Volvo 164 1969 Service Manual
SERVIC_
M
NAL
o
General
FOREWORD
This Manual contai
Volvo
164.
The
book
is di
vided
by the reg ist
illustr
ation
way
that
part
concerned
number
particular
"Electrical system";
way
of
ing
for
back
so
index
various
The
Tools
Description
Repair
er opposite. The pages and figure
s in each part
the
fir
st
while
of
the
page or
part,
for
finding
marks on the
is
to
bend the
that
the
parts are
Instructions
the
arrows
ns
serv icing instructions
up in
to
10 parts
are num
group
shows the numb
the sec
ond
group show
figure
illustration
example,
3-1,
particular
first
divided
under
3-2,
etc. A
section
right
side
in the register
page
of
up
as
as indicated
bered
in such a
er
the
heading
convenient
you
are
of
the
Manual
point
each section.
follows:
for
of th e
s, the
in
that
look-
to
the
the
1
2
3
4
5
Servicing
and
maintenance
Engine
Electrical
we.
rear
Brake
axle
s
system
t
iul
s
•• iss
iulI
,
The specifications
General.
The instructions given in this
that
sume
experience
results
thods,
instructions given in this
achieve the best results in the shortest possible
time.
special tools are used and are based on
gained
may
but
we are convinced
Reprinting
be
obtained
AB
Göteborg
permitted
are
to be
from
method
VOLVO
found
book
studies. The same
with
other
that
by
Manual
- Sweden
if
source
generally
working
following
you
will
quoted
in Part
always
.
O,
as-
me-
the
&
7
a
9
Front
steering
Frame,
end
and
gear
suspension,
wheels
Body
Instruments,
and
other
accessories
equipment
Part O
GENERAL
j
GROUP
01
This
Manual deals with the Volvo
Type designation
164-134
164-155
164
-156
164-137
* App
li
cab le
in
Sweden
TYPE
164
Engine
B 30A M 4
B
30A
B 3
0A
f33
0 A
Gearbox
M
BW
BW
DESIGNATlONS
car
of the fol lowing types: *
Rear axle
00
410
35
35
3.73: l
3.73: l
3.31: 1
3.31: l
TYPE
PLATES
Length
Width
Height
Wheelbase
Ground c1earance ...
T rack, front
Turning circle
Curb weight
...........
rear . .
. . .
.............
..........................................
............................................
...........
........
l.
Vehicle type designation,
chassis number and code
number for colour and
upholstery.
2.
Body number.
3.
T ype designation
chassis number (stamped
on the front right-hand
door
pillar).
DIMENSIONS AND WEIGHT
......
...
...................
.....
..................
.. ......
............
.
..........
.......
........
. . , .
. ..................
and
GROUP
.....
...............
....
.....
. ..........
.....
.....
.
....
,
....
approx.
03
. .
..
4.
Engine type designation,
part
number and manu-
facturing serial number.
5.
Gearbox
tion,
manufacturing serial
ber.
6.
Plate
inspection cover showing
•
4715
mm
(186")
1735
mm
(68.3")
1440
mm
(56.7")
2700
mm
mm
mm
mm
mm
mm
(106.3")
(7.0")
(53.2")
(53.2")
(31.6
ft.)
(2992
.
.
180
.
1350
1350
9600
.
1360
number of teeth and reduction ratio of final
drive.
Ib.)
type designa-
part
number and
on
lower
part
num-
of
o : 1
ENGI
NE
. Lubri ca nt, type ........
grade
....
viscosity, all
Oil capacity , excluding oil filter . .
including
CO
il
for carburettor damping cylinder . .
......
. .
.. ...........
year
round
below
_10° C
between _
abbove + 30°
oi
l f
ilt
er
LU
........ .........
. .... ....... .
....
. . .... .....
(14°
F) . .
.. .......
10°
and +
30°
C (
90°
F) ........ . . .... .
........ .
. . . . . ....
........
...
...... . . . . . .
BRICATION
...
" .....
...
. . . .
...
. . . . .
....
.
.. ..
. .... . .
. .
....
. . .
C (
14
and
90°
F)
..
.
...
. . . .........
. . .
........
......
. .
.
.
Engine o
Se
Multigrade O
SAE
SAE 20/
SAE
5.2 litres (
6.0
O
il
rvi
ce MS
il
SAE
10 W-3
0
10W
20
W
30
9.15
Imp.pints=
litres (10.
il
for Automatic Transmissions, Type A
56
Imp
.pints=
10.97
12.66
US
US
pints)
pints)
GEARBOX
~.L
Ll!lbricant,
. ,Alternative lubricant, type . .
~
.oil.
capacity
':'GEARBOX
; l.lJwnricant, type . .
O
il
capacity,
AUTOMATIC
Lubricant, type ..........
Normaloperating
Oil capacity
FINAL
Lubricant, type, without differential brake
Oil capacity ......
(WITHOUT
typ e .....
viscosity
WITH
g,
rade
viscosity, a
gearbox
.................
DRIVE
viscosity,
OVERDRIVE
. . . . . .
...................
............
at
continous air temperature below -
(14°
F)
viscositY
a
lt
ernative .
. ....
................
.. .............
!i-1fOII
year
........
OVERDRIVE
...
.. ..
. . . .....
.........................
ll
year
alt~rnative
and overdrive
.....
round .........................
. ....
TRANSMISSION
........
temp.
of
with differential brake . . .
above _10° C (14°
below
-10° C (14°
...
. .
...................
......
oil ............
. . .... ....
)
. . . . .
.......
. . .
.............
...
...........
. . .... ..........
round
..........
. . .
...............
. .
...... .
.........
. . .....
..........
.......................
...............
.........
....
...............
..................
..
............
F)
..............
F) .......
....
..........
......
.....
. .... .
...
....
...
. . . . .
10°
. . . .
...
. . .
...
...
.. ..
. .
...
Gear
oil
S
.
AE
90
C
SAE
80
.
Engine oil
SAE
30
.
Multigrade oil
0.6
litre (
. .
Engine oil
.
Service
.
SAE
30
.
Multigra.de Oil
1.4
litres
Oil for Automatic Transmissions, Type A
100-115°
.
.
8.2
litres
.
Hypoid oil
.
Oil according to
provided with additive for differential brake
.
SAE
90
SAE
80
.
1.6
I.itres
SAE
1.1
Imp.pints =
MS
SAE
(2.
46
Imp.pints=
C (212-239°
(14.43
Imp.pints =
(2.82
Imp.pints =
20 W-40
1.3
US
20
W-40
2.95
F)
17.30
MIL-L-2105
3.38
pints)
US
US
or
US
pints)
pints)
pints)
MIL-L-2105
B,
MECHANICAL
Lubricant, type
Oil capacify ...............
SERVO
Lubricant, type
Oil capacity ....................
STEERING
STEERING
........
viscosity . .
...
..........................
...
. . .............
...................
GENERAl
T ype desiglnation
Output, h.p.
Max. torque,
0:2
at
kgrm
....
............ .........
r.p.m.
(SAE)
(DIN)
{lbJt.)
at
GEAR
..........
.........
...
. .....................
r.p.m.
.... .
.......
(SAE)
(DIN)
...
...
...................
....
......
...........
. .
.. ..
........
.. .
............... . .
.
.................
.........
..
approx.
ENGINE
...
. .
............
. . . .... .
....
. . .
.......
..
........
...
. .
Hypoid oil
..
.
SAE
80
0.6
litre
(1.1
Imp.pints=
.
Oil for Automatic Transmissions, Type A
1.2
litres
(2.11
Imp.pints=2.53
.
B
30
A
.
145/5500
. .
130/5000
.
22.5
(63}/3000
.
21
(152)/2500
1.3
US
pints)
US
pints)
C
omp
ression pressure (
st
arter
moto
r,
250-3
C
ompression
mber
Nu
Bore . .
S
trok
e . . .
D-isplace ment . . . . . . . . . ....
We
ight,
We
ight exclud'ing
ratio
of cyli
nders
..
. . . .
...
...
. . . . . . . . .....
included
warm
00 r.p.m. . . . . .
. . . .
...
...
. . . . ......
elec
trical equipment
gearbox, starter
engine) wh
. . . . . . .
. . . .
...
. . . . . .
. . .........
....
. . . .
............
en turned
..
. . . .... .
............
........
. . . ....... .
...
. . .
.. ..
....
and
motor, oil
over
...
.....
. . .
...
. .... . . . .
. . .
....
. . . .... .
...
. .
.. ..
. . . . . . .... . .
.............
gearbox
and
. .... . . .
water
with
.....
...
. . . . .
. . . . . .
. .
11
9.2: 1
6
..
.
88
80 mm (3.15
2.98
2
192 kg (422 Ib.)
- 13 kg/
.90
mm
litr
41
kg (530 Ib.)
(3.50")
es
cm
")
2
(
156
, 185 Ib/
sq.
in)
CYLINDER
Mater
Bore,
BLOCK
ial ... .
standard .....
oversiz
....
e .030"
...
. . . .... ....
. .
PISTONS
Material
Weight
Permissi
Height,
Height from
Piston cle
PISTON
Pist
Oversize on piston rings
CO
Marked "TOP". Upper
Number
Height ............
Pis
. . . . . ....
, s
tandard
ble wei
tota
aran
...
. . .
. ....... . .
ght
deviat
l . .
..........
piston pin centre
ce ...
. . .... . . .... .
RINGS
on
rin g
gap
, measured in ring open ing .... . ....... . . . . . .
MPRESSION
ton ringl clearance in
RIN
GS
on e,ach piston .
. . ......
ring· chr
.. ..
. ....
......
. ....
....
. .... . . . . . . . . . . . . . . . . .... ....... . .
...
. . . . .
...
. . . . . . . . . . . . .....
.............
ion
betwe
. ......
..
....... ..
groove .. ..
. .
omed
....
to
...
.......
. . .
piston cr
. . .... . .
...
. .......
en pistons in same engine
....... . ....
.....
. .....
.
.........
. . ....... . ......
.....
own
......
. . . .... .
...
...... .... . . .
. . . .
...
. . . .... .
. .....
. . . .
.......
...
. . .
. . . .
...
...
. . . . . .
. . . .
.......
. . . . . . . .
........
.. ..
..
..
..
. .
. . .
.
Special all
88
.90 mm
89.66 m
.
Light a
500.
d;:5
10
'gramm es (.35 oz.)
71
mm (2.79
46
.
.
mm
.02-.04
.40- .55
.030"
.
2
1.98
.045-.
mm
072
(3.499
m.
(3.523")
lloy
gramm
(1.81")
mm
mm
(.078")
oy
cast
iron
")
es
(1
7.5± .18 o
")
(.0008-.0016")
(.016- .022
mm
(.0017-.0028")
z.
)
")
Oll SCRAPER
Number
Height ...........
Piston
ring
G
UDGE
Floating
Fit:
In connecting
In
piston
Diameter,
CYLINDER
Height,
heads
Cylinder
RINGS
on each piston . ....
clearance
ON
PINS
fit.
Circlips
standard ... . . . . ....... . .
oversiz
HEAD
measured
......
. . . .
heod
gasket ...
CRANKSHAFT
Crankshaft,
Main
i-
end
Big
end
bearings,
bearings, radial
. .
...
. . . . . .
in g.
at
both
rod ... .
es
.05"
.10"
.20"
from c.ylinder
..
: . .... .
float
...
radial
clearance
...........
.........
roove
. .
ends in piston.
...
. . . . ....... . .
....
.... ...... ............
. . . ........
...
. .
...
........ . . . . .
....
. . .... . . . .... ......
.. .. ............
...
. . .... . .
....
...
. . .... . .... . .
clearance
...
contact
. . . . .
.. ........
. . . . . . .
.. ..
. . .... . ........
. . . . .
...... . .... . .
face
.......
.....
..........
............
. . . . .
. . . .
...... ......
.. ..
...
..........
......
. . . ....
.....
to
face
. . . ....
. .
.........
. . . .
...
. . . . . .
. .
...... .... .
. .... .
.. ..... .
.. ..
.......
.....
. . . . . . . .
...
. . . . . .
for
.....
. .
..
. . .
. . .
. .
... . .
bclt
..
..
....
...
. .
1
4.74 mm (.186")
.045-.072
.
Close
Push
22.00
22.05
22.10
22.20
86.7
.
.
.
mm (3.41
mm
.7
.
047-.138
.038
-.
.039-.081
mm
running
fit
mm
{.866")
mm (.868")
mm
(.870")
mm (.874")
(.028
")
mm
089
mm
mm
(.0017-.0028")
fit
")
(.0019-.0054")
(.0015-.0035")
(.0016
- .0032")
:3
0
MAIN
BEARINGS
Main bearing journals
Diameter, standard
.
undersize
010"
.
020"
.
030"
.040"
.050"
Wid
th
on crankshaft for pilot bearing she"
Standard
...................................
Oversize l (undersize she" .010") ....
2 ( .020")
3 (
4 (
...
.030
") ......
.040") .......
5 ( .050" ) ..
....... ..
....
...
. . .
......
....
......... ..
.. ..........
. . .
.....
...... .. .....
...
........
. .
...
........
..........
. .... .
..
. .
. . .
...
63.441-63.454
63.
187-63.
62.933-62.946
62.679-62.692
62.425-62.438
62.171-62.184
.
38
.930-38.970
39.031-39.072
.
39.133-39.
39.235-39.275
39.336-39.376
.
39.438-39.478
mm
(2.4977-2.4
200
mm (2.4876-2.4882")
mm
(2.4777
- 2.4782")
mm
(2.4677
- 2.4682")
mm
(2.4577
- 2.4581")
m m
(2.4477-2.4482")
mm
(1.5327-1.5342")
m
m.
(1.5366
- 1.5383")
173
mm
(1.5407
- 1.5422")
mm
(1.5447
- 1.5463")
mm
(1.5487
- 1.5502")
mm
(1.5528-1.5542")
982
")
Main bearing
Thickness,
shelIs
standard
. .
........
. ....
undersize .010" . . . . .
.020" .............
.
030" ..................
.040" . .......
.050" . . . ....... ...........
BIG-END
Big-end bearing journals
BEARINGS
Width of bearing recess ......
Diameter,
standard
undersize .
......
.......
010" ........
.020"
..........
.030" .......
.040" .
...............
.
050" ......
Thickness,
standard
undersize
.010"
.020"
.
030"
.040"
.050
"
....
...
. . .... . . . .
........
. .
. . ..........
.....
........
.. ..
. . . .
.....
.. ............. . .
......
. . ...........
. . .
...... ....... . . . . . .
...
..................... . .
. .
...........
. . .... . .........
......
. .
...
. .
.......
. . .
..........
. .
....
. . . . .
. . . . ....... .
...
. .....
. . .....
....
. ........
....
. .... . .
. . .
........
.. ........ .
1.985-l.991
. .
.
2.112-2.118
2.
239-2.245
2.366-2.372
2.493-2.499
2.620-2.626 m m (1.
. . . .
3l.950-32.050
. .
54
.089
. .
53.835-53.848
53.581-53.594 m m (2.1095-2.1100")
. .
53.327-53.340
53.073-53.086
.
53.819-52.832
1.833-1.841
1.960-1.968
2.087-2.095
2.214-2.222
2.341-2.349
2.468-2.476
-54
mm
(.
0782
mm.
(.0832-.0834")
mm
(
.0882
mm
(.0931-.0934")
mm
(.0981-.0984")
0315-1
mm
(1.2579-l.2618")
.102
mm
(2
mm
(2.1195-2.1200")
mm
(2.0994-2.1000")
mm (2.0895-2.0900")
mm
(2.1189-2.0800")
mm
(.0722-.0725")
mm
(.0772-.0775")
mm
(.0822
mm
(.0872-.0875")
mm
(.0922-.0925")
mm
(.0972-.0975")
- .0784")
- .0884")
.0339")
.1295-2.1300")
- .0823")
CONNECTING
End
float
on
Length,
Max. permissihle
centre-centre
RODS
crankshaft ... . .
...
. . .......................
we·ight deviation
same engine
FLYWHEEL
Permissible axial throw, max.
Ring
gear
(chamfer forwards)
CAMSHAFT
Marking . ..............
Number of bearings . .
Journal, diameter
Radial clearance
End
float .... .
.................
.......
Valve clearance for controi
Inlet valve should then open
0
:4
...
... ...
.........................................
.....
....
......
. . . . .
.......
of
camshaft
at .....
. ......
. . . . . ............. . .
between
. . . . .
......
. . .
...
connectings
...................
................
........
......................
~etting
...........
..
......
fO'ds
...
..........
(cold engine)
...........
. .
in
. . .
. . . .
.
. .
.
.
.15-
.35
mm
145±.1
6 grammes
.05
153
C
mm
teeth
mm
(.21
(.002")
4
46.975-47.000
.020-.075
.020-.060
1.45
0°
(T
mm
.D.C)
mm
mm
(.057")
(.006-.014")
(5.71
±.004")
oz.)
at
a diameter of
mm
(l.8494- 1.8504")
(.0008
- .0030")
(.0008-.0024")
150
mm
(5.9")
CAMSHAFT
Bearing
diameter
BEARING
.............. .... . .......................
47.020-47.050
mm
(1.8512-1.8524")
TIMING
Crankshaft
Cranksh
Backlash
End
VALVE
VALVES
Inlet
Disc d i
Stem
Val
Seat
Seat
Cl
Exhaust
Disc
Stem di
Valve
Seat
Seat width
Cle
aft
float
SYSTEM
ameter
diameter .....
ve
seat
ang
width
earance,
diameter
ameter
seat
angle in cylind
aran
ce, both warm a nd cold e ngine . . .
GEARS
drive,
gea
r (fi
...
. ....
, camsh
angl.e
le
in cyli
in
cyli
both
ang
in
cylind
numher
bre
), number
.............
aft
. .
.....................
..........
.....
...
. . . . .... . . ........
nder
head
nder
head
warm
and
. . . . . .... .
le
.....
. .
er head ....
er hea
of
teeth
. .
...
....................
of
teeth
. . ....... .
. .
.........
. .... .
. . . . .
.........
........
....
. .......
. . . . .
...
.............
...............
..........
............
...
............
.............. ................
cold
eng
ine . ..... .............
.......
...
. . . . .
...
. . . . . .
...................
.. ..
. . . .
d .
............
. . ....... . . .
...
.. ..
. .
....
...
.....
. . . . .
.......
....
...
....
....
...
.......
.. ..
.......... .
.......
. . .
. . ..........
.. ..
. .....
. .
. . . .
. .
..
...
..
. . . .
.
.
.
.
.
.
.
.
.
21
42
.04-.08
.
02-.06
mm
(.0016-.0032")
mm
42 mm (1.654" )
7.955-7.970
44.5 °
45°
2.0
mm
(.080")
.50-.55
35
mm
mm (.020-
(1.378"
7.925-7.940
44.5°
45°
2 mm
(.0
80"
.50-.55
mm
(.008-.0024
mm (.313
2-.3
.022")
)
mm (
.3120-.3126"
)
(.
020-.022
")
138")
)
")
VAlVE
GUIDES
Length, inlet
valve
exhaust
Inner
diameter
Height
C
VAlVE
Length,
learan
above
upper
ce,
valvestem-valve
SPRINGS
unioaded,
loading
with a
with a
loading
LUBRICATING
Oil
capacity,
Oil
pressure
Lubricant
l)
When
mul1igrade
including oil filter
excluding oil filter
at
2000 r.p.m. (with
..........
viscosity
or
viscosity,
cold-s1ar1ing difficul1ies
oil
SAE
. .
.........
valve
....
...
....................
face
of
cylinde r he
guide,
approx ....
of
25.5±2.0
of
66.
0±3
SYSTEM
. .
....
......
all
year
round
above
between -10°C
87°
below
5 W-20
+ 30° C
F) .........
_ 10° C (14°
are
can
be
used
...............
. . .... .........
.......
ad ....
inlet
valve
exhaust
. . . . . . . . .
kg (5
......
6±4.4
.5 kg. (145±7.7
...
. . ....
....
..
.. .....
. . .
warm
engine
. . . .
.........
(8r
F)
....... .
and
. . . . . .
.. ..... ..
F) ...
10
be
expec1ed
.
.
.......
. . . .
.........
. . .
............
........
..........
valve .
.. .. ..
Ib)
Ib)
...
...
...........
....... ...
.. ............
.............
and
new oil filter)
....
. . .... . . . . .
...
+30
° C
. . . ....
...
............
(below
_20
. .... . .
. . .
. . .
...
. . .
. .... . .
. . . .
..
..
...... . .
(14° and
..
0
0
(=_4
52 mm (2.047")
59
mm
(2.323")
8.000-8.022
17.5 mm (.689
.
.030-.067
.060-
.097 mm
.
45 mm (1.77")
.
39 mm
(1.54
.
30.5
mm
.
6.0 litres
5.2 litres
.
2.s---:6.0 kg/cm2 (36
Engine oil.
Multigl
rade
SAE
30
.
SAE
20/20 W
.
SAE
10W
F)
mm
(
.32-.321")
")
mm (.0012-.0026")
(.002
4-.
0038
")
(1.20")
(10.
56
Imp.pints= 12.
(9.1
5 Imp.pints= 10.97
- 85 Ib/sq.in.)
for
Service
oil
SAE
MS
10 W-30
")
1
66
US
pints)
US
pints)
)
Oll
T
ype
FilTER
. .
....
............
....................
....
...........
. Ful.l-flow
type
0
:5
Oll PUMP
Oil pump,
RELIEF
Length, unl
FUEL
FUEL
Di
aphragm
Fuel pressure,
type
number
end
radial
backlash
VAlVE
oaded ...
l
oaded
SYSTEM
PUMP
type
...
of
flo
a.t
clearance
SPRING (IN
with
pump ...
measured
CARBURETTORS
Type ...... .
Make
and
ber
Num
ntake di'
Air i
Idling
speed
M
ete
ring n
O
il
for damping cylinder ....
...................
designat
.......
ameter ......
.. ..
eed
le
...
. . .
des
. . .... . . . . . . . . . . . . . . . .
teeth on
. . . .
...
. . . . . . .
.. ..
5.0±.4
7.0±.8
ion .
...
...........
.. ..
ignation
each
gear
....
. .
........
.......
..................
........
Oll
PUMP
)
......
. . . .
.............
kg (
11.0±88 Ib.
kg (
15.4±1.7
................. .
at
same
level
.
...
. ...........
.....
. .................... . ....
.
.....
...... . ....
..............
...
. . .....
. .
...
. .
.......
. . .... . .
............ ......
wheel . .
. . . . . . .... .....
. . .
..............
) .
Ib
....
as
pump
. . ....... . . . . . .
........
.....
...
. .
..
....
. . .... . . . . .
.........
.........
at
1000 r.p.m.
.. ......... .
. .
.....
. .... .....
..............
.........
. . .
. .
.
......
approx.
...
....
. . .
...
...
...
.. ..
. . . . .
.. ..
. . . .
...
. .
. .
. . .
. . . .
....
.
G
ear
.
9
.
.
20-.10
.
.08-.014
.15-.35
39.0
26
21.0
Pierburg
min
max
Hori
Zenith-Stromberg 175CD-2SE
mm
(.0008
mm (.0032-.0055
mm
(.0060-.0140")
mm
(1.54")
.25
mm
{1.03
")
mm
(.83")
PV
3025
..
15 kg/
cm2 (
2.1
..
25 kg/
cm2 (3.5 Ib/sq.in.)
zontal carburettor
-.0040
2
41.3
mm
(1.63
")
750 r.p.m.
.
B l R
.
O
il app
rov
ed
as
oil f
Transmissions, T ype A
")
Ib/sq.in)
or
Automatic
")
COOLlNG
Type . ............... .
Radiator
Capacity
Fan
belt,
The fan
pulley
THERMOSTAT
Type
Marked ......
Begins
Fully
TIGHTENING
Cylinder
Main
Big-end
Flywheel
Spark
Camshaft
Bolt
for
Nipple
Sump bolts
SYSTE
cap
valve
. . . . .
... ...
designation
belt
is
tensioned
in
the
dh e:ction
~
...
.......
...
to
open
at
open
at ......
head .............
bearing
's .......
bearings ....
.............
plugs . . .
nut .....
crankshaft
for
oil fil
................
....... : .. ..
. . . . . . . . . . . . .
..............
TORQUES
................
ter
M
...
. . . . . . . . . .
opens
at
. .
.. ..
. . . . . . .
.......
so
of
rotation will
...........
. . . . .
.. ..
. . . .... .......
. . ....
. . . . .
.................................
belt pulley .
............. ...
........
.................
..............
. . .
.. ............
that
the
. .... . . ....
........
...
. . . .... . . ............ . .
....... . .
.........
.......
. . . .
........
......
........
. . .
friction
...
torque
be ... . . . . .... . . . . . . . . .
........
.......
. . . . . ....
................ . .... . .
. . . .... . .
.. .. ..
. . .... .
...
....
. . . . .
.. ..
...
...
...
.... ....
. . .... . . .
........
. . .
....
. .... . . . . . . .
...
. .......... .
of
. . .
...
.. ..
. ........
.. ..
. . . . . .
...
. . . . .
. . .
...........
. . . . . ....
...
.......
.............
. . . .
......
.....
. .
. . .... .
the
fan
.. ..
. . .
..
.. ..
....
. . .
....
. . . . .
..
.....
. . .
Sealed
.7
approx
(expansion
pints=3
HC
1.2- 1.7
Wax
82°
.
.
81-83°
. .
90° C (194° F)
8.5-9.5
12-13
.
5.2-5.8
.
5.0--5.5
3.5-4.0
.
13--15
.
7-8
.
4.5-5.5
1.
system
kg/cm?
(10
.0 Ib/sq.in.)
12.4
litres=2.73
tank
.2
US
pints)
38x875
kgm (8.6- 12.3 Ib.ft. )
C
(177-18T
Kgm
0-1.2
of
which 1.5
Imp.galls/3.27
litres=2.6
F)
Lb.ft.
61
- 69
87-94
38-42
36-40
25-30
94-
108
51-58
32
- 40
7.
3-8.7
US
gdls
Imp.
.
WEAR
TOLERANCES
CYLINDERS
To
be
rebored
oil consumption) . . .
0
:6
when
wear
amounts
........ . . . .
....
to
(if
...
engine
. .... .
has
......
abnormal
...
...
. . .
.25
mm (
.mo
"'):
CRANKSHAFT
Permissib le
Permissib le
C
rankshaft
out-of-round
out-of-round
end
float,
VALVES
Perm
issible
clearance
max
......
Valve
. . . .................................
stems, permiss
CAMSHAFT
Per
missible ou
Bearings, permissib
t-of-round
on
on
max. . .
between val
ible
wear,
(with
le
wear
main
bearing
big-end
.......................
ve
max
......................
new
. ....... .............
bearing
stems
bearings
journal
journals,
and val
) max.
s, max. .
max.
.....
ve
gJuides
.
...........
..........
....... . . .
...
.05
.07
'"
. . .
.15 mm (.0060")
,
.
.15
. . .
.02 mm (.0008")
.07
..
.02 mm (.0008")
mm
{.0020")
mm :(.0028")
mm
'(.0060
")
mm
(.0028
")
TIMING
Permissible
Tight
s
tages). 1 st stag
9.5 kgm
GEARS
ening s
(6~
backlash,
equen
e: 2.5Ib
BATTERY
Type ...
Grounded ..........
System
Battery,
Specific
Fully
When
Recommended
. . . .
........
voltage
gravity
charged
...
capacity ....
of
recharg
·ing
charg
max. .....
ce
for cylinder head
3.6
kgm (18-
J t.)
...
. ........ . . ....
..
.. ..... .....
.. .......
electrolyte
battery ......
is
iing
......
. ....... . . .... .... .....
:
.........
necessary
current
. .
..................
12
8 4
bolt
22 Ib.ft.};
s {tightened
2nd
stage
.
.......
: 8.
ELECTRICAL
.. ..
....
...
. . ......
......
............
...
......
. . . .
....
...
....
........
...........................
...
.............
. .... . .
....
..........
...... ..
. ....
......
.....
.12
mm
5
in
2
5-
SYSTEM
. .
Tudor 6 Ex
Neg,ative
.
12V
..
.
60 Ah
1.28
.
1.21
.
5.5A
.
(.0048")
9
4 F
terminal
13
op
or equivalent
ALTERNATOR
Type ...
Wattage ........... ..
Max.
Max.
Direction
Ratio,
Brushes, minimum
Tighten
Attaching
Pulley
............
continuous
spe'ed .... ..
of
eng,in.e-alternator ....
ing
nut ...............
current
rotation
torque·s:
screws
...
length
.........
.............
.. ..
...
....
........
......
. .....
........
...
. . .
......
. . . . . .
..
..............
.
.............
.........
...
. .
.....
. . .
.................
. .
.......
.......
.... ...........
. .
.....................
..................
.. .....
...
............. .
.....
.
.......
.....
.....
....
.......
.
........
......
.....
. . .
...
. . . .
...
...
....
. .
S.E.V.Motorola 14 V-26641
420 W
.
. . .
30A
15000
r.p.m.
. .
Optional
.
1.-2.15
.
5 mm
(.20")
.
.28-.30
..
.
4
kgm
kgm
(29 IbJt.)
(2.0-2
.2 Ib.ft.)
:7
0
TEST
VALUES
Fie
ld winding
V
olt
age
Rote d
drop
tes
t . . .
resistance
acr
oss insulation di
...
. .... . . . . . .
. . . . . .... .............
ode
.......
....
. ....
.. .. ...... ..........
. .
.....
...... ..
. . .
...
. . . . . . . . .
..
.
5.2±.2 ohms
.8-.9 V
30
.
A (min. a,t 3000 r.p.m. and
approx.
13 V)
VOLTAGE
Type . . . .
Controi
STARTER
Type . .
Voltage .....
Grounded ... . . . . . .
Direction
Output
Brushes,
TEST
Mechanica
Rotor
Brush
Di
stance
Fr
ictional
Pinion idling
Backlash
Minimum
Minimum length
REGULATOR
...
.. ..
...
voltage,
cold
af
MOTOR
........
. . .
number ... .... .
VAL
UES
end
spring tension .... .
. . . .
. . . . . . . .... . . . .... . .
of
rotation .....
....
. . .... . . . .
l
float
from
pinion
torque
torque
.......................
diameter
. .... .
....
.....
. .
...
. .
regulator
ter
running 45 minutes .
......... . .
....
to
of
rotor
................ ... ...........
of
commutator
of
elec.
. .
.......
.. .. ..
.........
...
. . . . . .
...........
ring
brake .....
brushes
...
. . .
...... . .
.........
. .
gear
......
.....
. .
...
..........
......... .... . . . . .
. . .
....
.. ..
. .... .
....
...
. .
......
.
........................
............
.........................
....
. . .
......
...........
. . .
........
. ...........
. . . .... . .
...
.. ..
............
....
.. ..... .
. . . .
.........
......
...
. .
....
......
...... .
........
...... .
...
. . . .
.......
. . .
. . . .
..
.. ..
. .... . .
..
. . . . .
......
...
....
. .
S.
E.V.
13.1
.
13.85-14.25
. .
Bosch GF
12 V
. .
Negative
. .
ockw
Cl
Approx
.
.
4
.05-.3
1.150- 1.300 kgl
.
1.2-4.4
.
2.
5-4.0
.
1
.3-
.
.3
5-.45
33 mm (1.3")
.
.
14
Motorola
- 14.4 V
ise
. 1 h.p.
mm
1.8 kg,cm (1.13- 1.56 Ib.in.)
mm
(.6")
' 14 V-33525
V
12
V 1
terminal
(.002-.012")
mm
(.047- .173")
kgcm
(2.1
mm
(.014-.018")
PS
(2.53-2.86
7-3
.81
Ib.in.)
Ib.)
Electrical
Unloaded
12.0
Loaded
9
Locked
6
Vand
Vand
Vand
starter
motor:
40-50 A ....................................
starter
starter
motor:
185-200
motor:
300-350
A
CONTROL SOLENOlD
voltag
,e
Cut-in
IGNITION
Firing
order ....... . . . .
Ignition timing
(at
600-800
Spark
plugs,
Pre-engaging
..........
SYSTEM
l
r.p.m. with
type ...... .
thread
spark
plug
tightening
resistance
DISTRIBUTOR
Type . . .
Di
rektion
Breaker
Capacitor
...
...................
of
rotation
points,
gap .....
contact
dwell
A
.... . . . . ....... .-
...
. .
...
.......
vacuum
...
.........................
gap
torque ... . ......
to
.....
. . . . .
pressure
angle
governor
. . ....
.......
.............
ignition coil . . . .
. .... . .
........
. .
....
..............
............... .
............
. .
................
...
............ . . .
disconnected) .
...............
.
.............
. . .....
......
. ............
..............
.....
. . .
.............
..............
...
. .
. . .
....
...
...
. . . .
. . .
........
. . . . . .
...... .
...
...........
.........
. .
.
..
.
.
.
.
..
.
.
.
.
.
6900-8100
1050-1350
Max. 8 V
1-5-3-6-2-4
10°
before
Bosch
14
mm
.7-.8
3.5-4.0
.9 ± .05
Bosch JFURG
Anti-clockwise
Min
..
500-630
40±30
.2
fL
r.p.m.
r.p.m.
T.D.C.
W 175 T 35
mm
(.028-.032")
kgm
ohm
25 mm (.010")
grammes
F-
25 %
or
equivalent
(25.3-29.0
(1.10-1.40
Ib.ft.)
Ib.)
0:8
Centrifugal governor:
Advance range, total . .
Advance begins
Values,
Advance finishes
Vacuum governor:
Positive
Advance range, total ...
Advance begins
Value,
Advance finishes
Vacuum governor:
Negative
Drop, total . . .... ..............
Drop begins
Values
Drop finishes
5°
10°
controi
2.5
controi
2°
at
..............
.............
°
at
.......
at
...... .
..........
at
....
at ...
... ...
at
........................
.......
. .
. . . .
.................
.. ..
....
........
. ................
.
...........
...
.......... ...
.....
.............
.................
.........
...
.....
......
. . .
....
..........
......
............
.
..............
. .
......
....
..........
......
...
. .
..............
...........
.....
.................
...............
. . .....
...........
..
. .
........
........ ..
.
...
. . .
...
......
... ......
. . .
......
..
..
. .
12±1 ° (distr. graduation)
.
425-525
625-725
.
1150-1000 r.p.m. (distr.)
. .
1850
5±
.
. .
6-10
9.5-14
1
4.5-
3±.So (distr. graduation)
.
16
.
2~31
. .
28-32.5
.
r.p.m. (distr.)
1°
(di
str. graduation)
cm
cm
16
cm
-25
cm
cm
cm
r.p.m. (distr.)
r.p.m. (distr.)
Hg
Hg
Hg
Hg
Hg
Hg
LAMP
Headligh
Parking lights
Flashers . . . . . .
Rear lights
Stop lights .
Re
Number
Interior lighting ....
GI
Engine and lugg;
Instrument lighting
Lighting
Controi lamp, instrument panel
Controi lamp, overdrive .
Controi lamp, elec.
BULBS
ts .........
.......
.....
versing lights .
plate light .
;ove compartment light
heater
. .
....
..............
.......................
...
........
. . ........
.....
. . .
...........................
....................
age
compartments . .........
........................
controls ... .
heated
. . . . . .
..........
...........
..............
... ......
rear window
FUSES
Rated current
Rated current 8 A
Rated current 5 A
ELECTRICALLY
Output,
Output,
16
A
HEATED
at
first position of switch ..........
at
second position of switch
REAR
......
. .
...... ..
. . . .............. .
.. .. ..
. ........
...........
...........
........... . . . ........
....
. .
....
...
............
. . .
... ...
. . .... .....
....
.....
. .................. . .
.............
. . ........
. . . .
...............
..................
...
....
WINDOW
.........
........
.. ..
. . .....
.............
. .
............
....... .
.. ..
. ......
. .
......
....
. . .
. . . .
.......
......
. . . ....... . .
. . . . .
....
. . . .
..
..
..
. .
...
. .
. . . .
. .
.
.
.
.
.
.
.
.
Watts
45/40
5
(4
cp)
32
CP
5
(4
cp)
25
(32
15
(32
5
10
2
18
3
1.2
1.2
1
.2
1.2
Number
1
3
5
Approx.
Approx.
cp)
cp)
40
150
W
W
Socket
p
45
t
Ba
15
Ba
15
Ba
15
Ba
15
Ba
15 s
SV
8.5
SV
8.5
Ba
9 S
SV 8.5
W2.2d
W
1.8d
Wl.8d
W 1.8d
W 1.8d
Number
2
s
s
s
s
2
4
2
2
2
2
1
l
2
2
3
l
1
1
POWER
TRANSMISSION,
CLUTCH
Clutch, type
Size . .
Clutch friction
Relea'se lever play, vehicle with leH-hand steering ...
....
................
.......
...
....
.........
.....
area,
total
.............
vehicle wit right-hand steering . .
....................
. .
...
........... ..
. . .
...
..........
......
.......
...
...
....
REAR
Single, dry-plate, diaphragm spring
...
.
9"
.
468
cm.2
. .
. . . .
4-5
2-3
.
(72.5
mm
{.16-.20")
mm
AXLE
sq.in.)
(.08-.12")
0:9
GEARBOX
M
400
. Reduction
l st
..
2nd
: 3rd
4th
Reverse
ange
Fl
Lubricant
Alternative lubricant . .
Oil
M
410 (GEARBOX M 400
Reduction
Oil
Nut
Lubricant,
Oil
ratios
speed ....
speed ... .... .
speed
speed
capacity
pressure
for
capacity,
........
..................
..........
nut tightening
...................
viscos ity
ratio,
·,
direct driv
overdrive
driving fl
................
viscosity .
qua
iity
gearbox
:
overdrive .........................
ange ...
....
. . . .
..............
................
. . .
.............
..
.......................
torque
.............
at
- 100 C (140 F)
viscosity
.........................
. . .
.
continuous
,
......
. .
........
WITH
OVERDRIVE
e ................ ..
...................................
.. ..
.............
...
.....
and
overdrive ... . . . .
.
..................
.
......
. . ....
................
.....................
.........
..........
......................
air
....
...
............
. . . .
temperature bel
...........
...
.....
...
.. ...................
)
.........
....................
.. ..
. .
......
...........
................
...
.....
..
.. ............
..............
............
...
.....
...
ow
. .
.........
..........
. . . .
..
.
.. ..
. . . .
..
.....
.....
.. ..
. . .....
.
....
..
....
...
....
. .
.....
.......
3.14: l
.
1.97: l
.
1.34: l
.
l : l
.
3.54: l
.
11.0--14.0 kgm (80--101 Ib.ft.)
.
Gear
oil
.
SAE90
. .
SAE
80
. .
Engine oil
. .
SAE
30
or
SAE20W-40
approx
..
6 litre
(1.
0.797: l
.
Approx. 1.5 kg/
.
36-39
.
11.0--14.0
.
Eng,ine oil
.
SAE
.
.
Service
approx.
.
or
kg/cmf!
SAE
cm2 (21
{510--55O Ib/sq.in.}
kgm (80--101 IbJt.)
20 W-40
ML
or
higher
1.4 litr
es (2.46 Imp.pints=2.95
1 Imp.pints= 1.3
Ib/sq.in .)
US
pints)
US
pints)
PROPELLER
Type
Universal joints
Lubricant, sliding joint (when assembling)
REAR
Rear axle,
Track
FINAL
Type
Reduction
Backlash
Pre-Ioading
Pre-Ioading
Lubricant,
Oil
capacity
SHAFT
................
..... .
.....
......
AXLE
type
...
. ....
......
........
DRIVE
..............................
ratio
..........
on
on
..
......
viscosity
. . .
..........
.....
pinion
bearing
differential bearingls
...........
........... ..
..........
. . ....
...........
........
.........
.........
..........
.........
's,
...........
..........
...
. .
.. .......
. .
. . . ...............
....
new
bearings
run-in
..........
..............................
...........................
..
. . .
...
...
.....
...................
...
......
.....
.................
.....
...
...
..........
. .
....................
..............
bearing
,s ............
.
.......
........... .
.........
........
.......
.....
...
...... . . .
.
Tubular, divided,
support
Fitted with
.
Molybdenum disulphide chassis
.
Further
.
Semi-floating
1350
. .
.
Spiral bevel (hypoid)
. .
3.31:1 (13:43}
.
.13-.20
11-23
.
.
6-11
.13-.20
..
.
Hypoid oil
.
SAE
.
1.6 litres (2.82 I mp.pints = 3.38
bearings
needle
addition
mm
(53.15")
or
mm (.005-.008")
kgcm
(9.55-20
kg:cm
(5.21-9.55
mm (.005--008")
90
not
3.73:1
three
universal joints,
bearings
required
(11
Ib.in.)
Ib.in.)
:41)
grease
US
pints)
TIGHTENING
Flange .
Caps ..........
Crown
.....
.......
wheel ...
O: 10
TORQUES
......
.........................
. . .
....................... .
.....
............
...
....
..............
...........
......
...
....
Kgm
28-30
..
.
..
.
5.0-7.0
.
6.5-9.0
LbJt.
200-220
35-50
45-65
BRAKES
FRO·NT
Type
Brake discs:
Thickness,
Warp
Brake
Nu
T
Wheel unit c
Number
Diameter ...
REAR
Type . ....
Brake discs:
Outside
Thickness,
Warp
Brake
T
Effect
Whe
N
D
WH
....
Outside
. ....
li
nings :
mber
per wheel ... ...
hi
ckness,
Effecti
ve
per wheel ..................
WH
..................
linings:
Nu
mber
hi
ckness,
ive area ...
el unit cylinders:
umber per
iameter ...
EEL
BRAKES
..........
diameter
new
reconditioned ...........
............
new
area ....
yli
EEL
....
diameter ... ...............
new ...
reconditioned ...... . . . .
per wheel .........
new
...................
...........
. . . .
......
. .... .
......
. .... . ....
nders:
..................
....
. . .
....
. ..................... .
....
. .... .
...
........
..........
BRAKES
. . . . . . .
.......
. .... . .
....
. .
...
......
.
..........................
. . . . .
........................
....
...
...
. .
.......
wheel ...........
.............................
...........
...........
........................
.....
........
... ......
........
. .... . . . .
.
.........................
......
.....
.. .. .....
...
...
......
.................... . .
. . . .
......
..........
... ...........
....
.....
. .
..............
....
........
. .......
. .... .
. .... ............
. .
...
......
.
............
. .......
...........
..
.......
........
. .
. . .
.....
...
. . .
...... . .
. .
.........
...... . .
........
...
...
....
.
.....
....
.
Disc
brakes
.
272.2 m m (10.7")
.
12.7- 12.8 mm
..
.
Min. 12.2 mm (.480")
..
.
Max
. . 10 mm (.004")
. .
2
. . .
10
mm
..
.
174
cm~
. . .
4
.
.
.
..
.
36.12
Disc
294.6
9.6
mi
n.
max
mm
brakes
mm
9.1
..
2
10
mm (.394
.
93
cm2 (1
.
2
36
.12 mm (1.422
.
(.394
")
(27.0 sq.in.)
(1.422")
with AS.B.
mm
(
1l.6
(.378")
mm
(.358")
15
mm (.006")
")
4.4 sq
(.500-.504"
")
.in
.)
")
)
device
MASTER
Nominal
Bore
Piston
BRAKE
Outer
BRAKE
Make.....
Operating
SERVO
Make.... . ....
Designation
TJGHTEN
Attaching
Attaching
Wheel
Stop screw,
Attaching
Venting
Brake
Warning
Brake
Plug,
Lock nut,
CYLINDER
diam
eter . .
.......
. . . .
diameter
LINE
diameter
VALVE
.....
pressure
CYLINDER
.. .. .....
...........
·ING
bolts,
bolts,
rear
nuts . .
hoses
pipes .......................
brake
..........
master
nuts,
master
nipples
...
......
valve, switch .
valve ...............
brake
............
.....
.. .........
.. .................
...
. .... . . . . . . .
...... . ...........
. .
. . .
. . .
...
.......................
.............
......
................. . .
....
. .
................. . . Ate
....
. . . . . . . . . . .
. . .
TORQUES
front
brake
caliper
brake
caliper
....
cylinder
...
............... ..................
valve
. .
cylinder ...... ..
......
.. .. ..
...
. .
......
. .
.. ..
. . .... . . . . . . .
. . .
. . ....
. ....
...
............
........
...........
.......
. .
...............
.............
...
. .... .... . . .
..
............
............
........
.....
...
........
...
....
....
. .
....
. .
...
. . . .... .
. . .... . . .
.........
.....
...
.. ..
. . . .
. .....
.......
.. ..
. . . . . . . .... . . . .
.. ..
.........
...........
...
.....
...
..
....
. . .
. . . .
...
. . . .
. . .
. . .
.
23.81
Max
. 23.92
Min. 23.66
3/16"
50±2
Ate
Bromsgerät T 51
Kgm
9-
10
6- 7
10-l4
.
.5---.8
1.
2-1.5
.
0.
4--0
1.6-2
1.4- 2.0
.
1.1-1.5
.
10-12
2.5---3.5
mm (94")
mm
mm (.93")
kg/cm2 (711
.6
.0
(.95")
±28.4
Ib/sq.in.)
Lb.ft.
65---70
45-50
70- 100
3.6-5.8
8.7- 10.8
3.
0-4.5
12- 15
10-15
8-
11
70-85
18-25
o :
11
FRONT
END
AND
STEERING
GEAR
WHEEL
Caster .....
Camber . . . .... . . . . . .... ......... ~ ..
King
Toe-in . . ....... . .
Turning a
Shims
MECHANICAL
Steering wheel diameter .
ALl
GNMENT (
...
....... .
pin
inclination
ngl
es :
at a 200 turn of the outer wheel the
t
urn
ed
21.50 to
23.5
, thickness . .
STEERING
UNLOADED
...... . . .
at
a camber of 0
.............
0
•
...........................
.....................
0
....
. : ...
GEAR
....
....... .
VEHICLE)
......
•••
.••.•••
.. ..
inn
er whee
........
. . . .... . '"
• • •
. .
...
. . .
..........
.............
Number of turns from stop to stop in vehicle ... . . . . .
ing
Steer
Ball
him
S
Lubricant
Oil capacity .....
gear:
Make . .
Type .................... .
.........
. . ....
.....................
.................
Reduction ratio, centre position . .
Cl
earance
s .
, steering shaft-bus
diameter, bearings .... .
ball nut
...........
........
...
. . . .
.........
.................
........
hin
g,
...
...........
......
..
...
..................
. . ....
...
..............
new
part ...
wear
limit .............
. . .
........
. ....
.....
......
....
.. ...........
. ...............
. ...............
...........
.....
. .
......
•••
• •
••••
...
.......
l should be
. .
....... .
.......
. . .
.......
.........
...
. . .
...
. .... . .
....
...
. .
......
. .
o to + 1 °
.
O to +0.5
7.5
.
O to 4
.50
1.0
3.0
6.0
.
423
4.8
.
Burman
Cam
.
.
18
.
.025--.063
.
.18
7.14
7.
.
th
th = .127
th
Hypoid oil
.6
0
.15
mm
mm.
mm
mm
mm
mm (16.6")
and bal
.3: 1
mm
mm
93
mm (.3
= .05
=
.254
litre
mm
(
.006
(.0
(.039")
(.118")
(
.236"
(.007")
(.28")
mm
mm
mm
(1.1
0
20")
(O
to 0.16")
")
)
,l
nut
mm (.001
1")
(.002")
(.005")
(.010")
Imp.pint=
0-.0025"
1.3
US
)
pints)
SERVO
Steering wheel diameter . ......
Number of turns from stop to stop
Steering
STEERING
gear:
Make and type
Reduction ratio
...
....
....
..........
in
vehicle
...
.......................................
.... ....
. . . .... .... .
.......
...
Servo pump:
Make
and
type
.............. . . .
Max. pressure .
Theoretical capacity
Min.
capacity,
,(
1760 F)
Regulated capacity
Drive .
Ratio,
...............................
engine-pump
Oil type .
Oil changing quantity . .
TIGHTENING
....
.................
at
500
r.p.m.,
.................
..................
..................
.........
..................
...
TORQUES
500
...
. ...................
Attaching bolt for upper wishbone shaft
Nut for upper wishbone shaft
Nut for steering' wheel
Nut for pitman arm ....
Lock
nut for tie rod
Mechanical steering
......... ...
..............
........................
gear:
.......
r.p.m.
....
50
kg/cm2 (711
......
..........
.................
........
..........
...
......
............
Ib./sq.in
...............
...............
.....
....
.....
. . . .
....................
.
..... ..............
......
...........
..
...................
...
............
Screw for steerin9' box screw cover ................
Screw for stop plate
........
. .
.. ..
.............
.......
. . .
.. ..
..........
........
.........
.},
.
.....
. . ........
........
...........
.....
....
...
80
....
.....
.....
423
.
..
.
3.7
. . .
ZF,
15.7: 1
. .
ZF,
. .
...
.
75±5
.
6.65
0
C
..
.
4.5
. .
5--8
pints =
.
With belt
. .
1 : 1
. . .
Oil
Transmissions, Type
.
Approx.
Kgm
.
4.8-5.5
..
.
5.5--6.2
. . .
3-4
.
17.5--20
.
7.5--9
.
1.7-2.1
.
1.7-2.1
mm
(16.6")
ball nut
vane pump
kg/cm.2 (1066±71 Ib/sq.in.)
l/m
(12
Imp.pints= 14
l/m
(8
Imp.pints=
l/m
(9
Imp.pints= 10.5
17
US
approved
9.5
US
pints/minute)
as "Oil for Automatic
A"
1.2
litres (2.
11
Imp.pints=2.53
US
pints/minute)
pints/minute)
US
pints -
Footpound
35--40
40-45
20-30
125--145
55.-65
12-15
12-15
14
Imp.
US
pints)
(ft.lb.)
o :
12
SUSPENSION,
SPR
ING
S
FRONT
Type
Wire
Externai
No.
Test
REAR
Type ...............
Wire diameter ...... . ....... . .... . _ ... . .
Extern
No.
Test
SPRINGS
.............
diameter
diameter .........
of
effective turns . . .... . .... ....
values
:
Load
ing for a
a
spr
ing l
ength
Le
ng,th, f ully co
Lengt
h, wh
SPR
INGS
a i d ia m
of
effective
va·1 u
es:
Loadin
g (fo r a
Len
gt
h, fully
Load/~pr
ing
. .
.....
.....
...... ..
compression
of 185-205
mpressed
en
loaded
eter ... . .
compressed .... .............
l
eng
with
...... . .....
...
turns
. .
compression
th .
....... . . .... .
. .
...
. .
...
......
............ . . . . .....
. ....... .
. .... .
. .
....
of 1 cm
600-630
....
. .... . . . .
......
.. .......
(25/641/)
9
/
mm
= 7
22
...
. . . . .... . ............
kg (1320- 1386 Ib.) .
. .... .
......
........... ....
of 1 cm
= 25/
...
- 8'/
.....................
....
. .
.......
....
. ......
. .......
........
. ..........
641/) ....... . .... . .
. .
......
....
. .
...
(measured
'6)
.....
.. ......
. . .
......... . . . .
.. ..
.. ..
. .
...... .
within
........
... ...
.......
...
. . .
WHEELS
...
. .
Helical
15.5 mm
. . . .
125.7
. .
5
6
.
61
max. 127
. . .
195
..
.
He lical
.
12.0 mm (
. . .
127.0
.
2
.
8
15.7- 16.7 kg (34.5---36.7 Ib.)
max
201
..
.
spring
(.611/
)
mm
(4.95
1/)
/
6
.9- 65.9 kg: (136- 145 Ib.)
mm
(5.01/
)
mm
(7.
61/
)
spring
,471/)
mm (4.91/
/
3
. 114
- 216 kg/283 mm (442-475 Ib.)v'l1,4
mm.
(4.
)
51/
)
1/)
SH OCK AB
Type .
Totallength
front
rear
SORBE
...... . . . .
:
shock
sho
ck
absorbers,
abs
RS
...........
orb
ers,
compressed ....
unloaded
compressed
unloaded
WHEELS
WHEEL
Type ......
Designation .....................
Radial
Warp
Imbalance,
Tightening
TY
Type ... .... . .... . . . .
Size .
throw
...... ......
RES
............
RIMS
com.pl,ete
torque
...
.. ..
....
..................
. . ....
.......... ...........
.. ..
......
wheel
for
wheel
...
. . . ............. . . . .
..........
. . . . . .... . . .
. . .....
.. ..
........
nuts ....................
. . . . . .
. . . .
. . .
.....
.
..............
...
............
...
...........
.. ..
. .
....
. .
...............
....
. . .
.............
....... . . . .
. . .
...............
. . . . . . . . . ....
..
...
. . . . .......
. . .
.................
.......
.. .......
....... . . .
...
.
..........
.. ........
.....
.......
.
.........
..
. . .
. . .
..
. .
. .
.
.
.
.
.
.
.
.
165 S 15-4
D
oubl
e-a
appro
x. 223
approx.
approx.
approx.
Disc
J X 15 L
4.5
max.
1.6
max.
1.6
900 g.
Cln
10--14
Tubeless
165
SR
15-4
6.85-15-4
cting, hy
mm
340
mm (13.
279 mm
443
mm
mm
(.063")
mm
(.0631/)
{7.8 Ib.in.)
kgm
(72-101
PR
PR
(USA)
PR
draulic, tel
(8.781/)
391/)
(10
.98")
(17.44")
Ib.ft.)
escop
ic
o : 13
Part 1
SERVICING
AND
MAINTENANCE
CONTENTS
Instructions
Engine . .
Gearbox (wit
G
earbox (wi
Automati
Final
Steering box, mechani ca l steering .... . . . . . .... . l : 3
Servo steering .
Check ing the
Instructions
Di
stributor ...
Body ........
bricating
Lu
for
oil level checking
...
. .
...
hout overdriv
th ove
c transmission . .
drive
. . . .
......
...... . ..... ..............
brake
for lubricating
.. .. ..
. .... . . . . . . . .......
chart
and
changi
ng ... ........
. ........
rdriv
. . . . . . .
...... .......
e)
. . . . .
...
...
. .... .
e) ...
. ....
......
... ......
.......
.......
......
. . . . . . .... ..... ..
fluid
level ... . . . .
......
. . . . .
. . . . . .... . . . . . . . . . . . . .... . l : 4
........
......
...
. . .
....
. . . .... . . .........
. .....
......
. .
....
......
. . .
.......
..
....
. . l : 4
. . .
. . . .
..
. . . l : l
...
. . . . l : 2
. . .
..
. . . . . . l : 3
. . .
l:
l : l
l : 2
l:
l : 4
l:
l
3
4
LU
BRICATION
ENGINE
With a new
be
changed
Subsequent
every
10000
following
The
intervals
to a very
of
used.
marily
dem:anding
driving
ing
l
engl~
10
ing
engine
20/20 W
every
a
year.
The
has
For
the
plug
the
As
Service
Concerning
primarily
great
the
engine,
Concerning
recommended.
in
and
stopping
hy
periods.
W-30
(
multigrade
takes
oil with viscosity SAE
or
5000
oil
should
been
this,
use
oil
has
tiglhtly
rocker
is
shown
MS"
INSTRUCTIONS
or
reconditioned
after
the
chang
.ing
km
(6000
conditions
operating
city
for
extent
oil
traffic
:
changing
grade
viscosity
This
uninterrupted
and
For
),
10
place
every
30
is
used,
km (
3000
be
drained imme
driven
and
the
oil
drain
run
out,
check
into
position
arm
casing
above,
is
viscosity, multigi
recommended.
used
an
for
on
conditions
engine
10000
miles
while
eng
first
2500
should
miles},
eng.ine
the
"For
a
type
with
normally
however,
oil
used.
Service
mu
of
oil
the
oil with viscosity SAE
W-40
or
km
10
the
oil
should
),
however,
diately
the
eng:ine
plug,
see
the
washer
again.
Oil is.
after
removing
engine
subsequen.t
At
oil with
rade
very
FOR
AND
.ine,
the
oil
should
km
(1
500
mile$l).
take place
under
oil
are
dependent
For
lubrication
MS"
should
lti
grade oil
is
better
such
as
by
frequent
en9Jine
20
W-50,
(
6000
W (
at
Fig.
and
added
the
topping-up.
oil SAE 10 W-3D
low
is pri-
suited
continuous
start-
idling
oil
chang-
miles).
If
singlegrade
be
changed
least
twice
after
the
is st
ill· warm.
1-1. When
screw
through
filler
grade
temperatures
Oll
lEVEl
CHANGING
the
be
for
F
ig.
for
(be
low
an
),
ear
all
the
cap.
"For
is
-200 C
ties
are
recom.mended.
If
multigrade
SAE 10 W
- 100 and
above
300 C
tempe
rature.
(9.15
Imp.pints=
quantity
(10.56
Imp.pints=
CARBURETTORS
Every t·ime
the
centre
checked
(
1/4/1)
from
ca
se,
oil
sions,
Type
CHECKING
1-2.
Checking
=_40 F}
anticipate
oil
below -100 C (140 F),
+300 C (14
(860 F)
The
when
the
spindle
to
see
the
approved
A"
d, m
is
not
" all· this
quantity
10.97
the
oil
12.66
eng,ine
that
edge
as
should
the
or
US
filter
US
oil
of
it
of
"Oil
be
oil
ultigrade
used,
and
pints).
is
the
reaches
the
used
VOLVO
103240
level in
centre
when
col:d~
startin9
oil SAE 5
the
viscosity should
SAE 20/20
860 F)
and
presuming a stable
of oil
changed
pints
).
The
correspondirrg
is
included
chang,ed,
carburettors
spindie.
for
up
to
If
Automatic
for
filling up.
the
this is
spindle
difficul-
W-20
be
between
SAE 30
is 5.2 litres
is 6.0 litres
oil leve!.
should
about 6 mm
not
the
Transmis
for
air
be
is
in
-
Fig.
l-l.
Drain
plug
on
sump
VOLVO
1
03239
GEARBOX (
In
the
ca
se
oil s
hould
be
af
ter
the
first
subsequently
(
25000
miles).
The
oil
should
ear
has
been
When
draining
and 2 in
Fig. 1-3.
WITHOUT
of a new
changed
5000
km
be
changed
be
drained
driven
and
the
oil,
OVERDRIVE)
or
reconditioned
and
the
(3000
miles
after
off
immediately
while
remove
gearbox
}.
every
the
oil
the
plugs
gembox,
flushed
The
is
oil
should
40000
after
still
marked
the
out
the
warm
l : 1
km
.
1
The flushing o
(l
,~.fig.
1-3)
bbcick
into
position. The
~
..
to run
for a few
.-
gaged
engine
lower
ed
and
shou
and
WARNING!
wheels
of a vehicle
be
iacked
wheel
in
contad
can
topple
oH
Fill
up with
screwed
reach
tightly
Gear
round.
below
tightly
up
back
oil SAE 90
Where
100 C (140 F),
Alternately
multigrade
round
.
The
oil
chang
US
pints).
Fig.
1.
F
ill
er
il
is
after
the
minut
both
the
ld
then
the
oil
drained
On
no
accou
equipped
up
since
this
with
the
iack.
new
oil
af
back
the
filler
into position.
is
used
the
SAE
can
engine
oil
SAE
,ing
quantity
1-3.
Gearbox
plug
2.
Drain plug
added
through
drain
eng,in
e s
es
with
rear
wheels
be
stopped, the
plugl h
as
hould then
one
the filler!-'
of
jacked
out.
nt must only
with a
transfers
the
ground
ter
the
drain
one
differential
torque
so
that
plug
into position. The oil
hole
(l) . .
Screw
the
for
the
gearbox
air
temperature
80
should,
however,
oil with viscosity
20
W-40
be
used
is
.6
litre (l. T Imp.pints = 1.3
hole
beenc serewed
be allow
the
gears
ed
en-
up. The
rear
wheels
of
the
rear
brake
to
the
other
the
vehicle
(2)
has
been
should
filler plug
all
the
year
is
continously
be
used.
SAE
30
or
all
the
year
GEARBOX WITH OVERDRIVE
In
the c
ase
of a new
shou
ld
be
changed
The
oil
sho
uld sub
40000
km (25000
The
o
il
shou
ld
ear
has
been
To
do
this
remove
as weil
1-3
1-4.
Al
43
B.
Fil
l with
1-4. Al
the
oil
dr
ive. The oil
Screw
1-3).
For a
as
so
clean
new
so clean the oil
an
opportun
the filte r plug
gearbox
sit Y SAE 30 is
tive,
multigrade
changing
US
quant
pints).
AUTOMATIC
Normally
when
on
10000
The
lever
speed.
paper
rags.
level.
a
warm
sion, which
miles)
lower
oil
the
transmission
the
other
km.(6 000 miles).
vehicle
to
should
position
Wipe
or
chamois
Insert
the
See
Fig. l-S. N.B.
or
cold
is
the
uppe
section
or
reconditioned
af
ter
the
first
5000
sequent
ly
be chang
miles}.
be
drained
driven
the
the
cover
the
oil
oil
af
ity
should
with
used all
oil
SAE
ity is 1.4 litr
off
immediately
and while the
plugs
marked l and 2 in
for
the
strainer
ter
strainer
of
reach
on
overdrive,
the
as
the
drain
as
flowing
up
to
tightly.
engline oil with visco-
year
round.
20 W-4Q
es
T~ANSMISSION
changing
hand,
off
only needs
is
reconditioned.
should
stand
"P"
and
the
leather.
be
level.
let
the
dipstick with a nylon
Do
not
checked
dipstick, pull it up
There
are
transmission.
the
case
,r
section
(l
and
2, Fig.
after
applies
For a
driving
(3
1-5)1
gearbox,
km
(3000 miles).
ed
after
af
oil is st
oil
strainer, see
indicated
plugs
indicat
over
the filt
can
ill
in
have
ed
in Group
into
the ove
er
hole (l,
As
as alt
be
used. The oi l
(2.46 Imp.pints
to
be
carried
The oil level,
af
ter
Move
the
engine
run
at
use
waste
or
and
check
different
and
applies
war
m transmis-
8-10
4,
Figl.
to a cold
levels
km
the
every
ter
the
warm.
Fig.
Fig.
group
been
Fig.
erna-
-2.95
out
every
seleetor
idling
doth,
fluff y
the
for
(5--7
1-5)_
The
oil
r-
oil
1 : 2
Fig.
1-4.
Overdrive
Fig. l-S. Checking the oil level
1.
Max. oil level, cold fransmission
2.
Min. oil level, cold fransmission
3. Max. oil level, warm fransmission
4.
Min. oil level, warm fransmission
VOLVO
103243
Fig. 1-6. Filler plug on final drive
transm
ission. The
you
of
this.
If
necessary, fill
the "Max
can
The
is
Aut
If
ind i
te
ly.
FINAL
With a new
hould
s
mil
only
Oil chang;ing s
after
still
drive,
can
this
ord
Check
otherwise
When
drain
Then run
wheels
lower
warning
" mark. Do n
cause
difference
abo
ut 0.5 litre
omat
ic
frequen
t f illin g up is fo und
cates leakoge
DRIVE
be chang.ed
es).
Oil
when
the vehicle
warm
. As
the
olso
be
case
the
er
to pre
that
repface
about
plug
the
jacked
the
give'n un
text
up wit h o
the
transmission
between
(l p int }. For
Transmissions, Type
which must
or reconditioned
chang
,ing s
overhauling
hould pre
has
there is
oil
is
sucked
emptied
utmost
vent
dirt
the
cover
it.
to
flush
and
fill
engine
up
and
vehicle
der
overdrive" applies al
After
the
drain
plug
new
with
hole
pints=3.38
drive
air
however,
A final
oi/. The oil
and
the
US pints). For
hypoid
temperature
SAE 80
drive
oil
capacity
oil SAE 90
is
continuously
should
fitted with a
on
the
il
ot fill
the "Min
after
the
houl
;d
is
bei
ferably
been
driven
no
up
throug
by
removing
cleanliness
from g!etting
gasket
the
final
new
oil
for
several
with a
and
dmin
the
section "
so
when flushing
or
cover
should
is
about
chang,ing
is
normal/y
be
used.
differential
VOLVO
1
01822
dipMick will a,lso
until
the
level
above
this
mark,
to
becom.e
topping~up,
A".
to
be
final dri
first S 000 km
therefore
ng
don
be
and
drain
lh
must be obs
is
drive,
through
minutes
gear
off
overheated.
and
"Max" marks
use
be
necessary,
put ri
gnt immedia-
ve,
be
carried
e.
done
imme
while
plug
on
the
filler
, the cover
into
the
final driv e.
in
g,ood
screw
the fill e r
with
engaged.
the
oi/. N.
the oil
the
condition,
tight
After
Gearbox without
the
final drive.
has
been
refitted,
reach· up
below
to
the
1.6 litres (2.82 Imp.
the
oil
in
used.
Where
_ 100 C
brake
remind
rea
·ch
as
"Oil
the oil
(3000
diately
final
hole.
but
erved
hole.
the
B.
filler
the
final
(140 F),
is
fil/ed
es
this
for
this
out
the
rear
this
The
fill
the
i
Fig.
1-7.
Steering box filler plug l
at
the
factory
requirements
L-2l0SB
with
differential brake.
and
when changing,
having
shou
ld
i
nterva
ls
witho
ut a di
STEERING
Norma
l/y it is. not n
eer
ing gear exc
st
arri
ed out.
c
chang;ed
by
using a
s
yring
,e, which
teering
is
It
in
in
the s
Hypoid
the ye
The oil
pint
s = 1.3 US
ar
SERVO
CHECKING
The oil
with a
of
the
provided
the
above-mentioned
be
checked
and
in
the
fferent
BOX,
However,
for
any
suitable
is
gear
oil
SAE
80
round.
capacity
of
pints).
STEERI
levet should
THE
NG
OIL
transmission
American Mil
with
an
additive
For su
oi l
is
according
additive.
and
the oi l
same
way
ial
brake.
MECHANICAL
ece
ssary
to chan
e pt a ft e r
reason,
inserted
can
is
the
LEVEL
Fig. 1
reconditionin
should
the
old
device, f
through
also
be
removed
used
for the
steering
be checked every
-8
. O
il
level
changled
gear
VOLVU
03244
oil which
itary
Standard ,MIL
for
final
bsequent
as
topping
to
MIL-L-2l0SB
The oil level
at
for a final drive
STEER'ING
ge
the o
g h
the oil
or
can
exampl
the fil/
ste
is
have to
be
sucked
e,
er
and
ering g
.6 lit
re
la
VOLVO
103245
meets
drives
the
s.ame
il
in the
as bee
an
ho le,. or
em.ptied.
ear
(1.1
Imp.
000
the
.-up
be
out
oil
all
km
,
<
n
1 : 3
(6000
miles). First
standing
should th
level mark.
with
being sucked in.
level, which
see
should
mark
Oll
NormaHy
with
see
the
CHECKING
Every
the
mark.
cap.
cl
utch fluid c
to
check
en lie
If
the l
the
eng.ine s
should
Fig. 1-8.
.
rise
When
to
CHANGING
the
replacement
Part 6 of
filter
in
the
THE
10000
km
master
cylinder con
This
check
On
righ
t-hand
ont
check
possib
abo
ut 5-10 mm (5/8")
evel is
tanding
Start
about
oil
of
this Service
oil
the
now
hav~
the
engine
5-10
should
the
container
to
servo
BRAKE
(6000 miles}
tainer
can
be
made
steered
a i
ner
is almost full
the
level with
le oil loss. The oil l
lower than
eliminate
eng
,ine
and
fallen
has
mm
be
changed
steering.
Manual.
should
FLUID
check
reaches
without
veh
icles,
.
this,
the
recheck
to
the
stopped,
(5
/8")
in
components,
On
this
also
be
LEVEL
that
up
taking
check
a l
the
above
fill
with oil
risk
level
the
above
connection
occasion,
chang.ed.
the
fluid In
to
the leve
off
so
that
engine
eve
the
of
air
the
oil
mark,
level
the
the
the
l
l
If
necessary, top
meets
the
Cl
ean
the
observe
sp
damage ii'
in
ill
the
ing
the g,reatest
brake flu
cap
Fig. 1-9. Brake fluid
up with first-class
requirements
master cyli
id
on
. Ch
eck
to
is
not
block
con
accord
ing
nder
cap
before
cleanliness wh
the pain
make
ed.
twork sin
sure th
tainer
bra
ke fluid which
to
SAE
removal and
en
filling.
ce
at
the
vent
70 R
Avoid
th is wi
ing hole
3.
ll
DISTRIBUTOR
After
every
la
shaft,
cam
and
l . Lubricating wick 2. Cam disc 3. Oil cup
I NSTRUCTIONS
000 km
ignition
Fig. 1-10.
(6000
advance
Distributor
miles)
mechanism
the
VO LVO
103247
distributor
should
FOR
be
filling
filling,
cam
grease,
ignition
pouring
.
the
BODY
To
should
buttons
approx. every
of
winter
locks
which
LU
BRICATI
lubricated.
the
oil
dose
disc
should
Bosch
advance
2- 3
wick (l)
avoid
the
in
squeaking
be
of
body
the
should
would
The distribu t
cup
(3,
the
cup. The
be
Ft
l v 4,
mechanism
drops
the
distributor
lubricated
the
door
10000
about
door
handle
be
lubricated
prevent
NG
or
shaft
is
lubricated
Fig. l -la) with
contact
lubricated
or
corresponding
should
of
light
engine
shaft
ond
unnecessary
as
described
hand.le
km
(6000
once a year. Moreover,
lug.g,
with a
them
from
engine
surface
with a thin
be
oil
(SA
.
wear,
below
should
miles}
age
be
and
compartment
suitable
freezing
greas
lubricated
by
oi!.
After
{2)
of
the
coating
E 10
. The lock
lubricated
other
e. The
W)
the
body
parts
during
lock oil
up.
of
by
on
lid
1 : 4
la
11
la
13
12
la
11
la
No. Lubricating point
l Bonnet catch
.................
2 Bonnet hinges . . .
3 Ventil
4 Stri
ation
hinges
ker
window
........................
plate ...... . ....... . .
5 Roof opening wind
6
Door
handle lock buttons .
Keyhol
es
....
...
7
Outer sliding surface
lock
...........
....
.......
catch and
defledor
. .
..........
of
door
............
Fig. 1-11. Lubricating points
Lubricant
.
Petro leum jelly
. . .
Oil
.
Oil
See
..
...
...
. .
..
..
Fig.
.
.
Oil
Petro l·eum
.
Oil
Petrole u m; je Ily
.
1-l3
jelly
on
the
body
No. Lubricating point
8
Lug
lg,age
compartment
9
Luglgag
:e
compartment
Keyholes . .
la
Door
11
Door
12
W i
ndow
Locks
(Accessible
tery
13
Front seat slide rails and catches
..........
stops ... .
hinges
winders
..........
...
.................
.............
. . . .... .
after
the
. . .
door
panels have been removed.)
lid hinges
lid
lock
.........
........
......
uphols-
Lubricant
Oi
l
..
Oil
.
Oil
.
Petroleum jelly
.
Oil
Oil
. .
and grease
.
Si~icon
Petro leum je
and oil
g,rease
lly
VOLVO
101827
de plate
Fi
g.
1-12
. Hinges
1. Hinges (light oi
2. Door
stop
3.
Hinges (light oil)
(petroleum je
'/'OLVC
102965
Fig. 1-13. Striker plate
Inn
er
sliding
sur
l)
lly)
lubricated with molybdenum di s
faces, spring
and
pin a
ulphide
re
grease
Fi
g.
1-14.
Apply petroleum jelly
Door
lock with gui
1 : 5
'1
INSTRUCTIONS
SY
MBOLS
Engine
D
c
~
~
•
Oll
CHANGING
Engine" oil c
Gearbox,
Final
drive
Stee
ring
oil
Grade:
Viscosity:
See
Final drive oil
Grade:
Viscosity:
Does
brake,
Lubricant,
Light
Brake
Grade:
"For
Multigrade
also
page
Hypoid
above
below
not, apply
see
see
engine
fluid
SAE 70 R 3
hang
quantity
including oil
filter
gear
.ing
with
out
overdrive
with
overdrive
a utom atic
transmission
FOR
LUBRICATING
Service MS"
page
oil
QUANTITIES
SAE
1 : 1
oil
- 100 C (140 F)
- 100 C (140 F)
to
final
1 :
3.
respective
approx.
(9.15
US
pints)
approx.
(1
0.56
US
pints
approx
(1.1
approx.
(2.46 Imp.pints=2.95
approx.
(14.43 Imp.pints= 17.30
US
pints}
approx.
(2.82 Imp.
US
pints)
approx
(2.11
10
W-30
SAE90
drive
note.
Imp.pints=
Inm.pints=
.. 6 li
Imp.pints = 1.3
Imp.pints=2.53
SAE
with
5.2 litr
es
6.0 litr
es
tre
1.4 litr
es
8.2 litres
1.6 litres
pints=3.38
1.2 litres
10.97
CHART
80
differential
12.66
US
pints)
US
pints)
US pints)
NOTES
Not
e 1.
Note
Note
Note
Note
Note
Note
Note
Note
In conn
tions
ings,
cleaned,
class
structions
Subsequent
in
place.
2.
Check
3.
Check
with
l
4.
Lubricate
the
5.
Every
oil
40000
changed (mechanical
N.B. The
on
and
Check
6.
chang
Ch
7.
to
Change
8.
tions
Every
9.
o
Concerning lubricant
with
ection with such
involving.
the
durable
addition
the
the
right-hand
eve
!.
See
instruction
10000
reaches
km (25000
the
1 :
2.
the
ing
ange
the
instruction s
on
10000
il
reaches
differential
bearings
and
in
filling
to
oil level.
brake
page
the
up
grade
type
oil l
the
the
the
page
up
uncovering
then
g'rease
Groups
or
the
above should
fluid l
steering
1 :
4.
distributor
on
page
km (
6000
to
the
miles)
of
oil
of
gearbox,
evel in
engine
oil filter
in
oil
according
1 :
1.
km (6000
to
the fill
brake,
workshop opera-
the
should
fubricated
46
replacement
See
evel and,
filler plug.
gearbox
the
oil,
complete
Part
be
according. to
and
77 respectively.
page
, al
so
the
in
accordance
1 :
4.
miles)
check
the
oil
).
to
be
used
see
carburettors
see
2.
to
miles}
check
er plu
g.
for
the
see
page
wheel
bear
removed,
with high-
the
of
grease
not
1 :
3.
for
vehicles
clutch fluid
that
After
every
should
depends
pages
when
page
1 :
ly
according
the instruc-
that
final drive
1 :
3.
-
in-
take
with
the
be
1 : 1
1.
the
OTHER lUBRICATING POINTS
In
addition
chart,
year
handbrake,
CHECK
THE
FUEl TANK
1. The oil level
2.
That
above
without
hand
tainer
3.
That
marks
4.
That
is filled.
About
be
carried
1. The
2. The e l
to
the
chassis
at
all
the
pedallinkages
THE
FOllOWING
the
the
removing
steering,
is
almost
the
on
the
fluid
every
out:
tyre
pressure.
ectrolyte level
the
points
indicated
should
joints
in
the
level·
"Min." mark. This
check
full.
coo
lant
the
expansion
container
other
for
eng1ine.
in
the
the
leve~
week
be
the
etc.
WHEN
cap.
also
the
in
the
brake
tank.
for
in
greased
throttle
FllLlNG
fluid
check
On
vehicles
that
the
is
between
the
windscreen
following
battery.
the
lubricating
about
container
can
be
with right-
the
checks
once
linkage,
"Max."
washer
controi
clutch fluid
made
con-
shou
a
is
ld
LUBRICATING
CHA'RT
164
Wheel
bearings
Note
l
Steeri ng
Note
2
Brake fluid
container
Note
3
gear
lubricate
after
every
~
c
CD
Jl
..... ~ _
E.!
~'e
~§
'-'0
___
-.:
~~
..
Lubricafe
after
evety
O)
E.!
~
.-
ö
E
c
O)
Q)
~§
'
V)
....
'00
Wheel
I
bearings
Note
l
Carburettors
Note
6
Oil
filter
Note
7
Distributor
Note
4
Gearbox
Note
5
Wheel
bearings
Note
l
...... -_____
i.
. I . .
O
•
Engine
·Ndlte 8
Final
Note
Wheel
Note
drive
9
bearings
l
Part 2
E NG I N E
Tools
.............
Group 20. General
Description
Repair Instructions
Removing
Installing
Oil sump
.........
the
the
....
engine
Group 21. Engine
Description
Repair Instructions
Dismantling
Assembling
Valve
Cylinder
Cylinder
Pistons, pi
Connecting
Cran
Repl
Repl
Repl
Posit
....
the
the
grinding
head
block
ston
rods
ksh
aft
. ...........
acing
crankshaft
acing
oil
sea
ac
ing the timing g·
ive crankease
(ONTENTS
....
............
.....
..........................
engine . .
.........
.......
....
.............
.......................................
engine
engine
and
and
.............................
rings
. . ....
l,
...............................
.....
decarbonizing
valves
andgudgeon
.....
. .....
rear
timing
ears
ventilation
............
.......
............
......................
................
.................
.
...........
. . ................
......................
.....
....
pins
. .
.......................... 2:
. ...............
oil
seal
. .
gear
casing
. . .
...........
.......
..
.
....
...
...
.......
.................
.
.............
......
.. ..
...
. .
.........
...... . .
. .
....
. .
...........
...
. .
..... 2:
. . .
....
..........
.
........
.........
..........
. . . .
..... 2:
.. .......
.
..
.......... 2:
.
..
...
.. .. ... 2:
......
. .
..
.... 2:
.......
2:
2:
2:
2:
2:
2:
2:
2:
2:
2:
2:
2:
2:
2:
l
3
4
4
5
5
7
9
9
9
10
11
12
13
14
14
15
16
17
18
Group 22. Lubricating System
Description ....
Re
pair Instructions . .
Group 23.
Descriptio n
Repa ir
In
struct ions
Periodica
Ad
Remed
Fl
Air
Fuel p
l checking
justin
g the
ying faul
ap
housing, a ir preheating ....
c1
eaner
ump ...........
Fuel
.......
carburetto
. . .
................
..................
System
...... ..
.......
...........
ty carbur
.........
ettor
......
rs ..........
. .........
Group 25. Cooling System
Description ........
Instructi
Repa ir
ons .
...
.................
...........
..
. .
...
. ......
. .
..
: .
....
. ......
. . .... .... . . .
functi
on
. . .
.. .....................
.......
. ................
. . . .... . . .
........
. . ......
. ..........
...................
..........
.............
.....
. .
...
.......
. .
...
.
.........
........
. . . .... .
....... . . .
. . .
. ....
.....
......
. ......
.....
..
....
......
. .
...
. .
. . .
...
...
...
..
.
2:
19
2:
20
2 : 23
2:
29
2:
29
2:
30
2 : 30
2 : 33
2:
33
2:
33
2:
35
2 : 37
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