater
21. Oil dipstick
22. Generator
23. Fuel filterwith fuel pump
24. Junction block for elec-
trical leads
25. Chain for radiator blind
26. Steering gear
27. Filling cap for radiator
(Engine type BUB)
Description
The engine ii t toiir^TttlfiK^'&rburMor engine with overhead valves. The
pistons ire made of light-alloy and the upper compreuion ring on each piston
is chromed. The main bearings and connecting rod bearings are replaceable.
The crankshaft is statically and dynamically balanced.
Engine type B 16 A has an output of 66 h.p. and It equipped with Zenith
down-draft carburetor,
Engine type B 16 B has an output of 85 h.p. and ii equipped with twin
SU horizontal carburetors.
Fuel system
The fuel system is fed from the tank to the carburetor by i Fuel pump which ii
driven by a cam on the engine camshaft. There Is a filter in the fuel pump which
traps water and other impurities in the fuel.
Lubricating system
The engine lubrication is taken care of by a gear pump which sucks up oil from the
oil pan on the bottom of the engine and forces it through the oil filter out to the
lubricating points in the engine. Under the oil filter there is a relief valve which
prevent] the oil pressure from reaching excessively high values.
Cooling system
The engine is water-cooled and the cooling system is of the pressure type.
Water is circulated by means of a pump fitted on the fan shaft. A thermostat
with an opening temperature of about 76" C (169' F) prevent! the cooling
water from passing through the radiator before the engine has reached its
normal working temperature.
(
10

Wiring diagram
38
37
Electrical system
. The electrical system is of the six-volt type and is fitted with a voltage control
generator. The starter motor is controlled from the instrument panel by means of
the ignition key. This key also forms the main switch for the rest of the electrical
system. The cables to the headlights, parking lights and internal lighting, however,
are not taken over the ignition switch but can be switched on and off without the
ignition key being in position.
Lighting
The lighting on the vehicle consists of two headlights (full and dipped) together
with two combined flasher and parking lights. At the rear the lighting consists of
two tail lights including flashers as well as combined lamps for the tail lights and
the brake warning lights. Internal lighting consists of a roof light above the rear
view mirror.
See pages 42—44 concerning replacement of bulbs.
Fuses
The electrical system is protected by means of fuses fitted in a fusebox to the left
on the bulkhead under the hood. When replacing a fuse, be sure that you use a
fuse of the right rating. If one of the fuses should blow repeatedly do not fit a more
powerful fuse. Instead, take the vehicle to a workshop for a check of the electrical
system.
26. Fusebox
15. Control for fan
27. Roof lamp
28. Switch in front door
29. Distributor
16. Charging control
lamp
17. Full headlight
warning lamp
1. Left-hand tail light
2. Right-hand tail light
3. Number plate lighting
4. Connector
5. Ventilator fan
6. Lighting switch
7. Brake pedal
8. Flasher impulse unit
9. Lighting control
10. Direction indicator
switch
11. Instrument lighting
12. Ignition switch
13. Cigarette lighter
(order of firing 1-3-4-2)
30. Plug
18. Direction indicator
warning lamp
31. Battery
32. Starter motor
33. Generator
34. Horn
35. Flasher and parking light, left
36. Flasher and parking light, right
37. Headlight, left
19. Oil pressure
warning lamp
20. Fuel gauge
21. Horn ring
22. Ignition coil
23. Windshield wiper
motor
24. Charging relay
25. Windshield washer
motor
38. Headlight, right
14. Controls for windshield
wipers and windshield
washer
12 13

Description
Power transmission
Clutch
The function of the clutch Is to transmit the power from the engine to the
transmission. The clutch Is of the (Ingle dry plate type. The pressure ptate is
operated by means of three release leven operated by means of the clutch pedal.
Transmission
The transmission li uied to regulate the speed ratio between the engine and the rear
axle so that the engine always operates in its most favorable speed range. The
transmission is synchronised on all the forward gears, this means that gear-shifting
can be carried out without double declutching. Since the transmission is fitted with
bevel gears and the gear lever is rubber insulated, excellent sound insulation is
obtained. See page 56 for data.
Propeller shaft
The propeller shaft, which is the connecting link between the transmission and the
rear axle, is divided in two sections. The forward section Is |ournaled at its rear
end in a bearing housing supported by two rubber-bushed bolts,
Rear axle
The driving power of the engine is transmitted Irom the propeller shaft to the rear
wheels through the rear axle. The rear axle is of the hypoid type, i.e. the Input
drive shaft is below the horizontal level of the axle shafts,
Brakes
The vehicle is fitted with two independent brake systems, a footbrake system and
a handbrake system,
The footbrake system is hydraulic and Influences all four wheels. The hydraulic
system consists of a fluid-filled master cylinder which, when the brake pedal is
depressed, transmits the brake pressure through the brake fluid in the lines to the
cylinders at the wheels. The plungers and these cylin ders are then pressed upwards
and these apply the brakes. The handbrake system is of the mechanical type and
only influences tbe rear wheels. Movement of the handbrake lever is transmitted
through a system of pullrods and levers to the leven on the rear wheel brakes,
whereby the rear wheel brakes are applied.
Wheels and tires
The vehicle has pressed steel wheels with lug* for th* attachment of the hub caps.
All wheels are carefully balanced and the tire* are of the tubeleM type. Tyre size:
5.90—15.
Transmission
15

Description
Body
Hood (1
The hood Is fitted with a locking device
which is operated from the driving seat
by means of a lever under the instrument
panel. The hood II unlocked and can be
lifted up after this lever has been pulled
backwards,
The hood ii retained In let tipped up
position by means of \ spring clamp
which engages the hood hinge. As a
further safety measure, this can b«
locked in this position by means of a
screwdriver, see illustration.
Doors and locks(2
The car is provided with locks for
both the doors. The doors are locked
from inside by moving the handle
downwards (position 3). In order to
prevent you from being locked out
of the car, the door handle lifts again
automatically when the door is
closed.
Jf you happen to lose the keys, you car go
to your nearest Volvo dealer who will
supply you with new keys.
In order to prevent the locks from
freezing during the winter, these
should be regularly "lubricated" with
some antl-freeze agent. Several pre-
parations of this type are available
commercially.
Remember to apply it in good time , and
to apply this ''lubricant'
1
regularly to the locks
during the winter.
Position 1 Open
Position 1 Closed
Position 3 Locked
If the lock has frozen up in extremely
|cold weather be careful that you do not
break the key. A good plan is to warm up
the key and then insert it quickly into the
lock whereby the ice there melts.
Adjusting the front seats
^k The front seats can be adjusted both
forwards and backwards by moving the
small handle an the Inner adjuster rail to
one side. Sit in the seat with your leet
on the floor and move the seat to the
most comfortable position. After
adjusting make sure ihat the catch on
the handle engages properly with the
hole in the adjuster rail.
The angle of the front seat backrests can
be adjusted by removing or adding
further shimi under the backrest set ting
screws,.
Luggage compartment
The luggage compartment is locked
with the same key as used (or the door.
The compartment is opened by turn-
Ing the handle anti-clockwise. The lid
' Is lifted up as far as it will go and then
lowered slightly. The lid is then held
in this position by a catch built Into
the left-hand hinge. When the lid
ij to be closed again, it should first
be lifted up so that the catch is re
leased and then lowered,
^- The spare wheel is attached by a bolt
^P with washer and a wing nut. When
the wheel is to be used, unscrew the
wing nut after which the bolt should
be lifted upwards and moved out
wards as shown in fig. 3.
Always be careful to tighten the spare
wheel securely and to pack in the toolbag
and jack properly as otherwise irritating
rattles can arise.
^^^

When overnighting in the car. always be
sure to have one of the ventilation
windows lully or partly open so thit
there is * good supply of oxygen.
4. Place the rear seat backrest on the
support bars between the front and rear
teats- The backrests of the front seats
should then be placed In the position of
the rear seat backrest with the back
sides facing forwards and the brackets
upwards.
3. Lift the seat cushion at the back edge
and move it backwards. Insert the
countersunk parts of the support bars
under the seat cushion and place the
bent ends in the front seat slide rails.
2. Remove the rear seat backrest by
grasping the lower part and pulling it
outwards until the catch at the top
releases.
1. Undo the leather straps of the pivot
studs and remove the studs. The
backrests can be taken off. Insure chat
the seau are slid forward as far as
possible.
Arranging sleeping places
There is > special bedding set (or the
Volvo PV 544 which can be ordered
from four Volvo dealer (part number
79772).
The bedding let consist! of two
support bars ind four plvoc studs
with leather strap for locking. The
pivot studs are Intended to replace
, permanently the pi/ot boles with
which the front seat backrests are
equipped as standard. The old pivot
. \ bolts are removed and the new ones
with leather straps fitted ai shown
in fig. 1.
Bedding equipment
Description
Safety belts
Extra equipment on this vehicle in-
cludes safety belts for both the front
seats. Utilize this simple but effective
safety device. The practical design of the
belt type used makes it so simple to
engage and disengage the belts so that
you get used to fitting the belts as an
automatic procedure before starting the
engine.
The length of the belt can be adjusted on
that part of the belt which Is attached
to the floor. Make sure that the belt has
che right length for you.
When the belt catch is taken from the
button on which it is hung on the door
pillar, press in the handle in the mid dle.
The belt then passes round the waist and
over the chest and should be locked in
the fitting between the front seats,
To disengage the belt press the handle
in and lift it straight up. The belt should
then be hung up on the button on the
door pillar.
Make a habit of always hanging up the
belt when It Is not being used. If it is
allowed to lie on the floor it will soon
become dirty and frayed and will hinder
getting in and out of the vehicle. Check
now and then that the bolts that hold the
belt are properly tightened. If the belt
has become dirty it is best cleaned with
water and a synthetic washing
compound. Gaso line and similar must
not be used since this can cause stains.

Description
18 22. 23 14 25
1 2
Instruments and
operating
controls
Before you start
the engine, sit
behind the wheel
and carefully
check through all
the instrument!
and controls you
need for driving.
The location of
these is shown in
the illustration.
The Instrument!
and operating
controls are
described in more
detail below with
reference to the numbers under the illustration.
Immediately after starting and now and then while driving you should have a quick
look at the instruments and check that they are showing normal reading!
according to the values shown below.
13. Ignition switch with starter U.
Windshield wiper control
15. Radiator blind control
16. Ashtray
17. Radio panel 16. Heater
controls
19. Foot dipper switch
20. Clutch pedal
21. Brake pedal
22. Accelerator pedal
23. Horn ring
2i. Steering wheel
25. Gearshift lever
26. Cigarette lighter (extra)
20
1. Temperature gauge
2. Charging control lamp
3. Trip meter
4. Speedometer
5. Indicator lamp for full
headlights
6. Indicator lamp for direc-
tion indicators
7. Mileometer
8. Oil pressure warning lamp
9. Fuel gauge
10. Direction Indicator .
control
11. Lighting switch
12. Choke control

Description
1 Temperature gauge
The temperature gauge shows the temperature of the cooling system and thus
indicates the working temperature of the engine. The indicator on this gauge
should remain within the green markings. If it should show an excessively high
temperature for a longer time without the radiator blind being pulled up. this cm
depend upon the fact that the channels in the cooling system are blocked and
circulation is thus being hindered. In such cases the cooling system should be
cleaned (see page 40).
Charging control lamp
Thii lamp lights up when the battery Is discharging, this being normal at idling
speed. If you accelerate a little, this lamp should go out. Should the lamp light up
while you are driving, this generally means that there is some fault in the electrical
system or that the fan belt is not sufficiently tensioned and is slipping on the pulley
thereby causing poor charging.
Trip meter
This trip meter, which is graduated in tenths of a mile, can be used to measure even
short distances. This meter can be reset to zero by means of a control under the
instrument panel to the left of the steering column.
Speedometer
The speedometer has a horizontal field, the right hand point showing the speed at
which you are travelling. Since the length of the red strip is proportional to the
speed, this is in itself a safety factor — the more r*d you can see, the more
dangerous your speed. >
Mileometer
The miteometer shows the total distance covered in miles. At a reading of 99 999
miles the mechanism returns to zero and starts to go round again.
Oil pressure warning lamp
When you switch on the ignition this lamp should light up and then go ojt again
when the engine has been started. Should the lamp remain on while you are
driving, the engine should be stopped immediately and the cause for this
determined. In most cases it means that the oil I evil is too low.
22
Dimmed headlights
scrlpllon
Parking lights
Headlights
The headlights are controlled by meins of a push pull switch on the instrument
1
panel and by a foot dimmer switch (21) to the left on the floor. The headlights
are switched from full on to dipped and vice versa by depressing the dimmer
switch with your foot- Instrument lighting
The instrument lighting is regulated by turning the
lighting switch button.
The more this button is turned clockwise, the stronger
the instrument lighting
wilt be.
Internal lighting
1. The lamp lights when the left-hand door ii opened. 2. The light Is off all the time, i.
The light is on all the time.
Full headlight*
Headlight flasher
If the direction indicator lever is lifted directly
towards the steering wheel, a special flasher
apparatus starts functioning.

2. If the engine is cold pull out the choke. If the en gine is warm,
do not use the choke bur. depress the accelerator pedal instead.
After the engine ha? started regulate the idling speed by meam of
the choke. Never use the choke more thin a minute or so and when the
engine il thoroughly warmed up, never use the choke at all.
Warming up the engine
Experience has shown that engines in vehicles used with frequent stopping and
starting are subject to abnormally rapid wear. The reason for this is that the engine
does not maintain its normal working temperature. The result of this is that
corrosive acids formed by the combustion residues have an opportunity to act on
the cylinders for a considerably long time. When the engine is cold, it should thus
be taken up to it! normal working temperature as quickly as possible.
Stalling (B1«A)
When the humidity of the air is high and air temperatures are between —5' C and
10' C (23' F and 50° F), ice can form in the carburetor idling system. The result of
this can be that the engine stalls when the accelerator pedal is released. This
tendency to stall usually occurs about 10 minutes after a cold engine has been
suited and can be counteracted by pulling out the choke knob about 'V so that the
rapid idling device comes into function.
After starting a cold engine do not rice it immediately but run it at mo derate
speed and do not subject it to heavy loading until engine tempera ture has
reached its normal level.
Gear positions on the 4-ipeed transmission
(M 30) (M 40)
Driving
3. Depress the clutch
pedal full
y
.
Gear position! on the 3-speed
transmission (M 30)
If the engine is to function in the best possible way it is important to insure that the
point at which gear-shifting is carried out ii suited to the speed in such a way that
the engine speed in maintained within certain limits, neither too high nor too low. If
the engine speed is excessively low. there is poor pulling power and unfavorable
loading on the engine and the power tram- mission. If the engine speed is too high,
on the other hand, this means that fuel consumption goes up, engine pulling power
decreases and acceleration will be no better.
As a rule the most economical running is obtained if gear-shifting is carried out
roughly in the middle of the speed ranges shown. If more rapid acceleration is
desired, however, the range for each speed shown can be taken to its upper
limiting value,
Never let the engine labor in high speed but change down in good cirtie. If you
require greater pulling power, however, and the engfne is running easily with light
acceleration, this naturally does not prevent you going down rather lower than
shown in the table (even for a longer period of time).
H*com mended speeds, m.p.h. for the various gear ratios
Vehicle type First
2nd speed
3
rd
s
p
eed
4th
Special I
Special de Luxe j
0-20 10-45
20-
-
Sport de Luxe 0-25
10-45
20-65
25-
Starting the engine
Gear-shifting
-
1. Make sure that the
gearshift lever is in the
neutral position.
4. Turn the ignition key
. to the starting position.
Release the key is soon 11
. the engine starts. il
29

Starting in a garage
If you start your vehicle in a garage,
always open the garage doors before you
start the engine. The exhaust gases from
the engine contain the poisonous gas
carbon monoxide which is particularly
dangerous since it is both invisible and
odorless. Air containing only 0.2 %
carbon mo noxide can be fatal if breathed
in for half-an-hour.
Braking
You should attempt to use the brakes as little as possible. Use the engine as a
brake instead by releasing the accelerator pedal in good time. Violent braking is
only justified in dangerous situations and even in such situations the wheels must
not be locked. Remember that the best braking effect is obtained if the wheels
continue to rotate slowly.
Steady acceleration and gentle braking are characeristic for a good driver and also
result in the most economic running. Apply brakes before going into a curve and
use your transmission on downhill gradients so that you save unnecessary wear
on both the brakes and the tires.
Binding brakes
When air humidity is high it can happen that moisture comes in into the brake
linings and this can cause the brakes to bind when applied. The best way to eliminate
this is to carry out a long, gentle braking whereby the moisture will evaporate
through the heat developed.
Towing
If the vehicle is to be towed, the
tow-line should not be attached
directly to the bumpers but should
be taken round the bumper
supports. While the vehicle is
being towed, the tow-line should
be kept evenly stretched since
violent jerks can damage the
bumpers.
30
Servicing
Before the vehicle was delivered from the factory it was subjected to a very
thorough inspection. Your dealer, in his turn, carried out a further delivery
inspection in accordance with the specifications of the Volvo factory. In addition to
this there are the two cost-free service inspections after 1 000 km (600 miles) and
2500 km (1 500 miles). After these inspections the servicing of the vehicle should
follow the routine in the service book which is based on a rubber stamp system
with all-round lubrication after every 1 250 km (750 miles) and service inspections
after every 5 000 km (3 000 miles) running. The simplest (and in the long run most
profitable) way to give the vehicle the servicing it requires is to have all the
servicing done by a Volvo workshop. You will then have all the work shown in the
service book carried out in accordance with fixed prices and the workshop stamp in
the service book will show how the vehicle is being serviced — this is also
extremely important as far as second-hand value is concerned.
If you prefer to carry out these simpler servicing procedures yourself or if you are
sometimes obliged to have these done by a workshop outside the Volvo
organization, this chapter contains some advice about when and how these
servicing procedures should be carried out.
I
For the sake of convenience, the servicing procedures have been summarised in a
maintenance scheme on the following page.
31

Lubrication
Body lubrication
In order to avoid squeaking from doors and locks, the body should be lubri cated
after every 10 000 km (6 000 miles) running.
Lubrication is the most important procedure in servicing a vehicle. The cost of
lubricant is insignificant compared with the cost of repairs caused by neglected
lubrication.
During the winter the locks should also be lubricated with some antifreeze
preparation which prevents the locks from freezing up.
All metallic surfaces, no matter how finely ground they are, consist of extrem ely
small uneven points. If two ground surfaces are pressed together and rubbed, the
uneven surfaces will engage in each other and result in friction and wear. If these
two surfaces are separated by a thin coating of oil, however, the friction disappears
and with it the wear. This is exactly what happens when bearings, pistons and
gears in the vehicle are lubricated. The oil or grease actually prevents the metallic
surfaces from coming in contact with one another.
This means that from a purely theoretical viewpoint the metallic surfaces in a
motor vehicle are never subject to wear and it should be sufficient to lubricate
them once. Unfortunately this is not so in practice. The uneven surfaces are worn
down more and more and the minute particles released contaminate the oil which
becomes also partially carbonized. It is thus im possible to avoid wear completely but
wear can be decreased and prevented to a very large extent by regular and
careful lubrication.
Chassis lubrication
Make a habit of insuring that the vehicle is given all-round lubrication accord ing to
the instructions in the lubricating chart at the end of this book after a certain
number of miles. You should preferably follow the recommendations in the service
book concerning all-round lubrication after every 1 250 km (750 miles) since this
mileage is based on research carried out by the Volvo factory. Use only top-quality
lubricants of well-known manufacture.
2 7 8 9 10 11
Lubricating point
Lubricant
No.
Light engine oil
1. Hood hinges
2. Door hinges
3. Hood lock
4. Windshield wiper arm attachment
5. Ventilation window lock
6. Door lock plungers
7. Front seat sliderails
8. Locking mechanism, etc. (accessible after the
door upholstery panels have been removed).
Lubrication need only be carried out about
every 20 000 km (12 500) miles or once a year
Keyholes
Luggage compartment hinges
Luggage compartment lock
§••• When all-round lubrication is
ordered at a service station, the
servicing procedures detailed for 1
250 km (750 miles) intervals in the
lubricating chart are followed.
Apart from this the oil level in the
engine is checked as well as the
cooling water level and the
electrolyte level in the battery.
Paraffin
Light engine oil
Before lubrication is carried out,
all the lubricating points must be
carefully cleaned to prevent dust
and other impurities from getting
into the bearings. 9
Pulverised graphite
Light engine oil
10
11
35