ElectricalSystem

(excl.Wiring Diagrams)

Section

Grcups

and lnstruments 242/244/245

Repairsand Maintenance

1976-

Battery Alternator Starter Motor lgnition System Lights Std. Equipment Instruments

31 32 33 34 35 36 38

Content of Manual
Group Battery 31:
Generalinfomation

GrouD Alt€rnator 32:
Specifications

3 5 6 7

N e wF e a l u r e s . . . . . . . , , , , D e s c r i p t i.o . . . . . . . . . . . .n Service Diagnosis C h e c o f c h a r g ' n g s t e m. . . . . . . . . . . . . . . k sy . ServiceProcedures Special instructions work on alternator for equipment.........

A 1-A12

12

Group33: StarterMotor
General Infomation SparePartslllustration Special Tools 22 23 24

Group34: lgnitionSystem Specificarrons L u b r a c a t. i.o.n . . . . . . . . .
lllusration Bre8kerl€ss Electronic lgnitionSysrem General ServiceProcedures: Replacing distriburor Replacing impulse sender

32 32 33

81 816

39

Group35: Lights
Specifications Headlamps Front lights

43 44
?t5

Lights,242 and 244, DL and GT
Lights, 245

46 47

Group36: Standard Electrical Equipment
Switches

Bulb Failure WarningLight
Tailgate Window Wiper and Washer. 245

Windshield Wiper Assembly

,$ 49 50 52

GrouD Instruments 38:
Instrument Cluster WarningLights
Replacinginstrument

Testing fuel gauges and tank levelsenderc Addilional Inlomalion

A1 A8

53 53 54 55 56 58 61

NOTE: references model All to 240 in thismanual alsoapply DL,GL and GT. to

TP 11402t2
3000.03.80
Printedin lJ.S.A.

Battery

Group 31

General Informalion

(@20'CrANDCHARGE GRAVTTY spEcrFrc
SpecillcGravltyReadlng (uselhe mlnlmumflguretor lestlng) Minimum Batleru Charoe 1.260..................100% arged Ch 1 . 2 3 0 . . . . . . . . . . . . . . . . . .7 5 . /C h a r g e d . 1.200 . . . . . . . . . . . . . . . . . 50%Charged . The Battery 1.170 . . . . . . . . . . . . . . . . . 25 Chaged . 1 . 1 4 0 . . . . - . . . . . . . . . . . V e r y i t l l P o w eL e t l L e r andmajorengine e s electrical compon€nts 1 . 1 0 . . .- . . - . . . - . . . . . . . C o m p l e tD li y c h a r g e d
'(80"F)

water, Thenflushwilhcleanwater.Be sureventcaps gels into cellsto neulralize are tight so no solution the acid. Alsowashbatlery carrier and holddowns. General Lack ot eleclrolylecauses prcmaturelailure of batteries tasierlhan anything else,Plales exposed ai lo delefioralerapidly.Check electrolylslevel fiequenlly, especially hot weather in whenevaporalion more as likely. Filldeslilledwateronlyto the battery,neveracid. Howsvsr, any watsr is batterthan no waler. Batlerylife is ext€nd€dby usingthe pureslwaler available. bolts. Tighlboltswillstrain Donolovenighten holddorvn the battery.Checkbanerycase for cracks. when charged,a batterygiv€s off hydrogenand oxygen,a mbdure whichis highlyexplosive. Keepopen a llamesaway Aom batleryand never disconnect the al chargerby removing connection the batterypost. tho Guad againslsparksby disconnecling ground it lest. Be caretul lo lel nol cablelirst andconnecting lhe battery tools or other meial objeclsfall across terminals. Neve. take rcadings right atter adding water. Water mustlilst be mixedwilh eleclrolyle. This is done by charging batt€ry running onlhe carfor a couple the or it readings, lt Takeelecvollte fromeachcell andcompare lowerthan itsplates onecellis0,030ormore olhercslls lo are not holding chargeand il mightbs n€cessary (0.0501or charged) dry replace batlery. the good by the specilic gravilytest,il ll batlerych€cks mightstillb6 necessary makea highraledischarge lo lest,duplicaling staner lhe motordemands. Group See 33, Slarter MolorandEleclrical specilicaiions. test load longerthan n€cessary, Donotmaantain on bailery

o
O

Banery Checking
The mostcommon to checkbattery way chargeis wilh a gravity hydrometer.measures lt specific whichis a directmeasure percenlage of sulphuric intheelectro' acid lyl6. batlery As drops lromchae€dto discharged condition, acidleaves solulion enters plates. lhe and lhe This causesa decreasein specilicgravity. Prolonging lile battery is tusl a matlerol oeveloping goodhabils lesling mainienance. ol and Adirtybattery discharges ilsel{:acid corrosion dirtaclas conducand tors. Corrosion aroundbatlerypostseats awaycopper cableterminals. A darty batleryshould €movsdandscrubbed a b€ with solution bakingsoda and wateror ammonia oJ and

Group 31 Battery

1

Banery WARNING!
Caution
We wouldliketo strcssthe importance not havjng ot openllames spa*s in the vicinity the battery or of b€cause theexplosive which gas ol lonnsin the battery. Thereis thus a danger sparks of fromshoding lhe at poslswhrch cause gas to ignde. batlery can the

Prccedures
-Both batteries (sender receiving) and musthavethe samevoltage. -TheAmperageolthe senderbattery mustnotbevery muchgreater lhan lhatfor the receiver battery. -The battery cellcaps mustbe position in (thisreduces riskol gas igniting). -lf lhereceiving batlery frozen, mustbeattowed is il lo thawoulbetore connecling thejumber up (A cabtes. flal battery lrcezes -10"C. (15"F.)) al

SENO G CAL IN

RECEIViNG AR C

os itive

N e g a ti v e Terminal

-The sender baltery engine muslbeswitched The off. receiver battery mainswilch mustb€ off.Thebodies ofboth carsmuslnotbeinconiacl €ach lhe with other (risk oJ sparksfoming whenthe cablesare connected up.) 1. Connect redcablefromsender the plusterbattery minallo receiving pluspost. battery 2. Connectone oflheblackcabte aground end point to somedistance lrom lhe receiving batlery. Suitabty lhe receiving groundconnection banery's should alsobe on the bodyor on the engine. -Slart thecarof lhesender battery idteit at about and 1500rpmfor several minules. -Starl the car of the receiver battery.

Useof Jumper Cables

F I T TI N G C A E L E S

NOTE!Do not alterthe position the cabte of clampsdu ng lhe startingattemptotheMise lhereis riskof spa*s forming. Do nol bendoverthe batteryl -Remove the cables precisely reverse in the orderto fltting them.

RE]'1OV

CABLES

2

Gtoup31 Battery

Specifications

Group 32 Alternator
Specifications
Alternator
Tlpe

13.0-15.0V 55 Amps 225 t/s

Output
\,4., sppFd ..

I
= 13500rpnr

D r e c t i o no f r o t d to n .. q o r o . e _ g e a l r p r ' 3 r o._ . . . . . . . . . S I D ' r n g s .r n i - J m d i d m e l e . ra: o-r oI o-no Stdtor Loil res stdnce F o r o r c o r lr e s r s t a n c e O-rpu esl

Clockwise 1:2 3 1 . 5m m = O.OO12 0.O3 mm O.14ohm + 10% 4.Oohms+ 10% 48 Amps at 3000 rpm, 13.2 Vohs and 24oC ambienttemperature

Voltage Regulator
Tlp. .. ... Colt'o. vordge ol 40OO pr Loadru r.rr owo 'wo co.racrs C o n t r o lr a n g e ,b e l w e e nu p p e ra n d l o w e r c o n t a c ts e t s . . . . . . . . . . .

13.9-14.8 Volts 4511 Amp O O.4 Vohs 3-8 Amps

I

Description

o
1. &ush holdor 2. M6gn6iizing Diodes 3. Slip ng 6ndshield 4 B€crmd (slrien diodas) -. T1. allernaror rs a th'e" pl'ase sld. Lonnpcl.d a Fcl 'ie' rs burl rnro_l_e o r' q s nar n9 un r. lhe "nd shield and consisls of six silicon diodes. Aso ho{rsed n rhe slip rng end shield are three so called mag ne /rng dodFs. wl_cl repd rhP rred via ll"e vor;9.

a A n a r F ' a t o r h a sa r o t a ! . S , r ed . o r l ( r o _ o r lr d . s l d . main coil(stator). The rotor is a 12 pole clawtionary pole rype w,rh rl"e l,ed Lo' 'ed ac oss lwo slip rings. Since the ahernator outpul s self-limited(max. 55 amps), simplereguatoris used. t conlrolsthe vo tage a

Gtoup 32 Ntomator Specitications

3

Design

NewFeatures

A newtypeSEValtemator (SEVP/N71655302) now is beingslocked underVolvoP/N 5462893€. The new allemalor can be identilied a blackplasticdaode by guardand a mold€d (See wiringhamessassembly. PiclureBelow). Whenreplacing olderstyleSEV the allernalor the newversion,lwo with minorchanges lo lheoldwiring hamess rcquired. are Reter lhe instructo tionsbelow.

After styleallemalor removed in-car old is and hamess js disconnected, proceed with the operations shown during inslallation lhe new allernator. oJ 1. Connecl in-car harness leads terminals backoi to at newalternator followsi as gauge, twin a. Heavy rcd lead10B+ teminal. b. Single leadto D+/61teminal. red c. Blackleadto D- teminal.

.)

d. Useelecvical to securely green lead lape fasten DF Nole: Makesure ihe lead is well insulated and

I
I
2, Carelully theold in-carwiing tape harnessconnector piugas shown. Theconnectorplug lhe newmolded irom alternalor harness should plugged the regulalor. be inlo Nole: Do not under any circumslances anyoJ cut the old leadssincetheymay be needed for Juture altemalor installations.

4

Gtoup 32 Altemator

Design

Altomator

When $e ignition is switchedon, current nows throughthe charging warninglamp ro terminalD+ on the voltage regulator. the regulaior, current Via rhe rs conducred rhrough the roror corlro ground.

02s-0,40mm
Voltagaregularor Regubtor contactfor 3. Springrensioner
2. ower conro! range Regulalorcontacl tor upper contol range 4. Spring upper seciion:

lf the vohage ises in spite of thig rhe armature on the voltagecoil is pulledfurtherdown so that rhe upper contol range contacts close, Thus ihe rotor coil is grounded at both ends which causesthe voltage ro d.op rapidly. The cycle is repeated continuouslyso that the voltage is maintainedconstant.

5Wr

t_-!
When the roior starts rotating,ahematingcurrent is formed in the stator. Most of the current is recrified by the positiveand negativediodesand is conducted via B+ on the alternatorro the battery.A small part of the currenr is rectified by the exciter diodes and is led via 61/D+ to the voltage regulatorand rhen to the rotor coil. This cycle is repeateduntil the regulating voltage has been reached,at which point the lower controlrange coniactson the voltageregulator open and field current must oassa control resistance.
lo0o500060007ooo

AIIEBNAIOR BPM f:j9 Arr€matoroutputcurue A = amps RM = ahernator speed/mi.ute Thealternator maximum outpuiis55 amps. speed Top is 13500rpm.

Group32

5

Diagnosis

ServiceDiagnosis
Condition:
Action Testlamp(12 volts2 wattstbetween and61/D+ B+ on alternator lights. Test lamp betweenB+ and 61/D+ doesnot light. Test lamp between61/D+ and groundlights. givesa weak Testlampbetween 61/D+ andground light.Remove plug at the regulator connect the and an ammeter between and DF on the alternator. B+

Warning lamp does not light with engine off. Possiblecause Warninglamp burned or opencircuitto D+ on out regulator. Positive diodeshorted.

O amp 2-2-5 amps

Worn brushes, oxidizedslip ings on breakage rotor in Open ckcuit in regulatoror in lead DF from regulator to DF on alternator,

oi'

o

Condition:
Action

Warninglamplightswith engine oftor running.
Possiblecause Circuit shorted between ontheregulatorand D+ 61/D

Disconnect plug at the regulator the Controllamp still lights. plugi. the rcgWarning lampgoesout-Re installthe ulatorandconnect ammeter an between and D+ B+

Lessthan 2.0 2.5 Ampsl More than 2.0-2.5 Amps:

Defective regularor(brcakage). Circuil shorted between DF on regulatorand DF on Coil shoned.

I
0.

Condition:

Warninglamp lights with 6ngin6off bu1starts to give a weak light when€ngine running. is Possible cause resistancethecharging Transition in circuit in the or
leadto the waminglamp. (overchargingthebattery)or de Defective regulator of (insufficient fective charging oflhe battery). ahernaior

Actionr Testlampbeiween and61/D+ on the alternator B+ wirh the enginerunningl Doesnot light, Givesa weak light. Installnew regulator. Test lamp betweenB+ a n d6 1 / D + : Doesnot light. Givesa weak light.

Removed regulator defective. Defectivealternator.

6

Group32

Diagnosis

Check ol charging system Generalorientation
Connections altemator at
FEDwlFE. TO CHAFGTNG CONTROL LIGTIT

ir

iiJ"
t FEDor aRowri
PLUGAT ALTERNATOR WITHWIFE LOOM VOLTAGE TO FEGUIATOF

ro D
o
'1.,,

o
Connections voltageregulaior al
idenlifcalion f wtres n plug o

_.._.i...t_

REDo. BFOWN

D+
GREEN WHITE or

DF

Procedures
Checkdrive bell tehsion
D e f l e d o n t m d p o n t s h o l J d e a p p r o x5 / 1 6 ' ( 8 a b .

Gtoup 32

A2
Check batlery condition shouldbe usedfo' rhe A batteryin good condition are terminals cleanand tighl Checkthat batterY

I

The battery battery. Reler1o Group31 for checking lor and be should in fullycharged goodcondilion the lesls. tollowing

A3 Switch on ignition illuminaie lighton instr!mentpanelshould Charging go a. Light illuminates. to A4. plugal vol discon.ect b. Lightdoesnot illuminate: groundred wire D+. and rage regulalor - Light illuminates: to 44 go wires,control not illuminater check Lightdoes lightbulb etc.

A4 Connect a voltmeter to alternator B+ and grouno // al off. All lighlsandaccessodes switched Runengine approx.2000 rpm for one minute,then read voltage. a. Voltagereadingcoflecl go to ,q5, higher than14.4volts:go to 410b. Reading lovver than13.0volts:go to A10. c. Reading (Refer to s€ction Tesling the VoltageRegulatol for chargingrats). A5 Voltmeter stillto alternator B+ and ground andheadlighl rearwindowheater Switchon blower,

I

II II I
I I I
\
VOLT-I']ETEF

0)
,

BEDor BBOWN

\s
\\

Run engineat 2OOrpm for one minute shouldbe lessthan O.7volt lower Vollagereading a. b. Lessthan 0.7 volt: go to A6. More than O.7 volt: go to A1O.

GREENof WtllTE

32 Group

I

T
Diagnosb A6 Connectvoltmeterto alternatorBi and battery plus

Switch on headlighruppe. beams.Run enginear approx. 1500 rpm. Voltmeter readingsho! d be O.O-O.3 a. Less than 0.3 vok: go ro A7. I M o r et h a n 0 . 3 v o t : ch€ck wire from a lernator 8+ io starter motor to batiery pl(]sfor loose or corrodedconnecton.

N

b.

Connect voltmeter gineground

to battery minus and en-

S w n c ho n h e a d l i g h t p p e r e a m sR u ne n g n e a t 1 5 O 0 u b .

-xF

Voltage reading should be 0.0-0.2 voll. a. b. Less rhan O.2 vok, go to A8. M o ' e l l _ d . 0 . 2v o l r . h F c k r e l . o m b a e r y m r - u s w c to eng ne ground to alternatorground for or corroded connectons.

FEDor BFOW{

A8 GFEEN orWHm Charging system should be correct if all previous tests have proven satistactory.

Gtoup32

With incorrectsystemtest readings
A9 Re{erence A4 to
{Voltage reading higher than 14.4 volts)

'/.-_'

Connectvoltmeter to D+ and B+ on alternator. Runengine l5OOrpm. at
a. b. Vollage readingexceeds 0.5 volt ahernatormust be defectiveand should be replacedor repaired. Voltage readinglower than 0.5 volt voltage regulator should be replaced.Recheck.

/l

I

I

At0
Reference to 44 (voltage reading below 13.0 volrs) of referenoo to a5 (voltage drop more than O.7 voh) Connect voltmeter to O+ and B+ on alternaBunengine 1500 rpm. at a. Voltage reading exceedsO.5 volt:alternaror must be defective should replaced repaired. and be or b. VoltagereadinsbelowO.5 voh: so ro A11. Priorro this test,carefully checkthat wiresfrom atternator voltage to regulator in corect order.No are shons,no grounds, looseconnections. no

Atl Checkrotor circuitresistance
Disconnectwire DF (plud at vohage regulator.Use ohmmetertocheckrotor resistanc€. Correctresistance is approx.4 ohms. Howevet dependingon brush conditlon,resistances 4-10 ohms might be considered of R u n e n g i n ea t 1 5 0 0 r p m . qoror ressrancechecksour coiiect: go to 41r. OlIU.UETEB b. Botof resistance checks out lower than approx rolor is orobablydefectrve. When reDaiflng. checl rotor resislance direcrlyonslipringslo venfytautt. BLACKWIRE Rotor r esr$anceconsrderably hrgher than app'ox. 4 ohTs clea' ahernarorbrushesand shp rings.

I I I I
I

i

I

10

Gtoup32

Diagnosis

JUMPEA W|FE ,.-_-\

At 2 Full Fielding Test Thisis alullcharge ol alternator, test airnsd atdefinitety problems separating allernalor fromvoltage regutator D+ RED WIBE a. Remove plugat the vollage the regulalor conand necla jumperwirc between andDF as shown. D+

(

I
\ \-DF GREEN WHIIE o.

Connect voltmeter toalternator B+ and ground

/a
d.

bower, rear wrndow heater. headighr upper Run eng ne at 2OOOfpm. Pe"d, 9" I gr er rhcn 4.O rol,s rndrudre aller a,d oa\eoJert\ volragF Pgur lator sho!ld be replaced. Beadings below 14 volts, usually considerably l o s e : i n d i c a r er l - ed l r q n j o ' , n o - l o b . e p a , - o o r ' e o d n e d r 'r. 1 e .d r o d e >F r o s i l p l y a r , a r l r . o

(
VOLT-METEF

o
GREEN WHIIE or

CAUTION: notrun Do engine higherthan 2000RPN4 or pedod-it coulddamage lor lengthly the battery andotherelectrica circuits lo due HighVoltage.

\s
\\

Group 32 Altematot

11

Removingaltenator

Procedures S€rvice equipment lor instructions work on alternator Special
makesurclhal banery. or 1 . Whenreplacing installing baltery A properpolarityis observed, misconnected ruin will immediately the r-ectifers. ckcuit broken lhe Neverrun allemalorwith main lhe and regulalor leads The battery and/or altemator whrF lhe engne is must neverb€ disconnecled running. 3 . No attemptshouldbe made to polafizethe allhe disconn€ct battery vehicle in fastcharging When batterygroundcable. 5 . Whenusingan extra battoryas a starlingaid, connectit in parallel. the disconneci on Whenarc welding the vehicle, gound cableas well as lhe B+ lead on the battery and alternator lhe plugal lhe voltageregulalot.The the beconnectedcloseto always welding unitshould

0l
alternator Removing

0(
BI

Removealternator a. b. c. wires at alternator. Disconnect bar, hex 13 mm Remove bolt for tensioner Lift off drive beltsand lower alternaior.

0),
B2
Removealternator and bracket bar. ALso removethe tensioner Hex 13 mm

cr

12

Group32

Diassem ling dItematol b

Disassembling alternator cl
Remove nutand washerfrompulley.Pulloff pulleyand

o

Bemove brush holder retaining screws. Remove blush holder.

C3
Remove nuts and bolts connecting akernator end Remove front end shield from stator and rear end

Press rotorlrcm lronl endshield. out Note:oldtypeshown.

Gtoup32

Testing

Removethe screws retainingthe fronl ball bea.ing. Press out ihe bearing.

tu,*

C6
Femove nuts for p us diode plate.Lift up and bend

0

c7
loose staror the connections the terminal frorn Solder

0

and NOTE:Aways use a heat sink whensoldering to damage to soldering around diodes prevent

alternator Test of disassembled
C8 Stator Test stalor insulation. Connecta 40 Voll alternatingcuffeni across ground and phase termrnal. indeiinite. Correct resistance:

0

O
c9
Test stator coil resistance. Connectthe iest instiurnentacrossthe phase termi O.14 ohm + 1O%. Conect resistance:

-.

14

Group32

Testing

c70
Rotor Test rotor insulaton. Conned a 40 Volt alternaringcunent across roror g r o l n d a n d a s l r pr i n g . Corred resistance: indefnite.

o o

cl l
Test rotor coil resistance. Connect the test instrument across rhe slip rings. Corect resstance 4.O ohms + 10%. Sllp rngs which are burned or damaged should be turned in a athe. use tail stock. S l i p r n g m i n i m l m d i a m e i e rs 3 1 . 5 m m = 1 . 3 ' . Use a dia indicatorto check out-of-round.max mum 0.03 mnr = 0.OO12".

ct2
Brush holder Use40 Voh altemating cuiienr. Correct r€adng: indeiinite C h e c k h a t m i n i m l m b r u s he n g t hi s 1 4 m m = O . 5 5 ' . t

Group32

15

Replacingdefective rectifier diodes ct3
Diodes Test rhe diodeswith

Boschtesting equipment shown, is NOTE:Although is similar equipmenl availabbfromdomeslic manulaqurers.

alternator Assembling
cl4
lnstallthe stator in the slip ring end shield.Solder the stator wires to the terminals. Install the plus diode plate assembly.

c15
Greasethe drive end ball bearinswith srease Bosch Ft1V4 {orequivale.t). InstaI bearng assembly the driveend bearlngshield. in

O O

16

Gtoup32

, Assembling altemator

c16
Press drive end bearing h i e d o n t o t h e r o t o f . s lnstal rhe spacernng.

cl7
Greasethe slip rlng €nd shield bearing wth grease r B o s . r ' F r 1 V 3 5 o ' L o i i e s p o n d r n C.o a l t h e s L i p i n q g Assemblethe end shield bearingseal with N/lolykote. D o o f o r g . r r o a s a . lr l - es o n n qo r l - - . [ p aq e_d

-oro-e rcrarrlg A s s e m b l ea l t e r n a r o r o m p o l e l t \ . c to 3.6 4.3 lb.ft. = 5.G-6.9 Nm and nuts to screws 3 . 3 4 . 3 L b . f t= . 4 . 5 - 6 . 0 N m . .

ct8
InsraLl brushholder. rhe

cl9 Position washer the fan, and Installkey, spacer pulley. the andlorque nutto 29 lb. tt. = 40 Nm.

c20
installalion. Teston a lest benchbefore

Gtoup 32

17

lnstalling ahenatot

c21
Alternator terminals L DF To field winding 2. 61/D+ Frommagnerizing 3. B+ To batrery

Installing alternator
DI Installaltemator with bracket and tensioner
DAr Hex 13 mm

0

Cl
D2
Installdrive belts
Install bolt for tensione. bar. Adjust

f(

Oldallernalor shown,

18

Group32

Tesnng voltage rcgulator

Testing voltage regulator

-{:-._:

llilN

Charging Regulator have now been IntroElectronic charuing regulalors parts lor cars which do nol have lhe duced as spare thr€e-teminalclnnection contacton the regulalor. These nsw regulato|scan be easily identiliedby lhek grey cover,Theold type regulators haveblack covers.

ldentitying the regulEtor with Sev P/N72610102 diode(ed plate) Magnetizing diode SevP/N726-10002 Marking

Spot Blueor Black Spol

1259303-4 12593026

ldentitying the alternator walh diodes havea red plateon Allemators protectivg Thoseallernalorswhichdo not havea red plateon the diodes. rearend arefitledwithmagnelizing

r||gnetlzlng Olodo3

Group32 Altematot

Test vohage rcgulatol ing

Testing voltage regulator
(Ontest benchor in vehicle) EI
Connect the regubror to an alternator n good condition.

E

-'l

L JI! 'l

H

Ltli.ii!

'

D

Wiringdiagramfortssting voltag€ regulator Voh€selamp 12 vohs Conlrollamp 12 vo rs, E. Ammeter 50 amps. 0 F. Fesuarorresistance G. Batery 60 amparehours
L

0,25-A,1O.r'm
Voltage regulator for Fesularor contacr rowerconrror range Fegulalor contaclJor upperconlrolEnge 3. 4. Sprinsrensoner spring uppersecrion Sreetspring Lowerseclioni Br meta spfng

0
V

c.
D.

(

2.

-24

Runthealternatorat 5000rpm(alt.speed) or2500rpm (enginespeed) 15seconds. for Read voltage the the on voltmeler. no loadon lhe allernatof, vollmeler Wilh the should read13.1-14.4 wilhthe regulator volts ambient lemperalure 25rc (77"F). at Load altematorwilh lhe 10-15 amps, suchas switching headlights ripper on 10 beam, read and thevollage. The voltage should readbetwe€n still 13.1'14.4 volts,bul mustnotdrop more than,4voltslessthantheunloaded specification. For exactvoltageat ambientlemperatures disee agrams opposite.

0
0

.2o

.4O

r80

20

Group 32

Testing voltage regulatol

Testing voltage regulator
lon test benchor in vehicle)

El€ctronlc F€gulalol!

regulalorshould be llvollage isoulsidespecificationlhe regulator to be tssledmorc is replaced. ihe voltage lf lhenb€ accuhtely, installit thevehicle in which should d v€n for approx,45 minulesat speedabove30 mph. The €asonlorlhe diving is to letlhe regulator obtain cofiecl wo*ing temperature. lt NOTE: vehicle The must driven. isnotsufficient be iusl to havethe engine idling. lmmediately or prelerably after, during driving, measure The thevollag€ between andD on thealtemator. B+ shouldbs tumingover al i50O rpm,whichis engine approximately sameas 3000 lpm allernatorspeed tfie temperature whenmeasu Withregulator ambient ng. at ol approximalely 25'C (7rD the voltageshouldbe Please notevollage variations according diagrams. to according ambient lo lemperalures.

-20 -10

0 +to +20+30 +{o +50+60 oc 0 + l r i +32 +tO +68+85 +lo4fl22 +140oF

Gtoup 32

Group 33 StarterMotor
GeneralInformation

0

(

0
The starter motor is rnountedon the fiywheel housing on lhe left side of the erg ne. I is a a pol€ ser€s wound motor. The pinion on the starter motor armature shaft moves axally to engagethe f ywheel r ng gear. The pinion is controlled by a solenoid. T J r _ i n gt h e r g nr i o n l e y r o s r a f l r r gp o s r r o nc L l s r r the soenoid, causingthe armatureln the soenoid to p b e d r a w n I ; n d l h e s l a r r e . i no n r o e _ g d g e h e . i . 9 r gear on the engine flywheel/drive plate. When the armatLrre has moved a ce.tain distance, the contacts for ihe main curfent closeand the starterrnotor starts running.

(

Specifications
D e s i g n a t i o. n- . . . . . . . . . . ................. Bosch

f'(
12V

I

Direction of rotation O!iput

8 1 0 W (1 . 1 I

22

Group33 Staftet Motol

Mechanicaltest specificat;ons .. .. A r m a r u r ee n d I ' o a l

Brushsping tension.
DEranc" hor p,nron end ro ,ing gear race F iclondl rorque oI 'olor brakP i no i d l i n gI o q u e . . . Backlash C o r n m u r a l om . d r d - e r e ' . r Brush min. length Etecrricaltest specifications 1-.5 Volrsard 30 50 Amps 90 Volts a d I85 220 A-ps 7 Vohqa_d 400 490 Aaps ... C-r ir rokage Be'easevollage....... ...

0.01 O.03mm t4 t6 N 1.2-4.4 mn 25 40 Ncm IrL l8 Ncm 0.3-0.5 mm 2.12 33.5 mm 13mm

0.0020.0123.1 3.5 tbs o.o47,0.173 2 . 1 73 . 8 1 b .n 1 . 2 01 . 5 6b .n 0.006-o.oo r 318" o.52'

9 7 1 3 0. / s 1 1 . 52 2 . 5t / s 0 r/s M n I Volts Lessthan1 v.

s80O7800 rpm 1050 1350 rpm O rpm

o
ie
7 26

nt,

t:
13 14 \15

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e 18 17
\

1 5 .C o n n u r o r o r . n d i o m e r

3 T.minorlor bd!.ry reod 9. Coniedion l.dd ro rield

Group 33 Staftet Matol

23

-T

Specialtools Renoval, disassembly

SpecialTools

EF 2122 Sleeve 6nd drifl for inst.lins cnclip EFAL 3 Smoothing drift FG 2649/ 1 Sr.oothing drift EF 2649 Drift for installingbushing

ili

0
ServiceProcedures
Removal

0

(

Disconnectthe battery ground cable.

Disconnectthe leads from the staner motor.

A3
Removethe bolts which hold the starter motor to the timlng gea. housing.

tl

I
Disassembly
8l
Rernovethe two screws retainingthe cover-

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Gtoup 33

24

starter Motor

Disassembly

B2 Bemove lock ring and spacer rings. retaining corn the mutator end Remove two screws the

B3
Lift up the brushes. Remove brushholderbridgelrom the armature rhe shaft. togeiherwith the The minusbrushes retained are brushholderbridge. The plus brushes stay with the field coils.

o

B4
Removethe nLrtconneclingthe field coil to the so_ Removerhe screwsrerarni"gthe so eroid to the prno' Remove the solenoid.

B5
Remove ihe stator assembly from ihe pinion end

Group33 StafterMotor

25

Examination

B6
Removerubb€r stop and steel washer Remove pivotpinfor the pinion the levsr. out arLift matureassembly from the piniondrive shield.

B7
Use 6 fitting sleeveto remove the end stop. Remove lock ring,stop and pinion. (

(

Examination
B8 Check armature damagss wear.Replace the for and the armarLrre the shaft is worn or warped. if Turnthe commutator a latheif it is scorsd, in pitted Minimumdiameter 33 mm = 1.3OO is . '. Max.permittedout-of-roundis 0.08 mm = O.0OO32

0
B9
UseaMicaundsrcutter undercut mm = 0.008". to 0.4 lf no machineis available, a properlygroundlrackus€

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26

Group33 StarterMotor

Examination

Bto

Bll Use a "Growler" to check the armature for shorts. Switch on and hold a hacksawblade close to the ac mature. lf the blade vibrates in any position,one of the following faults can exist: - commutator shorted Replaceihe rotor if faulty.

c

812 lJse Volts cufientoravailable 40 AC equipmentlo check the stalorcoil insulation.

(0
Bt3
Checkend shields and brushholdsr. Replacs parts worn or damaged No morethan0.005 (O12 mm)bushing playis perCheckotherpans and replace worn or damaged. if The lock ring should alwaysb3 r€placed it might as havebeendamagedor lost its tensionwhen removed,

Group33 StaftetMotor

Installing bushings

T

Bt4
Beforeinstallation, new bushings shouldbe immersed in oil, Bosch 01 1 V 13 or similar,for at least 1/2 hour.OtherwisetheirseNicetime willbe considerably

m-

The bushings are made to correct dimensionsand must not be machined. Any machiningwill block the pore holeswhich in turn obstructsthe lubricating abil Use Bosch specialtool EF 2649 to pressout the old bushing. Clean the hole and remove any burrs. Use same aosch tool to press in the new bushing.

(

Replacingfield coil
Bt5 polesand housing. polesshouldbe reinlvlark The stalledin exactpositions. Place siatorin a clamping the device, BoschEFAW9 or similar, and slacken pole screws. the Remove statorfrom the clamping the device. polesand field coils. Remove (

816
Positionthe newfield coilsand the polesin the stator. Heatthe f ieldcoilsslightlybefore installation. Orientate the poles according to markings.

a
,

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1

..JI-J
Group33 Stafte,Motor

28

Replacing brushes
-)-: -"'' ",,

Bt 7 Brushes siroder 9/ 16 = 14mm should re than be
1. 2. Solder loosethe brushesfrom their attachments. Solderon the new brlshes. llse a sufficienty hot Do not allow any soder to Rrndown in the brush leads.This would stiffen the leads and prohibir iree movements.

: . -7 . , - 1 1

u;

:i,,;
Assembling starter motor +
Bt8 Lubricateas shown- Use Bosch lubricanrsor similar: A p p l y a t h i n a y e r o f g r e a s e oin s u l a t L o n l n washerc, shaft bearingsudaces,spacer washers and lock r ng. 2. 01 M3 l m m e r s e t h e s h i n s o i l 1 / 2 h o u rb e bu n fore lnstalation. 3. Ft 2 V3 Apply generouslyof grease in the ar m a l u r e g e a r g d e s a n di t h e p n i o nl e v u er groove. 4. Ft 2 V3 Apply a thin layerof greaseon the shatt bearing sLrrfaces. 5 . 0 1 1 V 1 3 l m m e r s e h e b u s h l n g sn o i l 1 / 2 h o u r t l before installalion. 6. Fl 2 V3 Lubricateshifi leverjoints and solenoid i.on core with a thin ayer of grease. lnstallprnion, stop ring and lock ring.Tightenthe stop rng into pace with a fitling puLler. I FI 2 V3

$E

il

&, llnrr.LnJl
Bt9
Attach the shift lever to the pinion, lnstall the armature n the drive end shied. Install the shift lever pivot stud.

@

F

Group33 StarterMotor

29

AssmW 820
lnstall steel washer and rubber stoo.

821
Install solenoid.

@

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o
822

(

{(

{(

823
Installbrushholderbridgeand brushes.

Gtoup33 StarterMotor

Install commuralor end shield. Installthetwo long screwsthat hold rhe staner motor

825
washersand lock ring.Thearmatureend Installspacer play should be 0.002-0.006- = O.05-O.3 mn Installsufficient amount of washersto keep the end playwithin theselimits. overlhe shaftend. Attach the smallcover

o

Installing starter motor

Connect the starter motor leads. Feconnect the battery ground cable. Stan the engine to check the starter motor function.

Fi!. L0.

Sb'l r hor.r

t.roii.ll

L Fr.n 6ct..r 2. Fron isnition *irct'

3. To fi.ld windiig 1. To ilnnion .oil

Gtoup33 Staftet Motol

_...-!
Specifications

Group34 lgnitionSystem
Specifications
Tvpe .. ... .. F i r i n o r d e r. . . . . . . . . . . . s lgnation timing,vacuumunit disoonnoct€d (checkenginespecificalions) . Sparkplugs(Check 6ngin€ sp€cifications) cap ... ... Tighrening rorque Distributor (Check Bosch engine spscificalions) ... .... ... lsnitioncoil EoschNo,
Bosch No. Centrifugalgovernor Toral advance.distibutor degrees Advance begins at, distibutor Distributor rpm at 50 advance 9 ' a d v a n c e. . . . . . . . . . . . f ' r l la d v a n c e . . . . . . . . . . . Retard,dislributor degrees(doublefor crankshaftdegreed . . .. . . . Retard egins t ....... .... .... .... . b a 2 0 r e r a r da l , Retard ends al Consull correct specifcations for Model yoar,

Metric US specs ignition Ereakerless electronic 13-4-2

I I
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0.7-08 mm 20-30 Nm

0.028-0.0032" 15-22 tb.fr

0221 122 006 0227 100 005

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430-600 rpm 910-1100 lpm 1 4 O U 2 O 7rO m y 24OOtpm

7.2-1O / s | 15.2-14.3 t/s 23.3-34.5 r/s 40 t/s 5.Oot 10 6 l - l 0 7 m m Frg 79-129 mm Flg l5O mm Hg

2.44.3 in Hs 3.1-5.1in Hg 5.9 in Hg (

Lubricating distributor
permitted applying couple Theonly lubrication is of a dropsof oil on the felt wick in the center the rotor of shaft.

fll

Remove distributor cap and rotor. Lubricate wick under felt rororwith a couple drops of of light oil.

B€careful, not splash do anyoilon the impulss sen-

32

Gtoup34 lgnition System

D 0

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0

lr

Group34 lgnitionSystem

33

Breakerless Electroniclgnition System
General
Two main changes frcm the conventional ignition 1. 2. The breakerpoinis are replacedby an induction type impulse sender. An electronicmodulehas been added.lt is wired betlveen distributorand ignition coil. lt amplifies the impulsesbefore sendingthem on to the ig-

Otherlvisethe designand function is the same as the conventonar system.

{

(

Specific Function lnformation
sender 1. lmpulse
It is locatedin the distributorwhere the breakerpoints Insreadof closingard openingan eLecrric circuit. rhe m p u l s es e n d e ' o p e n s n d . l o s e s a m a g n e r i c i r c u r r . c a This inducesimpulsesin a coil (or magnetic pick-up). The impulse s€ndsrconsists of: 2. 3. 4. coil (magnetic pick-up) armature kotor) permanent magnet

0l

Stator. coil 6nd pemanent magnet are connectedto the distributorhousingwhilethe armatureis connected to the disr butor shaft.

n(
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Note1: Whenusing distriburor a lester, alsothe electronic
module mustbeconnecled order geta distributor in to

Stator and armaturehave as many pole teeth as the ensin€ has cylinders.

Note 2: When makingCylinder Balancs testing, most instru mentsrequire that a special adapter used(or the be enginewill die).

34

Gtoup34 lgnitionSystem

Futiction

Thepermanent magnetcreates magnelc field which a goesthroughthe stator.The rnagnetic cirorh is clos€d lvhenths poletesth areoppositaeachothe..The magneticcircuitis openwhen lhe poleteeth areseparated. This m€ansthat the armature clos€sand opens the magneticfield while it is rot8ring This generates cllr rent pulsesin the diskibutor coil {magneticpick-up). Vacuumand centdfugalcontrol of lhe dming is per formedsimilarto the conventional distributor.

o

2. Electronic module
The electronic module is a solid state design with transistors. amplifiesthe impulses h from the impulse 'dwell sender. lt also controls the angle".

pick-up) Theimpulse from the coil(magnetic received in the distributor converted is and reinforced the in electronic moduleand governs outputtransistor the whichin turn governs ignition primary the coil circuit.

ro
For 240 S6d6, a 1,o g r6istor is l@t6d on thoiirewart

When the pole teeth are in front of each other, the the moduleoutput transistor breaks primarycircuil inducing voltage the coilto firsthespark in secondary plugs. The poleteethhavea functionsimilar that of the to cam bb€s in a conveniionaldistributor. NOTE: ignition Ths coilisdesigned specifically the for breake ess solid state ignition sysrem.lt is identified by specifications number only andcannotbe reand placedby other lype coils.

Group34 lgnition System

35

Diagnosis

ffiH
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til Eqil
Gtoup34 lsnition Sysbm

36

Replacingdistribut$

ServiceProcedures
Replacing distributor
AI Disconnect tension (or high leads capl primsry wire andvacuum hose the distributor. at

Removeattaching bott and tift oft distributor.

A3
Rotate crankshaft until No. 1 pisron is at top oeso cent€r {TDC}. - Thecams willthenpointobliquetyupand mark pulley will b€ at Oo.

Line up rotor Turnrotor so markis approx. frcm markon o|s600 tributor housing.

Install distributor Pushdistributor position engine into in block.Check that rnarkon rotor and mark on distributor housino lineup. Install dislnbutor retsining boft,hex 13 mlrl-.

Group34 lgnhionSystem

A6 Install dust cover rotor. Remove rotor,fit dust cover,and r€-inst6ll

A7 Installdistributorcap

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A8
Reconnect P mary wire, vacuumIinestc.

(

c)A9
Set timing Refer v€hicle to specificatrons.
/./.'

38

Group34 lgnitionSYstem

Beplacing impulsesEnder

Replacing impulsesender
Ramoval Unclasp lock clasps. the Bemovecap. rotor and dust cover,

io

Remove vacuumunit anclclasps. Caution: The retainingscrewshave ditterentlengthsand if im, pnoperly placedcan projectand damagsmovingparts. Theretore,alwaysplace the screwslogelher with the componenl which to theybelong.

B3
Rsmove the screwssecuring contact. the Removethe contact pulling carefully by it straight out.

o
io
84 Remov€ screws ths plat6. retaining impulse ths sender

I

Group34 lgnitionSystem

Replacng impulse 'endel

Remove snap ring and shims

B6
Lift off the armature and the smalllock Din.

87
Use sn6p ring pliersto removethe snap ring. Lift up the impulse senderand plate.

88 impulse sendet. Remove thr€escrews replace and

40

Gtuup34 lgnitionSystem

Replacing impulsesetd]aii B9 lnstallation Attachthe impuls€ sender the ptate. to Theconnector should ptaced pins be opposite abovs the attachment lor ths impulse sar s€nderplate.

Bto
Installimpulse s€nder. S€cure it with ths two screws. hstall sn6p ring.

Btl
Installthe armature. Th€slotshould opposit€ dgeon thedistributor be the shaft. Fit the lock.pin that the lift facesthe dg€ on the so distributor shafL OtheMiss tha lock pin may be shear€doff.

Bt2
hstalt shimsand snap ng.

Gtoup34 lgnkion System

41

Replacingimpulse sendel

813 R€connect wir6 conn€ctor tighten screw. the and the

Bt4
Installclaspsand vacuumuniL

R15
Installdust cover, rotor and cap,

Bt6
Check distlibutol Rotats thg distributor shaft s6v6raltums in both directions It shouldrotatefreelyandwithout anynois€or s€izure. The only resistanc€which may occur is the littl6 stiffnss causedby the magnetin the impulsosend€r wh€n the teeth pass each oth€r.

i/r t\

42

Gtoup34 lgnition System

'v
Specifications

Group35 Lights
Specifications
Llghts,12 V Headlights 244-245 DL4DWagon' Headlighls 242,GI

USbulbNo.
5Ya"Typ€ 1 5%" fype 2 S€aied Beam

Powor

Sockel

No.ot bulbs

7" rype 2 67 5w4cp TumSignals, front 1073 21wl32cp TumSignals, rear 1073 21wl32cp Tailljghb 67 5w4cp Stop Lighls 1073 21wl32cp Back-upLighls 1073 21wl32cp Sidelvlarksr Lights 57 3wlzcp The followingbulbsmay be obtained from a Volvo dealefi FositionLights,tiont Re3r Ash Tray Light License PlateLight lntsriorLight Glovs Locker Light Instrument PanslLight ControlPanelLight Shift Positiong Autom. EngineCompartment Light ControlLamps Charging Turn Signals BrakeFailure Parking Brake Headlights Oil Pre:sure Overdrive WarningFlashers El. Heated Window Seat Belts Bulb Failur€

Balss Bal5s 8a156 8a15s Ba15s Balss S 8.5

2 2 2 2 2 2 2 2 No of bulbs ,I 2 1 \245:21
I

1,2W

Socket w 't.8d s 8.5
Bags BaTs w 1.8d wt.8d w 1.4d w1.8d w1.8d wl.8d w 1.8d w 1.8d w 1.8d

1.2W 1.2 W 15w 1.2W 't.2 w 1.2 W 1.2 W 1.2W 1.2W 1.2W 2W 1.2W

3 3

wr,8d

w1,8d Bags w 1.8d

l 2 1 1 1 1 I I 1 ,I 1 1

Gtoup35 Lights

43

ServiceProcedures
Replacing SealedBeamheadlamPs

Turn 1/2 turn to rcmovethe plasticscrews. Remov€ he.dlightrim. the

clockwise. Turn the chromedring slightlycounter the ring and lift out the headlamp Remove chromed unit. Disconnectthe socket contact.

q,:1,>.

Feconnect socket contact, install headlampunit, chromed ing and rim.

alignment Headlight

lJssthe wo Bcrsws adjudths hsadlight to alignm€nt.

44

Gtoup35 Lights

Models 240,DL 2d, and GT

flril
ii:,- :.; iit;:::,4)

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llttt

,ilJlll
i NNER BIA{, -BqAM sEAtE Tvpe 1

OUTER BEAIq, 3/4" 5 SEALED BEAfi TYPE 2

l1\\\i

K
Group35

Models240, DL 4d and DL 5d

45

U9hE,242,244,DL & GT

2 q3>

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tr
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Irj? *s*.1-.. .

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fr
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t4

30

cr
c4
\OLVOPARTS 1 0 3 02 3 0 r 8 (103 ) 6

/.rfl

I

Lights 245

15 l/ @rNTERroRLrcHrs

6;>

IC t/

c

€<"

2t t/

5 l,l USBUL8 No,l0/t

I 0
5 l,l 4 cp, LIS BULB flo.67

t
Group35 Lights

Group 36 StandardElectrical Equipment
Replacing ignitionswitch

Removenose insulationpane and cefter side panel. Disconnect-the terminal block for the ignition swrch. Use a stubby screwdriver to remove the ignition

I
A2
Atlach the new ignition swLtch, Connect the terminat btock. Re-instal panels.

@l

Replacing turn signalswitch(headlight dimmer switch)

Rernove two casings the roundrhe sreering cotumn. Remove lwo retaining the screws. -rd_>fp, wres rhe to rhe r.w swtcn.Resror..

,

Replacing horn
CI

l_l

Disconnect battery ground cable.Turn and lift off the the lock pins. Remove the grille. Disconnectthe wires at the horns.

C2
Attach the wires as shown. lnstallthe gr lle and reconnectthe battery gro!nd ca,

48

Group36 Standad ElectricaEquipmen I t

Bulb Fatlurc Warntng System

Replacing light switch
DI
Disconnect defrosrerhosefrom the defrosteroutthe Remove the screws retainlngthe defroster outlet.

D2
Pull out the switch knob. Lift out the defroster outlet. Remove ihe nut and lift out the switch.

D3 Disconnect the switch from the terminal block. Connect new switch. the lnstall switch, defroster outet, switchhandle deand

Checking Bulb Failure warning light operation
NOTEiBuLb Faiure Warninglight may come on if con nected bulbs current draw ls disiorted.A short ndi cation may sometimes occur, when headlightsare switchedon, dependingon vaiation in "starting"time

Switch on €ninon. The warning lighi should come on. lf the warning light does noi come on, it is de

E3

E2

Start engrne, The warning light should go oLrt. Warning light andthe chargrng The Bulb Failure = light simultaneously alternator does control The Bulb FailureWarning light is on after ihe charging control light has gone out = Sensor in NOTE: llghr switch shouLdbe pLrshed and brake pedal not actuated durrng test.

E4 E5

E6 E7

EB

Switchon headlightlower beam. The Waming light should be out. lighl ison, butallbulbs The Bulb FailureWarning lor lower beam, parking lighl, laillighl,efc., are functioning= Sensor is defeclive. Switch off headlighl lower beam. B e m o v ef u s e N o . 1 l o r 1 2 . The waming lighl shoud come on. f not = Sen sor is defective. Re-connectfuse. Switch off ight. Depressbrake pedal. The warning light should be out. lf it comes on and both brake lights function, it is defective. Switch off igniton.

Grou?36 nt u rd Standa ElectricalEq iqme

49

Bulb FailurcTailgaE

Replacing Bulb FailureWarning Light sensor

F] F2 F3 F4 F5

Disconnect connector the SensorUnit. the ar Remove SensorUnit. the Installthe replacemenr Sensorunir. Re-connect connector the SensorUnit. the to Checkthe functionof the replacement unit.

Tail gate window wiper and washer,245
Spare Parts lllustration

Qr

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50

Group 36 Standad ElecticalEqu ipment

Tailgatewindow Wiperlwasher

Tail gate window wiper, 245
G7 Removing panel ground Removelhe cable. battery Disconnectlhe of on the inside the tailgale. for sc.ews lhe wrpermotorproRemove retaining the the Disconnect link arm ai the wipermolor.Foldthe plateasideand lift oul the wrper motor' prctection moat and Markthewires, disconnectthem lhe wLper

G2
lnstalling Reconnectthe wres to the molor' Attach motor and protection plate Reconne the link arm to the wiper moior' Installthe protecnon plate relarnrn9screws Insiallthe panelon the insideol lhe tailgale lhe batteryground cable, Reconnect

Replacing brushes

Fold rhe retaining bracket asde. Unhook the brush springs. Bemovethe brushesfrom ihe brush holders.Observe care not to damage the brush holders. lnstal the new brushes. Hook on the brush spring.

Gtuup 36 Standa Electrical uipment rd Eq

51

Windshield Wiper

Windshield wiper assembly

CoNNEcroR AssEMBLY Includ* $itch for p8rt pGition and @nn€ctoE wirlngh.r6. for l. ca€e p€rk$itch isdefsctiv€, th€ only lhk @nn6ctor e3s€Fbly shouldb. r€plac€d, the 6mi€ sip€r trDtor. not

P AVAILABLE s SPARE ARTS A

Replacing wiper unit

Removal Jl Disconnest batterygroundc€ble Remove side panel, panelunderdashboard. Remove Removedefroster hoses Removeglove box, Bemovewiper arms. Disconnect wip€r assembly and lift it out throughglovebox opening.

lnstallation K1 Install wiper ass€mbly. Remove device secudng wiper ass€mbly at transport and handling. Install glove box dsfrostsr hosss side panels panel unclerdashboard Installwiper arms. Reconnectbattery ground cable,I Checkfunction.

J2 J3 /

K2

K3

52

Group36 I Standa EIecuica Equipment rd

lGroup38 Instruments
Instrumentcluster
B Odometer D Mile reading E Speedometer F Left turn signalindica'tor light{green) Parkins brake reminderlight(red) High beam indicator(blue) Brake {aiturewarning light(red) H I

(green) Rightturn signal indicator wa Oilpressure rninslisht(red) Alternator warninglightked)

A

B

c

D E F G

c
J

K

L

N

o

P

(last figures represents1/ 10 mile) Trip odometer resst knob P Push in to reset Remlnder light, EGR Service (except Lambda-Sond) O Tachometer(certainmodels) thousandsof engine rpm. Reads O angp rdnge lor momentdrv Jse. during d' celRed prohibited range. Bulblailure warning light (yellow, Temperature gauge The gauge pointer should normally remain in_ side the green range.

lf the pointer enters the .ed range repeatedly, checkcoolantleveland fan bek tension,see page 49. Overdriveindicator(green) Lights when overdrive is engaged. Fuelgauge The fueltank capacityis approx 60 lhers= 15.8 U S s a l s . l 1 3 . 2l m p . s a l s . 1/2

o

The red range from R to O representsapprox. I itels = 2.5 US gals./2 lmp. gals.

Warning lights
These lights will light up when the ignitlon is turned on. before the €ngineis started.This is also to prove rhar rhe lightr f-nLrioi. The light should go our d'ter the engine has started.(However,the parking brake rem nder light will not go out until the parkingbrake this light tsndgrolnd is open. When the oi pressure drops below a pre-determinated value, the pressure sensitive valveclosesthe circuhand the warn ng light is illuminated. Brakefailure

warnins lishtked)
Oil pressure

warninglight lredl
lf the lishl comes on during drivlng,the oil pressure is too low Stop the engine immediaielyand check the engine oil evel, see page 46. After hard driving, wle_ rhe rhe lignt will come on occdsrondlly "ngrr. is idling. This is normal, provided it soes oul when the engin€ speed is increased. The warning light for the oil pressure receivescur.ent via the ignition switch. lt is groundedthrough a press u r a s a n s t r v e a l v eo n r l e F n S r n e . r r h l h p e n g i n F v W running and at normal pressufe,the circuit lhrolgh

lfthe lighr comes on whiledrivingand the brake peda f c a _b e d e p e s s e d- f t h e ' t h a - r c r m d l i l i s d ni d i , d l i o r that one of the br.ke cncuits is oul of fLrnctior. S h o - l d a ' a u k a . i s ei n a n y o i r h e l w o c ' c - i i s o l r l e hydraulic brake system, so that $ere is a pressure difference between the circuits of more than 8 10 kp/cmz 1114-142 psil when the brakes are applied, this actuatesthe valve and ihe warning light goes on. The warning lamp remains lighted r.rntilthe fallt n the brakesysternhas beenconected and the warn ng vdlvere ser. 9e .e 'elthg rhe wa'n 19 vdve. s"e SeL tion 5, Brake, Grolp 52.

Gtoup 38

53

lnstrument Cluster

Altemator warning light(red) lf the light comes on when engine is running,check the ahernatordrive belt tension as soon as possrble. The alternator waming light lights up when lhe alAs ternator voltage is ower than the battery voLtage. to the alternatorvohagerisesand commences charge ihe battery,the warning light goes out, indicatingthat the alternator is charging.

Parking brake light reminder
This light wiL be on when the parking br6ke (hand br.ke) is set. The parkingbrake lever is situated between ihe lront seats. The parkingblake reminderlight receivescurent vla the ign tion swich. When the parkingbr6keis app ied, t h e w a r n i n gi g h ti s g r o u n d e d y l h e s w i t c h . T h e a r n l b w ing lamp femainslightedas long as ihe parkingbrake

Reminderlight, EGRservice(exceptLambda-Sond)
lf the vehlcle is equ pped with an EGR(ExhaustGas Be&culation) 15OO0 mile serviceremindef light, as Agency. required bytheU.S. Envionmental Protection This the lighi wil come on ar 15000 mile interuals. The light ls a reminderto gei the EGRvalve servlced. wil stay on until .eset by rhe dealer. NOTE: Warning lights, generally, are lights which il prouminateto indicateth.t a deviceis noi operatrng

Bulbfailure warninglight
T h e l i g h , c o a e s o n i f . 1 y o i r h e ' o l l o w r n q. g l r 1 " ) i one of the lower beams One of the taillights one of the license plate lights one of the take lights {when the brake peda is de I n d i c a t o r i g h t s .9 q " r a l . a e l g l ' r s w h . h ' u r r n d r o l to indicate that a device is operating.

(

Testing speedometer and odometer assembly

lf speedometeror odometer s not functioning, ihe reason may be a fault in Lnslrument speedometer or cable or the worm gear in the transmission, ln the or

50O rpm lOO0rpm 1750 rpm

Speedometer readins 31.5 I 2.5 mph

f the sp€edometer funct ons while the odometerdoes not, or vice'versa, the instrument is deiective and should be replaced.No attempt should be made to repar rne Insvumenr. W h e _b o r hs p e e o o n e r e ' a no o o ne , e ' { o p f - n c o n d ing,the fault ls probablyin speedometer cableor gear. Disconnectspeedomeiercable f.om instrumeni and see if it can be roiated, ChecL rhe cable and the drive dt the trdnsmission C h e c l r h e d n v eL o - p n g s ' o l a l e e a s . l ' f r r . a - s h F instument should also be repaced. The speedometer can be checkedby rufning it at dffer€nl speecls. Thefollowing valuesshouldthen applyl

t
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drive cable SDeedometer
It is rnost important ihat the speedometercabe s correctlyiitted if the speedomeler to functon wthis out trouble. t is vitaly imporiant thar the cable is nol benl too sharply.At no point must the radius of a bend be less than 100 mm (4"). lf it s ess than this, vibration and noise can occur in the inslrument.The drive couplingsmust run trle in the outer casing of the cable. This is checked with

54

Group38

Replacing instrumentcluster
I Remove cove6 roundthe steering the coturnn. 2. Bemove the bracketretaining screws. Allow the bracket slip down on the sreerinq to

Removs retainingscrewstrom the instrum€nt the Disconnect speedometer cable, Grip the reve.se side of the speedometer and pressthe Instrument up,oul until the snaplock at the instruments upperedge releases. 5. Lift out the instrument disconnect rer and the m;nalblockon the reverce side. 3.

Replacingtachometer
1 . (Remove instrument cluster, above). see 2. Remove three retaining screws, 3. Carefully removethe instrument. terminats The can easilybe damaged. (or 4. Installtachometer cove, as shown.

Replacingspeedometer assembly
t . Remove instrument cluster, above, see 2. Remove tachom€ler blindcover,) (or 3. Remove threespeedometer retaining screws. Carefully rcmovethe instrumem.

Replacing instrumentplate("printedcircuit")
t. 2. 3. 4. 5.
{Remove instrument cluster, see above). Remove tachometer (or bl;nd coved. Remove speedometer. Remove three plate retainingscrews. Carefullyremove the plate. not damagrngremperature of fuel gauge.

Group38

Gauges

Replacing clock
the Disconnect batterygroundcable. Disconnect controlpaneland pull it out. the it the Bemove impactguardbY pushing down. Removetwo screws. the outletandclock.lMark wites Liftout defroster beforedisconnectang. clock screws.Beplace two retaining 6. Bemove is oder. 7. Installation opposite 1. 2. 3. 4. 5.

temperaturegauge/fuelgauge Replacing
1. 2. 3. 4. 5.

Remove inslrument clusler.
Remove tachometer (or blind cover). Remove speedometer. Remove instrument. Remove two retaining nuts on the instrument

6. Remove the gauge. 7.

Replacing 'uelgauge sendingunit (tankunit)
,5016 1. 2. 3. 4. 5. 6. 7. 8. 9, Disconnectthe battery ground cable. Unfold the mat in the luggage compartment. Remove cover and disconnectground wne. Disconnect wire at the sendingunit terminal. the Disconned the return hose at the sendrngunrl. Disconnectand move aside the breather hose. Use tool 9995016 to remove rhe sending unat. Installthe new sendingunit with a new gasket. Installationis opposite order.

o

t56
38 Grcup

Gauges

Testing temperature gauge or fuel gauge

lf a lemperalure orluelgaugeis notwo*ing properly, the gaugesystem be tesledas lollows: can

METHOD
A. T€slingthe voltagesiabilizer. 1- Connect testresistor (panno.9995158-4) the the to inslrument pfopedy.In other whichis functioning words, lhe,uelgaugsis nol functioning il prope y, disconnect lemperature gaugecablefromthe the sensorand connect test resistor the belween the ground. sender cableandvehicle 2. 140,160-1974 240,260 The pointer should nowbe horizontal (tolerance pointer + widlh). polnterpointsoutsidethe toleF lf the inslrumenl ence range,thenthe voltage stabilizer faulty. is It lhe instrumentpoinfer is within the tolennce range!continue SlepB. wilh B. Testing gaugeandsender. the 1, Disconnect cable thefaultyinslrumenl lhe !o sender andconneci lest€sistance the between sender ihe ground. cableandvehicle
w,@-19A/2AO,N

pointer horlzontal insidethe 2. ll the instrumenl is or ma*, thenthesenderis laulty(tolerance poanter + width). Checkthe luel gaugesenderaccording to lvanual,S€c-3 240 or 260 se es, Elec. Servace (TP System Instrumenls ii402 or 11413). & lfthe pointer oulside lolerance is range, the thenlhe instrument faulty. is Test resistol P/N: (bluecable) 9995158-4 Volvo140,160-1976, 240,260

SpareParts
P/N 9999145-7 Resislor 100 1W5%140,160-1974 240,260 Replacing the resistor Disconnect cables the and openthe holder. Place lhe newresislor the holder allow rcsistor in and the conneclions project to lrom lhe holder.Insedthe conneclion cables partofthe andlighten Cuttho up. resislor cablewhichprojecls.

Group38 Instruments

57

Testingfuelgaugesand tank levelsenders
To avoid unnecessary r€placemsntg following procedures should be used when checkingcomplainrson th€ fu€l gaug€indications. To check a mastergaugeis needed. This is a gauge which has corect resistance.

Masteagauge Obtain a fu€l gaugetank senderfrom Parts Department ancl check it with an accurate ohm-meter An extra accuratemaster gauge should stay within th€ followinglimhs: Upperend position {Fulltank} 40ohmst2ohms Boftom end position {emptyl 282 ohms a 14 ohms It mightbe a goodidea bsndths movement to limiter to obtain correct readings. Position Omm 15mm 84 mm 1 9 1m m

19?6ModelShorvn

282 t 223 A 98 a 40 t

48 ohms 26.5ohms 14 ohms 5 ohms

NOTE:Checkvehiclespecilicalions.

A2
Disconnect blue(brown) the wire at the fu€l gauge tank senderin the trunk Instead,connectthe master gaugeand groundit.

1,7mm

A2
Swhch ontheignition. Compare fuelgaugo rsadingwith pictureat leftr showing deviation permitted at €nd of st.okes. Correct reading:proca€d to A3. Incorrsct reading:proceed to A4.

n

58

Gtoup38 lnstruments

Testing fuel gauge

A3
Check connections Check that the terminal prns(1) have corect conracr and thal the nuts (2) are tighrened. Also check temperEturegauge nurs.

0
44 Test operation of voltage stabilizer To do this,usea new voltage slabiizer test gauge to puli To replace voltage stabilizer, straight out so the pins three loose come fromtheretainers-

A5
percistsin spite of operationsaccording lf mis-reading ro 1 and 2 above. re install the ordinaryvoltage stabilizer and replace fuel gaugethe The luel gauge tank sender rcmains as possible

A6
Bemove the tank sender.

,72!2
Check thai the tank sender lever operates without bind ns.

A8
Use an ohrn meter to check resisrance, urements as shown in il[]srration at left. ll might be convenientto make a fixilre c itates a quick sefting. 0mm 15 mm 84 mm

282 I 223 t 98 :t 40 :l

48 ohms 26.5 ohms 14 ohms 5 ohms

Group38

59

Testing fuel gauge

VOLVO 112 BB2
li a cusromerstil complainsin spite all specificalions a r e w l h n l i m i t s ,t m u s l b e e x p a i n e d o h m t h a t t h e t e x p a n s o na n ki n s i d eh e f u e l t a n kc a u s e sh e r e a d i n g t i t to drop fasler al full tank. The expansiontank capacityis approx. 6 liters (qts). t is slowy fiied with fuel. When filling f!el. the expanson tank is srill almost empry when rhe tuel tank has been filled. It lakes approx.30 minLrtes fill ihe expansion to tank. This will causethe leve in lhe fuel tank io drop and, in addition to the fuel used, this mght qive the m pressionlhe gauge readingis lower than normal and the gauge incorect. The p!rcose of the expansiontank is to prevent the flel tank from releasing fuel in caseswhen lhe tank has been filled whh cod fuel whrch then heats up

olr
I

olher publicaNOTE:Eadytype illustraled-consult fuel iionsfor newdesign lank specificalions.

Testingtemperaturesensor
The sensoris checkedby heatingh in water and reading resistanceand temper.ture. Besistancemay deviate :t 10%.

.l

50oc = 122oF loooc = 212oF = 12OoC 24AoF

282 ohms 60 ohms 40 ohms

t

107 366

60

Group38

Specifrcations

Additional Information

Mainand PumpRelayApplication
1974/1975 lrodelg

Eoth pump and main relay are the sarhe. They are locatedin the enginecompanment, They are inlerchangeable.

.1975/192 Models
Boththe main and pump rslays are locatedunder the dash nearlhe hood relsasecable, The pumprslayis easiv dislinguished lhe main lrom relay by a heavy gauge yellow wire in its mulliplug (#87),whichgoeslo luel pump. In most cases, lhe pump relay ls fitted with a whils plastic plug.

Eo5cn t0332 ?Ol lO2

v

I

PJr!!-Er&v lblF tlz3t75l ||lvo 'l2t50D! ,03t2 015 0t
r>

torP oa lla
!!F.!..d.. Ey

Theselwo relays CAUTION: mustneverbe interchanged.

Group36 Ralays

61

SpecrTlcadors

Maln& PumpRelays
lrodels 1978/1979

!2r5337-l

This relay is located underthe dash n€arthe hood releasecable.

192/1979Models gs!g:99!4-e,g a2

This r6lay is localedunderthe hood near the batlery, Volvo#1235013-8. Both rolaysus€ th€ same Volvonumber. bslween the Themounting bracket theonlyditference is ea.lyandlateversion.

62

Group36 Relays

llatioml Instihrte tot AUIO ONYT sElvtGt EXCEU.EilCE

VOI-VO SUPPOBTS VOLUIITARY

rrrEcMt{tc FtcAfl cEn 0rl 8YTHE lt.t.t.S.t.
(U.s.A. only)