instruction book VOLVO 164
Operating Instructions Description Servicing Reprinting permitted if source quoted
FOREWORD Before you start driving your new Volvo please read through this instruction book carefully. It contains all the information you need to be able to drive and service your vehicle in the best possible way. By following the instructions given in this book, you will find that your Volvo will come up to all the expectations concern2 i ng economical operation and excellent performance that you have every right to expect of a top-quality vehicle.
CONTENTS SERVICING INTRODUCTION Volvo Service Organization Warranty and Service Booklet Type Designations 4 4 5 OPERATING INSTRUCTIONS Instruments and controis Interior and body Starting and driving Running-in Starting the engine Gear-changing Towing Braking 6 14 19 19 20 21 23 23 General Maintenance scheme Lubrication Oil changes Engine Electrical system Power transmission Brakes Front end Wheels and tyres Body Servicing before a long-distance trip Procedure in cold weather Lubricating chart FAUL T
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 design and selection of material to ensure that the car in question only requires a minimum of servicing. We rely, however, on your co-operation with regard to the future maintenance of your vehicle. To help you with this, Volvo has built up a world-wide service organization.
I NTRODUCTION Type designations I n all correspondence concerning your vehicle with the dealer and when ordering spare parts, the type designations, chassis and engine number should always be quoted. 1. Vehicle type designation, code numbers for colour and upholstery; on bulkhead. 2. Body number. 3. Type and model designation and chassis number; stamped on right door pillar. 4. Type designation, serial number and part number of engine; stamped on engine left-hand side. 5.
OPERATING INSTRUCTIONS 6
OPERATING INSTRUCTIONS I NSTRUMENTS AND CONTROLS 1. Windscreen wiper and washer switch 2. Fog light switch 3. Choke control 4. I nstrument panel 5. 6. Lighting switch 7. Turn indicator switch, dimmer and headlight flasher Combined ignition switch and steering wheel lock 8. Fan switch 9. Warning hazard flasher switch Cigarette lighter 10. 11. The instruments and controls are described in more detail in the following pages with a reference to the numbers in the picture opposite.
OPERATING INSTRUCTIONS C Speedometer The speedometer consists of a horizontal scale marked in intervals of 20 m.p.h. The speed is indicated by a red ribbon. 4 Instrument panel A Panel light 'switch A Panel light switch B Fuel gauge C Speedometer D Coolant temperature gauge Turning the knob clockwise or anticlockwise increases or dims the lighting on the i nstrument panel.
OPERATING INSTRUCTIONS K Mileometer F Warning light, charging This lights red when the battery is discharging, which is normal at idling speed. As soon as you accelerate a little, it should go out. Should it light up 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 alternator pulley, causing poor charging.
OPERATING INSTRUCTIONS 5 Lighting switch The headlights are operated by means of a push-pull type switch on the dashboard as well as a lever (6) on the steering column. All the lights are extinguished when the l i ghting switch is pushed fully in. Pulling i t 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 (6).
OPERATING INSTRUCTION key has been forgotten in the ignition switch. Except for the engine ignition system, the electrical system is switched on with the key in the Garage position. To start the engine, turn the key to the Starting position and this automatically engages the starter motor. As soon as the engine starts, release the key which automatically returns to the Driving position.
OPERATING INSTRUCTIONS 14 Handbrake the handbrake lever is on the outside of the driving seat and operates on the rear wheels only. When the handbrake is applied and the ignition is on, a red warning light (4, H) shows on the instrument panel. Remember that the footbrake warning system is also connected to this light. Should the light show when the handbrake is not on, this may be due to a failure in one of the brake circuits.
OPERATING INSTRUCTIONS 17 Switch, electrically heated rear window I n order to obtain a clear view through the rear window during cold and damp weather, the Volvo is fitted with an electrically heated rear window. Heating is by means of wires on the inside of the rear endow. For this reason, avoid placing anything on the rear shelf which could damage the wires. The switch has two positions.
OPERATING INSTRUCTIONS I NTERIOR AND BODY Front seats Length and height adjustment, Lumbar support Backrest adjustment driver's seat The front seats are provided with an adjustable lumbar support. This is operated by means of the knob on the inside of the backrest. To tension the lumbar support, and thus exert more pressure against the small of the back, turn the knob clockwise, "FIRM", and to relieve the pressure against the small of the back, turn the knob anti-clockwise, "SOFT".
OPERATING INSTRUCTIONS Length and height adjustment, front passenger's seat The front passenger's seat can be adjusted forwards-backwards by pressing down catch C on the outside of the seat. Vertically the seat is adjustable to three different 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.
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. Automatic safety belts with emergency l ocking retractors The Volvo 164 is equipped with automatic safety belts with emergency locking retractors. The practical construction of the belt makes it extremely easy to use. To fasten the belt, pull out the webbing slowly.
OPERATING INSTRUCTIONS Do not leave the keys in the car. The door locks have been designed with a view to providing maximum possible protection against freezing during the wintertime. 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 immediately place it in the lock. This should unfreeze the lock.
OPERATING INSTRUCTIONS I nterior lighting Sun-roof 1. The light comes on when either front door is opened. 2. The light is always extinguished. 3. The light is always on. On certain cars, the Volvo 164 is available 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.
OPERATING INSTRUCTIONS STARTING AND DRIVING Running-in instructions When the vehicle is new, we recommend that a certain amount of caution be observed during the running-in period, for it is during this time that the movable parts of the car must be properly bedded in so as to obtain smooth and durable sliding surfaces. The maximum permissible speeds, therefore, should not be exceeded. 1st speed during the first 1000 km (600 miles) 30 km.p.h. (20 m.p.h.
OPERATING INSTRUCTIONS delivered. We are therefore assured that all clearances are satisfactory and we thus accept no responsibility for damage caused by careless running-in. Before your first drive Before you begin driving your new Volvo, we would advise you to become familiar with the vehicle and the various instruments and controls used during driving.
OPERATING INSTRUCTIONS GEAR-CHANGING The Volvo 164 is fitted either with a floormounted gear lever, a steering columnmounted gear lever, a floor-mounted gear l ever with overdrive or an automatic transmission. Note that not all these types of transmissions or combinations are available on a number of markets. Floor-mounted gear lever Gear-changing with the floor-mounted gear lever is quite conventional and the different gear positions are shown in the picture above.
OPERATING INSTRUCTIONS wheel before it can be moved into any of the other positions. If the car is temporarily stopped and the selector is moved to the "R", "D" or "L" position, apply the handbrake or the footbrake to stop any tendency for the car to "creep". Selecting Automatic Transmission At the bottom of the instrument panel in the middle there is a quadrant for indicating the selector lever position.
OPERATING INSTRUCTIONS Towing I f necessary, the car can be towed with the selector lever in "N" position, providi ng the gearbox is properly adjusted and the oil at the correct level. If a fault in the gearbox is suspected, disconnect the propeller shaft before towing. Towing loop, front Towing l oop, rear I f the vehicle is to be towed, the tow line must not be attached directly to the bumpers, but should be attached to the towing l oop on the front axle member according to the picture above.
TECHNICAL DESCRIPTION Engine compartment 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
TECHNICAL DESCRIPTION ENGINE The B 30 A type engine is a six-cylinder, water cooled carburettor unit with overhead valves. The engine has a very rigid cylinder block made of special cast iron and is cast in one piece. The cylinder l i ners are machined directly in the block. The cylinder head has separate inlet and exhaust ports, one for each valve. The statically and dynamically balanced crankshaft is carried in seven main beari ngs.
TECHNICAL DESCRIPTION Exhaust emission control The engine is fitted with an exhaust emission control system which produces a more exact and leaner mixture ratio between fuel and air resulting in a more complete combustion and thereby cleaner exhaust gases. The system consists of specially adapted carburettors and an intake manifold provided with a preheating chamber and control throttles. When driving at low speed, the throttles are closed so that the fuel-air mixture passes the preheating chamber.
TECHNICAL DESCRIPTION Gearbox The gearbox has synchromesh on all the forward gears. Due to the generously dimensioned synchronizing rings the gearbox has smooth gear-changing. As alternative the Volvo 164 can be fitted with a fully automatic transmission, BW 35. Overdrive For certain markets, the Volvo 164 model i s fitted with an overdrive (see upper right) which makes it possible to reduce engine speed while maintaining road speed. This i s less wearing on the engine and saves fuel at the same time.
TECHNICAL DESCRIPTION Final drive Engine torque is transmitted via the propeller shaft to the rear wheels through the final drive. The final drive is of the hypoid type, that is, the drive pinion lies below the centre line of the drive shafts. 28 Differential brake On certain markets, a differential brake can be obtained as extra equipment. A rear axle with a differential brake automatically transmits the tractive power to the wheel having the best road grip when a wheel begins to skid.
TECHNICAL DESCRIPTION FRONT END AND STEERING Front end The car has independent front suspension. The front suspension units are mounted on a strong box member. The member is bolted firmly to the front section of the body. The front wheels are journalled in tapered roller bearings. The front springs consist of coil springs in which telescopic shock absorbers are fitted. The car is provided with stabilizers secured to the l ower control arms and to the body.
TECHNICAL DESCRIPTION ELECTRICAL SYSTEM The electrical system is of the 12-volt type and is fitted with a voltage-regulated alternator. The starter motor is operated by means of the ignition switch. This switch i s also the main switch for the rest of the electrical system. The cables to the headli ghts, parking lights, interior lighting, radio, engine compartments and boot, however, are not controlled by the ignition switch, but can be switched on and off without the ignition key being in position.
TECHNICAL DESCRIPTION .. . r--I,D....~----_.
TECHNICAL DESCRIPTION BRAKES The brake system is of the two-circuit type with disc brakes all round. The system is provided with a tandem-type master cylinder and a directly-operating booster cylinder. When the brake pedal is depressed, the master cylinder is operated mechanically via the booster cylinder, this boosti ng the pedal force about four times. The brake pressure is transmitted hydraulically from the master cylinder through the brake l i nes to the wheel cylinders.
SERVICING GENERAL Before the vehicle was delivered from the factory it was subjected to a very thorough i nspection. 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 is the free service inspection after 2500 km (1500 miles). The oil in the gearbox and final drive should be changed after the first 5000 km (3000 miles).
SERVICING MAINTENANCE SCHEME I n the maintenance scheme below the servicing procedures have been given certain numbers which refer to the detailed descriptions on the following pages. 34 Some of the work must be carried out by skilled mechanics or requires the use of special tools and these have been marked 0.
SERVICING I n addition to the servicing procedures mentioned in this scheme you should also check regularly the following from the point of view of traffic safety: a) lighting, including brake warning light b) direction indicator lights c) horn 35
SERVICING LUBRICATION Chassis maintenance To simplify maintenance of your Volvo, the vehicle has been equipped with ball joints, steering rods and propeller shafts of such a construction that they do not require regular lubrication. This has been possible due to the fact that points that normally require lubricating have been packed with very durable grease at the factory and then carefully sealed, thus obviating the need for subsequent lubrication.
filler hole on the rocker-arm casing with new oil of the same type already in the engine. 2 Check the oil level in the engine The oil level in the engine should be checked each time the fuel tank is filled. The check should be carried out with the engine switched off but warm and, in order to obtain comparable values, about 1 minute after the engine has been stopped. Wipe the dipstick before measuring. The oil level should be between the two marks on the dipstick.
SERVICING 4 Carburettors At each oil change check that the oil level i n the centre spindle of the carburettors i s about 6 mm (1/4") from the top of the spindle. If it is not, fill up with oil ATF Type A (Automatic Transmission Fluid). The carburettors are adjusted and tested i n a test bench at the factory with a COgauge. No adjustment of the carburettors i s required other than when carrying out repairs to them.
SERVICING 9 Automatic transmission BW 35 The oil in the automatic transmission should not be changed but the oil level should be checked every 10 000 km (6000 miles). The filler pipe with graduated dipstick is to be found under the bonnet just i n front of the cowl. N.B. The dipstick has different graduation marks for a warm and cold transmission. When the oil level is being checked, the car should be standing level.
SERVICING 14 Steering box (mechanical steering) 15 Servo steering The oil level in the steering box should be checked after every 10 000 km (6000 miles). The oil level should be up to the filler plug. I f necessary, top up with new oil. As a rule, the oil in the steering box does not need to be changed except during overhauling. Should the oil for any reason need to be changed, the old oil should be sucked up by means of an oil syringe which is i nserted into the filler hole.
SERVICING ENGINE 17 Crankcase ventilation The engine is provided with positive crankcase ventilation which prevents the gases i n the crankcase from being released into the atmosphere. Instead, they are sucked i nto the intake manifold and take part in the combustion process whereupon they are blown out through the exhaust pipe together with the other combustion gases. Every 40 000 km (25 000 miles) remove and clean the nozzle (1), the hoses (2 and 4) and the flame protector (3).
SERVICING 20 a Replacing foam plastic filter for gas evaporation unit On vehicles fitted with a gas evaporation unit, the foam plastic filter in the holder on the cowl to the right in the engine compartment should be replaced every 40 000 km (25000 miles). 21 Valves The valve clearances should be checked after every 10 000 km (6000 miles). This check should be carried out by a workshop.
SERVICING Top-up with coolant lop up with coolant by filling the expansion tank when its level has gone down to the "Min" mark. Use 50% good quality anti-freeze mixed with 50 % water all the year round and top up to the "Max" mark. NOTE. Do not top up with water only. Water by itself reduces both the rust-protective and anti-freeze qualities of the coolant. It can also cause damage to the cooling system if ice should form in the expansion tank. Note.
SERVICING When changing the spark plugs, check that the suppresser connectors are in good condition. Cracked or damaged connectors should be replaced. 28-29 Ignition system The distributor contact breaker gap and the engine ignition timing should be checked every 10 000 km (6000 miles). 26-27 Spark plugs, adjusting the electrode gap, changing the plugs The spark plugs should be removed after every 10 000 km (6000 miles) and the electrode gap measured. The gap should be . 7-.8 m m (.028-032").
SERVICING 31 Check the state of charge of the battery The state of charge of the battery should be checked after every 10 000 km (6000 miles). The check is made with the left of an hydrometer which shows the specific gravity of the battery acid (this varies with the state of charge of the battery). See page 58. At the same time, check also the lead terminals and terminal studs to make sure that they are tight, smeared with rustproofing and that the battery is firmly fixed.
SERVICING Replacing the bulb for the lights for the luggage and engine compartments Replacement of bulbs To obtain maximum lighting effect and to forestall the chances of lights going out, the headlight bulbs should be changed every year, suitably during the autumn. Slacken the screw holding the lamp shade. The bulb i s now accessible for replacement. The following pages explain how the bulbs in the various lighting units are replaced.
SERVICING Replacing the bulbs for the front Replacing the bulbs for the rear Replacing the bulbs for the flashers and the parking lights flashers, parking lights, stop lights number plate light Remove the two Philips screws which hold the glass. The bulbs can now be removed by pressing them inwards and then turning them a little anti-clockwise. The inner bulb is for the parking light, the outer for the flasher.
SERVICING Replacing the headlight bulbs 1 2 3 4 48 The headlight bulbs are replaced from inside the engine compartment in the foll owing way; 1. Remove the protective cover over the space behind the headlight. 2. Remove the contact for the bulb holder and rubber sleeve. 3. Remove the spring which fixes the lamp holder in the correct position. 4. Lift out the bulb holder with the bulb complete as one unit. Do not grasp the bulb glass with your fingers.
SERVICING POWER TRANSMISSION BRAKES 33 Check the release arm free travel To avoid risk of the clutch slipping, the release arm free travel should be checked and adjusted if necessary every 10 000 km (6000 miles). For data see page 59. The clutch should be checked and adjusted at a workshop which has the proper equipment. 35 Check the brakes After every 10 000 km (6000 miles) the vehicle should be taken to a Volvo workshop for a check on the functioning of the brakes.
SERVICING FRONT END 37 Check the front wheel alignment Correct front wheel alignment is of vital i mportance for the steering of the vehicle. Faulty adjustment can mean heavy wear on the tyres. For this reason, have the front wheel alignment checked regularly at your l ocal Volvo workshop every 10 000 km (6000 miles).
SERVICING Changing a wheel Before the vehicle is jacked up, the handbrake should be applied and one of the gears engaged. Removal 1. Prise off the hub cap with the help of the removal lever. 2. Loosen the wheel nuts 1/2-1 turn with the help of the box spanner. All the nuts have right-hand threads which are loosened by turning them in an anti-clockwise direction. 3. Insert the lifting arm of the jack in the appropriate jack attachment of the wheel to be changed.
SERVICING BODY 40 Washing The car should be washed often since dust, dirt, dead insects, tar spots, etc. adhere firmly to the body and may damage the paintwork. Washing is also important to counteract rusting. During the winter, special care should be taken to ensure that all road salt residue is washed off as soon as possible, otherwise corrosion can occur. A vehicle, the bodywork of which has been well taken care of, has of course a higher second-hand value, should the owner consider selling it.
SERVICING 42 Anti-rust treatment The Volvo 164 is anti-rust treated at the factory. Underbody sealing compound is applied to the underbody on those places exposed to damage from flying stones thrown up by the wheels, i.e. the wheel arches, the entire floor plate and the underside of the sills. Anti-rust fluid is sprayed on the chassis parts. Inspection and any touching-up of the anti-rust protection should be done at regular i ntervals and at least once a year.
SERVICING SERVICING BEFORE A PROCEDURE IN COLD LONG-DISTANCE TRIP WEATHER I f you are thinking of taking your car abroad or on a long journey, have it checked at a Volvo workshop. You will enjoy your journey better if you know that your car is in perfect trim. Irritating incidents can be avoided as well as expensive and ti me-absorbing stoppages. Wherever you go there should be a Volvo workshop withi n easy reach to attend to your car if required.
SERVICING rust-proofing effectiveness of the coolant. I t is a good idea when topping up with coolant to have the concentration checked Experience has also shown that extremely weak anti-freeze solutions (10-25 % ) are very unfavourable from the point of view of rust protection. For this reason, the quantity of anti-freeze should amount to about 50 % of the coolant, that is, 6.2 litres (11 I mp. pints=13 U.S. pints), this lowering the freezing point to -35° C (31 0 F).
FAULT TRACING WHEN THE ENGINE STALLS OR WILL NOT START The information given below is only intended to serve as a guide in localizing and temporarily correcting minor faults. After having carried out any such measures, have them checked and adjusted by an experienced mechanic. The engine does not start although the starter motor turns it round at normal speed 1. Check that there is fuel in the tank. 2.
SPECIFIKATIONS MEASUREMENTS AND WEIGHTS Length Width Height uniaden (ready to drive) Wheelbase Ground clearance, uniaden (ready to drive) driver and 3 passengers Track, front rear Turning circle Kerb weight Permissible total weight Permissible load (excluding driver) Permissible axle pressure, front rear Permissible ro of rock load Max. permissible trailer weight ENGINE 4705 mm 1735 mm 1437 mm 2700 mm 210 mm (185") (68.3") (56.5") (106.3") (8.3") 160 mm (6.3") 1350 mm (53.2") 1350 mm (53.2") 9.6 m (31.
SPECIFICATIONS Ignition system Firing order Ignition setting stroboscope setting at 600-800 r.p.m. with both vacuum hoses disconnected Spark plugs, normal driving mostly town driving spark plug gap tightening torque Distributor, direction of rotation contact breaker gap 1-5-3-6-2-4 10° B.T.D.C. Bosch W 200 T35* Bosch W 175 T35* .7-.B mm (.02B-.032") 3.5-4.0 kgm (25-29Ib.ft.) Anti-clockwise .25 mm (.
SPECIFICATIONS POWER TRANSMISSION WHEElS AND TYRES Clutch Tyre size Release lever free trave I right-hand steering Air pressure, cold tyres, kg/cm' (p.s.i.) 4-5 mm (approx. 3/16") 2-3 mm (3/32") 1-2 persons Fully loaded Gearbox Type designation M 400 Reduction ratios : 3.140:1 1st speed 1.9.7:1 2nd speed 1.34: 1 3rd speed 1: 1 4th speed (with overdrive) 3.54: 1 Reverse M 410 BW35 3.14: 1 1.97: 1 1.34: 1 l :1 0.797: 1 3.54: 1 2.39: 1 1.45: 1 1: 1 1 X I h " "ratio verter 2.
LUBRICATING CHART About every other week check the tyre pressure and the battery acid level. Note 3. Check that the fluid reaches up to the MAX mark. (Right-hand steering: Check also the clutch fluid level.) Notes for lubricating chart Check the following when filling the tank 1. Check the engine oil level. 2. Check without removing the cap that the level in the brake fluid container is above the MIN mark. (Right-hand steering: Check also the clutch fluid level.) 3.
Wheel bearings Note 1 Wheel bearings Note 1 Steering box Note 2 Carburettors Note 6 Brake fluid container Note 3 Oil filter Note 7 Distributor Note 4 Engine Note 8 Gearbox Note 5 Rear axle Note 9 Wheel bearings Note 1 Wheel bearings Note 1 Oil capacities Engine excl. oil filter i ncl. oil filter approx. Gearbox, M 400 M 410 BW 35 Rear axle Steering gear (meth.) Servo steering approx. 5.2 litres (9.1 Imp. pints= 10.9 US pints) approx. 6.0 litres (10.6 Imp. pints=12.6 US pints) approx. 0.
The specifications and constructional details given in this book are not binding. We reserve the right to carry out modifications without previous notice.
AKTIEBOLAGET 672/1 18.000 Engelska 10.
