FOREWORD
This instruction book deals chiefly with the
Volvo 142, 144 (two and four doors)
Engine: B 20 A
Volvo 142, 144 de Luxe
Engine: B 20 A or B 20 B
Volvo 142, 144 Grand Luxe
Engine: B 20 E
The Grand Luxe model goes under the de-
signation of 1 42 E in U.S.A., where only the
two-door version is available.
Volvo 142, 144 de Luxe and includes only
the essential differences in the Volvo 1 42,
1 44 and 1 42, 144 Grand Luxe.
Before you start driving your new Volvo
please read through this instruction book
carefully. It contains all the information you
need to be able to drive and service your
vehicle in the best possible way. By follow-
i ng the instructions given in this book, you
will find that your Volvo will come up to all
the expectations concerning economical
operation and excellent performance that
you have every right to expect of a top-
quality vehicle.
This instruction book is not intended to be
a comprehensive technical manual and does
not claim to make the reader a perfect
car mechanic. It will, however, show you
how to look after your vehicle so that
trouble in the future can be avoided. The
better you know your Volvo, the better ser-
vice it can give you. Even for an experienc-
ed motorist this book can contain some
valuable information.
For a more detailed mechanical description
and repair procedures, we refer you to the
special Service Manual for the car which
can be purchased from the dealer.
I NTRODUCTION
Volvo Service Organization
To get the most out of the invested capital
represented by a car, it must be looked after
and serviced regularly. Volvo has gone to a
great deal of trouble in the design and selec-
tion of material to ensure that the car in
question only requires a minimum of
servicing. We rely, however, on your co-
operating with regard to the future main-
tenance of your vehicle. To help you with
this, Volvo has built up a world-wide service
organization. All Volvo dealers have specially
trained personnel and receive a continuous
supply of technical information from the
Volvo Service Organization concerning re-
pairs and adjustments. They have also spe-
cial tools, designed at the Volvo factory.
Moreover, all Volvo dealers have a compre-
hensive stock of parts which is a guarantee
that the part you get is genuine Volvo. That
i s why our dealers are in the best possible
position to give your vehicle first-class ser-
vice concerning both maintenance opera-
tions and repairs. You should also refer to
your dealer for any information about your
Volvo that is not included in this instruction
book.
Volvo not only has a workshop within easy
reach in your own country, it has also a
widely distributed service network in other
countries.
Warranty and Service Booklet
A warranty and service booklet accompanies
each vehicle when it is delivered. This book-
let contains a coupon entitling you to a
service inspection after 2 500 km (1 500
miles). If possible, let the dealer who
supplied the vehicle carry out this service
i nspection. Any of our dealers, however,
can do this if required. If our six-month
guarantee is to apply, we make one absolute
condition and that is that the above-
mentioned inspection is carried out at rough-
l y the mileage shown and that the vehicle
has been looked after in accordance with
the instructions given in this book.
Service Inspections
After the 2 500 km (1 500 miles) service in-
spection has been carried out, you should
come to some arrangement with your dealer
concerning continued, regular service in-
spections in accordance with the su gg es-
tions made in our Service Book. Thorough
and regular servicing is of vital importance
for the performance and length of life of the
vehicle.
Always use genuine Volvo parts.
 INTRODUCTION

Type designations

I n all correspondence concerning your

vehicle with the dealer and when order-
i ng parts, the type designation, chassis
and engine number should always be
quoted.

1. Vehicle type designation, code numb-

er for colour and upholstery: on
bulkhead.
2. Body number.
3. Type and model year designation (U)*
as well as chassis number: stamped
on right door pillar.
Type and chassis number are also to
be found on a plate on the windscreen
left-hand post.
4. Type designation, serial number and
part number of engine: stamped on
engine left-hand side. The final figur-
es of the part number are stamped
on a plate. The serial number then
follows with all its figures stamped
on the block.
5. Type designation, serial number and
part number of gearbox: underneath
gearbox.
6. Final drive reduction ratio, part numb-
er and serial number: on a plate on
l eft-hand side of final drive.
Not in U.S.A.
OPERATING INSTRUCTIONS


OPERATING INSTRUCTIONS

I NSTRUMENTS AND CONTROLS The instrument and controls are described

1. Windscreen wiper and washer switch
2. Choke control
Switch for foglights, page 10
3. Switch for electrically heated rear
window
4. Instrument panel
i n more detail in the following pages with
a reference to the numbers in the picture
opposite. Note that variations may occur
between different markets.
2 Choke control
The choke control is used when the en-
gine is started from cold. When the
control is pulled out about 10-15 mm
(1/ "), the idling speed is increased.
Pulling the control out further enriches
2

5. Lighting switch
the fuel-air mixture.
8. Turn indicator switch l ever, dimmer and
headlight flasher
7. Combined ignition s witch and steering
wheel lock
8. Fan switch
1 Windscreen wiper and
9. Emergency warning signal flasher washer switch
switch
1 0. Cigarette lighter The windscreen wipers are operated elec-
11. Heater/ventilation controls trically and can be adjusted to two
speeds. Normal speed is attained by 3 Switch for electrically
1 2. Ashtray
pulling the switch out to the first posi- heated rear window
1 3. Grab handle tion. This speed is recommended for
1 4. Parking brake normal driving in rainy weather or snow. I n order to obtain a clear rear view
When the switch is pulled out fully, the during cold and damp weather, the car
1 5. Fresh-air intake
wipers operate at full speed. Full speed i s fitted with an electrically heated rear
1 6. Bonnet release handle window. Heating is by means of wires
i s only recommended when driving in
17. Clutch pedal heavy rain or when driving at high speed on the inside of the rear window. Avoid
1 8. Brake pedal i n the rain. placing any objects near there which
When the switch is pressed fully in, the might damage the wires.
1 9. Accelerator pedal
wiper blades stop in their parking posi- When the switch is pulled out one notch,
20. Fuse compartment tion. The windscreen washers are operat- an output of approx. 50 watts is obtain-
21. Gear lever ed by turning the switch clockwise. The ed. With the switch pulled out fully, the
22. Clock switch automatically returns to its initial output is 200 watts. As long as the
position on being released. The fluid electrically heated rear window is
23. Place for radio
container for the washers is located in switched on, a warning lamp lights in
24. Glove compartment the engine compartment and holds the switch.
25. Place for loudspeaker about 1.5 litres (2 /4 I mp. pints=3'/4 Switch off when the rear window is clear
3

26. Fresh-air intake US pints). to save the battery.

OPERATING INSTRUCTIONS
4 Instrument panel
A Panel light switch
B Fuel gauge
C Speedometer
D Coolant temperature gauge
E Warning light, charging
F Turn indicator warning light
G B Fuel gauge
Parking brake warning light (functions
also as a warning light for both
service brake circuits)
H Mainbeam warning light
Oil pressure warning light
J Mileometer
K there are approx. 8 litres (2 Imp. g alls=
Speed warning indicator
L Trip meter
M Trip reset knob
A Panel light switch
Turning the knob clockwise or anti-clock-
wise increases or dims the lighting on
the instrument panel.
The fuel gauge is graduated "full", "half",
"reserve" and "empty". The red field
between "reserve" and "empty" is a
reminder that the tank should be filled.
When the gauge pointer is on "reserve",
2 1/2 US galls) in the tank. The gauge
pointer registers when the ignition is
switched on,
C Speedometer
The speedometer consists of a horizontal
scale marked in intervals of 10 m.p.h.
The speed is indicated by a red ribbon.
D Coolant temperature
gauge
The temperature gauge shows the tem-
perature of the coolant and thus indicates
the working temperature of the engine.
The gauge pointer should normally re-
main within the green sector.
During town driving and idling when the
weather is particularly warm, the tempe-
rature gauge pointer may enter the field
marked with oblique red dash lines.
E Warning light, charging
This lights red when the battery is dis-
charging. Should it light up during driv-
i ng, either there is some fault in the
electrical system or the fan belt is not
sufficiently tensioned and is thus slipp-
i ng on the alternator pulley, causing
poor charging.

F Turn indicator warning light
This lamp flashers with a green light
when the turn indicator switch is moved
upwards or downwards and the ignition
i s on.
G Parking brake warning light
(functions also as warning
light for both service
brake circuits)
This lights red when the parking brake
i s applied and the ignition is on.
The light also functions as a warning light
should a failure arise in one of the brake
circuits. If the light goes on during driv-
i ng, the car should be driven without
delay to a workshop for a check on the
brake system. Observe due care when
driving under such conditions.
H Mainbeam warning light
This lights blue when the headlights are
switched to mainbeam by the switch
l ever (6).
OPERATING INSTRUCTIONS
I Oil pressure warning light
K Speed warning indicator
This lights yellow when the engine oil
pressure is too low. When the ignition The speed warning indicator is mounted
i s switched on, the light should go on on the speedometer and consists of a
and then go out again when the engine
manually adjustable sliding arrow. Its
starts. Never start driving until the li ght purpose is to remind the driver of the
goes out. If the light goes op during
particular maximum permissible speed in
driving, stop the engine and find out the connection with speed limit regulations .
reason for this. In most cases it means
that the oil level is too low. After hard
driving it may happen that the warning
li ght comes on when the engine is idling.
This is normal providing it goes out
again when engine speed is increased.
L Trip meter
The trip meter measures distances of up
to maximum 999 miles. The window
furthest to the right is graduated in
tenths of a mile and is useful for mea-
suring short distances.
J Mileometer
The milometer shows the total distance M Trip meter reset knob
covered in miles. After 999999 miles it
returns to zero and starts to go round The trip meter is set to zero by pushing
again. i n the reset knob.
OPERATING INSTRUCTIONS -

The lever is also used for flashing with

mainbeam when the headlights are not
5 Lighting switch switched on. The headlight flasher is
switched on by moving the lever towards
The headlights are operated by means the steering wheel and it remains switch-
of a push-pull type switch on the dash- ed on until the lever is released.
board as weir as a lever (6) on the
steering column.
All the lights are extinguished when the
li ghting switch is pushed fully in. Pulling
i t out to the half-way position, switches
on the parking lights, and when it is
fully out, the full or dipped headlights
are switched on, depending on the posi-
tion of the lever (6).
Since the lighting system is not connec-
ted across the ignition switch, the lights
will function irrespective of whether the
i gnition key is in position or not.
On certain markets the Volvo 140 is
fitted with side marker lights. These are
l ocated on the sides of the mudguards
and are switched on by pulling out the
switch knob for the headlamp lighting.
6 Turn indicator switch lever, dimmer
and headlight flasher
Switch for foglights
The switch lever on the left-hand side of
The Volvo 142, 144 Grand Luxe are fitted the steering column just below the steer-
foglights. The switch for these lights is i ng wheel controls the turn indicators,
l ocated in the same place as the choke dipped headlights and headlight flasher.
control (2), see picture for instruments Moving the lever upwards, operates the
and controls on page 6. right-indicator, and downwards the left- 7 Combined ignition switch and steering
The foglights are switched on by pulling i ndicator. wheel lock
out the switch, providing either the park- Switching from mainbeam to dipped
i ng lights or dipped headlights are on. beam and vice versa is carried out by The switch has four positions: (0) Lock-
To conform to traffic regulations, the moving the lever towards the steering i ng position, (1) Intermediate position, (2)
foglights for certain markets are wired wheel and then releasing it. Here the Driving position and (3) Starting posi-
across the parking and fullbeam head- l ighting switch (5) should be pulled fully tion. The key can be taken out of the
li ghts or only across the parking lights. out. l ock only in the Locking position.

8 Fan switch
On certain markets the ignition switch is
provided with a buzzer to warn the driver
should he forget to remove the ignition
key when his door is opened.
Removing the key automatically locks
the steering wheel.
With the key in the Intermediate posi-
tion, the electrical system is connected
up except for the engine ignition system.
The steering wheel is not locked.
To start the engine, turn the key to the
Starting position and this engages the
starter motor. As soon as the engine
starts, release the key which automati-
cally returns to the Driving position.
OPERATING INSTRUCTIONS
I f the car is parked in such a way as to
make it difficult to unlock the steering
wheel, unlocking can be made easier
by slightly turning the steering wheel
one way and then the other.
9 Emergency warning
flasher lights
When the switch for the above is pulled
out, all the emergency warning lights
start to flash at the same time. A warning
l amp mounted in the switch blinks in
unison. The warning light is not connected
The fan is operated by means of a push-
across the ignition and therefore func-
pull switch which can be set at two
tions irrespective of whether the ignition
different positions. Pushing the switch
key is inserted or not.
fully in stops the fan, 'pulling it out to
The emergency warning flasher lights
the first position operates the fan at full
should only be used when the car must
speed and when pulled fully out, the
be stopped where there is danger to
fan operates at half speed.
other traffic.
Due to the aerodynamic design of the
Note that regulations for the use of
car, the overpressure in the air intake is these lights may vary in different count-
relatively small. Therefore, at speeds
ries.
below 80 km.p.h. (50 m.p.h.), the fan
should be allowed to operate at full
speed if maximum air capacity is de-
sired. On the other hand, however, the
fan should not be used if cooling air is 1 0 Cigarette lighter
required on a hot summer's day. Instead,
open both the fresh-air controls (15, 26), To use the cigarette lighter, push it in.
the defroster control "DEFR" and the The lighter releases automatically when
ventilation control "FLOOR". it attains sufficient heat.
OPERATING INSTRUCTIONS
11 Heater/ventilation
controls
The control on the left, TEMP, regulates
the temperature of the incoming air. The
middle control, DEFR, regulates the air
flow to the windscreen. And the control
to the right, FLOOR, regulates the air
flow to the front seat and rear seat floor.
The temperature, also the air flow, is
i ncreased by moving the controls down-
wards whereby a red strip marked down
the middle of the control in question
i ndicates the size of the opening. Note
that when altering the temperature con-
trol, there will be a slight delay before
the desired temperature is reached.
To avoid mist -on the windows, set the
fan and defroster controls at maximum
output. However, the fresh-air controls
(15, 26) should be closed. Try to avoid
water on the floor and under the mats
as this increases the humidity and there-
by misting, particularly during the win-
tertime.
1 4 Parking brake
The parking brake lever is on the outside
of the driving seat and operates on the
rear wheels only. When the parking brake
i s applied and the ignition is on, a red
warning light (4, G) shows on the instru-
ment panel.
Remember that the footbrake warning
system is also connected to this light.
Should the light show when the parking
brake is not on, this may be due to a 1 6 Bonnet release handle
failure in one of the brake circuits. If this
i s the case, drive immediately (but with The bonnet lock is released by pulling
due care) to a workshop for a check. out the handle situated to the extreme
l eft under the dashboard. This will re-
l ease the bonnet which is still retained
1 5, 26 Fresh-air controls by the safety catch.
Sliding the control forwards opens a
fresh-air intake on the driver's or pass-
enger's side. Note that the fan should
not be operating if cool air is desired
through these intakes.

The bonnet is opened by inserting the
fingers under the front edge and press-
i ng in the catch as shown in the picture.
Check that the bonnet locks properly
when closed.
The location of the bonnet when closed
can be adjusted if necessary by screw-
i ng in or out the rubber plugs under-
neath the bonnet at the front end and on
the mud g uards below the windscreen.
20 Fuses
The electrical equipment is protected by
a number of fuses housed in a compart-
ment under the dashboard. If a fuse has
to be replaced, always make sure that
i t is replaced with a fuse of the correct
rating. Should fuses blow repeatedly, do
not replace with a fuse of higher rating.
I nstead, have a check the
workshop
electrical system.
Eight spare fuses can be stored on the
i nside of the fuse compartment cover.
OPERATING INSTRUCTIONS
1. Windscreen wipers, windscreen washer 8 A
2 Warning lamp, fullbeam headlights 5 •A
3. Heater fan, Warning lamps,. Instrument panel 8 A
4. Reversing lights, Overdrive, Flashers 8A
5. Elec. heated rear window, Horn 16 A
6. Interior lighting, Glove locker 5A
Warning buzzer for ignition switch
7. Clock, Brake lights, Brake warning light 8A
8. Left rear light, Parking light ..; 5A
Left side marker light, Clock light ,
Number plate light (L-H steering)
9. Right rear light, Parking light 5A
Right side marker light
Number plate light (R-H steering)
I nstrument panel light
On the Volvo 142, 144 Grand Luxe there is an extra
fusebox fitted next to the relays in the engine com-
partment. These fuses protect:
1. Relay for fuel pump, Relay for start valve 8A
2. Left foglight 8A
3. Right foglight 8A
OPERATING INSTRUCTIONS
22 Clock
The clock is operated electrically. To re-
set it, push in the re-setting knob and
turn the hands.
The clock is not fitted on the Volvo 1 42,
1 44 and on all models for U.S.A.
I NTERIOR AND BODY
Front seats
The front seats can be moved forwards and
backwards by depressing the knob on the
outside of the seat. Exert leverage with your
feet on the floor and slide the seat to the
most comfortable position.
The rake is smoothly adjustable by means
of the adjuster lever on the outside of the
backrest support. (On 1 42 and 144 this
adjustment is done with a knob.) Lift the
l ever upwards in order to release the fric-
tion catch and adjust the backrest to the
desired position. Lock the backrest by
pressing down the lever.
Head restraints
The front seats are fitted with adjustable
head restraints. Before driving, you should
always make sure that the head restraint is
adjusted to a suitable height. Adjust by
slackening the plastic nuts on the head rest-
raint retainers, see picture. On delivery; the
restraints are adjusted to standard height.
After adjustment, lock by turning the plastic
nuts clockwise.

Lumbar support
The front seats are provided with an adjust-
able l umbar support. Adjustment is by
means of the knob on the inside of the
backrest. To tension the lumbar support,
and thus exert more pressure against the
small of the
andback, turn the knob clockwise
"FIRM", to relieve the pressure against
the small of the back, turn the knob anti-
clockwise "SOFT".
Lock device in folding seat fittings
The front seat backrest in the Volvo 142
model is locked against forward tilting by
means of a catch. To fold the backrest for-
wards, the catch device must be released
by pressing down the lever as shown in the
picture.
Adjustments
The seat level can be adjusted to three
different positions. To do this, remove the
seat cushion in order to reach the bolts in
the seat bracket. Remove the two bolts
attaching the frame to the seat bracket. Set
the seat to the desired position and fit the
bolts into the holes which are at the same
height on both sides.
When this adjustment is being carried out,
it may also be desirable or necessary to
adjust the entire inclination angle of the
seat. This is done with the eyelet screw at
the front under the seat frame. Remove the
bolt which goes through the eyelet and tilt
the seat backwards. Then slacken the lock-
nut on the floor and adjust the eyelet screw
to the desired height. Re-fit the bolt and
secure the eyelet screw with the locknut.
The passenger seat can be turned opposite
OPERATING INSTRUCTIONS
to the driving direction so as to provide a
safety seat for a small child. This is done
by removing the four nuts holding the seat
frame to the slide rails. Lift off the seat and
turn it round so that it faces in the opposite
direction. Re-tighten the nuts firmly. Note
that the catch fittings must remain in posi-
tion on the outside in order to be able to
l ock the seat.
Due to an extra group of holes in the seat
attaching member the seat can be moved
beyond the point permitted by the slide rails.
OPERATING INSTRUCTIONS

Safety belts
Always use the safety belt for all types of I f the belt requires lengthening, first slacken I f the belt requires shorting, pull in the
driving. Remember that it is possible even in the upper section of the lap belt and take upper part of the lap strap's double section,
slow city traffic to incur serious injury from hold of the adjusting piece with one hand see picture right. After a certain amount of
sudden, unexpected stopping. and with the other hand pull out the lap practice, all adjustments can be carried out
The practical design of the belt makes it strap to the desired length. Tidy up belt with the one hand. The belt is released by
very easy to use. Place the belt with one slackness by pulling in the upper part of the moving to the rear the respective lever in
strap over the lap and the other across the double section. the locking device.
shoulder - chest and fasten it by pushing
the buckle tongue into the slot of the lock-
i ng device located between the front seats.
A loud clicking noise indicates that the
tongue is securely locked.
Make sure that the sections of the belt in
contact with the body are not twisted. Al-
ways make a point of ensuring that the belt
l ength is such that the belt fits well against
the body.

Do not let the belt lie on the floor otherwise
i t will become entangled and dirty as well
as hinder getting in and out of the vehicle.
Now and again check that the bolts anchor-
i ng the belt are properly tightened and that
the belt is in good condition. Water mixed
with some synthetic washing agent can be
used for cleaning the belt.
As the safety belts lose much of their
strength when exposed to violent stretching,
they should be replaced after collision, even
though they may appear to be undamaged.
Never modify or repair the belt on your
own, but have this done by a Volvo work-
shop.
Automatically retracting inertia
safety belts
Certain models are fitted with automatically
retracting inertia safety belts.
To fit the belt, pull out the strap slowly to
prevent the mechanism from locking. Norm-
ally the safety belt roller is "unlocked". The
roller will lock automatically if pulled out
quickly, or if the car brakes °or inclines to
an angle greater than 14-15 or when tak-
i ng a bend rather sharply.
The belt is fitted, fastened and maintained
i n the same way as the ordinary safety belt,
see page 16.
OPERATING INSTRUCTIONS
Safety belts in rear seat
On certain markets safety belts are fitted as
standard in the rear seat. The belts are of
the two-point type.
The belts are fastened by pushing the
buckle tongue on the one strap into the
l ock of the other. They are released by lift-
i ng up the spring-loaded "cap" on the lock.
Adjustment is the same as for the ordinary
front seat belts.
OPERATING INSTRUCTIONS

To lock the rear doors it is not necessary

to press in the small knob under the outside
handle.

Do not leave the keys in the car.

The door locks have been designed with a

view to providing maximum possible protec-
tion against freezing during the wintertime.
As an extra measure, however, you should
l ubricate the locks regularly during very
cold weather with a suitable anti-freeze
agent. If the lock is already frozen, be care-
ful not to break the key in the lock. Instead,
heat the key and immediately place it in the
l ock. This should unfreeze the lock. Should
you lose the car keys, contact your nearest
Volvo dealer for new ones and quote the
code number of the keys which have been
l ost.

Doors and locks Ventilation window

The car is fitted with a lock and keyhole on
each of the front doors.
All the doors can be locked on the inside
by pressing down the lock button on the
window ledge. On the front doors this lock
button lifts automatically when the door is
opened from the inside. On the rear doors,
however, the lock button must first be pull-
ed up before the doors can be opened from
the inside. This is an advantage if children
are alone in the rear of the car.
The front doors can be locked from the out-
side by pressing the lock button on the
window ledge down and shutting the door
while pressing in the small knob just under
the door handle.
Rearview mirror
The inside rearview mirror is provided with
an anti-dazzle knob at the bottom of the
mirror. The mirror is switched to anti-dazzle
by pushing the knob sideways.
On the Volvo 142, the rear ventilation
windows can be partly opened by turning
the handle upwards as in the picture.
Front ventilation window opener
To open the front ventilation window, screw
out the lock knob on the small handle a
couple of turns, press in the knob and turn
the small handle forwards.
On certain markets another type of opening
handle is fitted and the ventilation window
i s opened simply by pressing in the button
and turning the handle.

I nterior lighting
1. The light comes on when either front
door is opened.
2. The light is always extinguished.
3. The light is always on.
Luggage compartment
The luggage compartment is locked with the
same key as that used for the doors. The
li d is opened by turning the handle clock-
wise and lifting the lid up at the same time.
Note that the key must be removed from
the lock in order to turn the lock knob. The
li d is balanced and will remain stationary in
i ts opened position. The spare wheel is se-
curely held in position to the right in the
compartment. The jack and tool kit are
fastened to the spare wheel. Under the floor
of the compartment to the left there is suffi-
cient space for an extra spare wheel, for
stowing tools or a reserve fuel can.
OPERATING INSTRUCTIONS
Sun-roof
Certain of the models are fitted with a sun-
roof.
The sun-roof is opened and closed by a
winding handle. When not in use, the handle
i s folded in the recess in the roof between
both the sun visors.
To close the sun-roof, wind it forwards
fully, then wind back the handle a little and
fold it into the recess in the roof.
OPERATING INSTRUCTIONS

Warranty inspection

After 2 500 km (1 500 miles) the vehicle

should be taken to a Volvo workshop for
STARTING AND DRIVING the warranty inspection. Included with the
checks and adjustments then made is a
Running-in change of oil in the engine, gearbox and
rear axle. It is very important to ensure
The maximum permissible speeds given below must not be exceeded in the beginning that this oil change is carried out since
when the moving parts of the car are in the process of adaption in order to achieve during the running-in period the engine oil
overall smooth function: usually collects a lot of impurities. Subse-
quent oil changes should be carried out at
below the first 1000 km between 1000 and 2000 km approximately those intervals indicated in
(600 miles) (600 and 1200 miles) the maintenance scheme on page 40 and in
1 st speed 30 km.p.h. (20 m.p.h.) 50 km.p.h. (30 m.p.h.) the lubricating chart at the end of the book.
2nd speed 55 km.p.h. (35 m.p.h.) 75 km.p.h. (47 m.p.h.) Before being delivered, all Volvo engines are
3rd speed 80 km.p.h. (50 m.p.h.) 1 00 km.p.h. (60 m.p.h.) test-run on test benches and in the ve-
4th speed 1 1 0 km.p.h. (70 m.p.h.) 1 30 km.p.h. (80 m.p.h.) hicles on test tracks. We are therefore
assured that all clearances are satisfactory
Avoid driving at high speed in low gear and using the kick-down (on vehicles with auto- and we thus accept no responsibility for
matic transmission) during the first 2000 km (1200 miles). damage caused by careless running-in.
 OPERATING INSTRUCTIONS
Gear-changing
The gearbox is synchronized on all forward
gears. If synchronization is to function satis-
factorily, the clutch pedal must be fully de-
pressed. Never let the engine drag in high
gear. Change down in good time.
The Volvo 1 42, 144 i s fitted either with a floor-
mounted gear lever, a gear lever mounted
on the steering column, a floor-mounted
gear lever with overdrive or an automatic
transmission.
Note that not all these types of transmis-
sions or combinations are available on a
number of markets.
Floor-mounted gear lever
Gear-changing with a floor-mounted gear
l ever is quite conventional and the different
gear positions are shown in the picture
above.
Steering column-mounted gear lever
On certain markets, Volvo 1 42, 144 models
can be obtained with the gear lever mount-
ed on the steering column.
Overdrive
The overdrive, which can be used on fourth
gear, is operated by means of a lever to
the right under the steering wheel. Moving
the lever downwards engages and up-
wards disengages the overdrive. No extra
operation of the clutch pedal or accelerator
is normally necessary but engagement of
overdrive is facilitated if the accelerator
position is maintained steady. When dis-
engaging the overdrive, light pressure on
the clutch pedal helps to make this opera-
tion more smooth.
The overdrive should not be used at speeds
below 60 km.p.h. (38 m.p.h.).

Automatic Transmission
At the bottom of the instrument panel in
the middle there is a quadrant which shows
the gear selector position. The gear selector
has the following positions:
P = Parking D = Driving
R = Reverse L = Low gear
N = Neutral
Starting the engine
Move the selector lever either to the "P" or
" N" position. The starter inhibitor switch is
automatically disconnected if the selector
l ever is moved to any of the other posi-
tions. The selector lever can be moved
freely between the "N" and "D" positions,
but not between the other positions. For this
reason, the selector lever must first be lifted
towards the steering wheel before it can be
moved into any of the other positions. If the
car is temporarily stopped and the selector
i s moved to the "R", "D" or "L" position,
apply the parking brake or the footbrake to
stop any tendency for the car to "creep".
Selecting
Normally position "D" should be used for
driving. The transmission then starts in first
gear and automatic upchanges to second
and third gear occur in accordance with
road speed and accelerator position. Auto-
matic downchanges from third to second
and first occur with decreasing vehicle
speed.
The "L" position is the so-called "low-
speed" position. Moving the selector lever
from "D" position to "L" position changes
down the transmission to the next lower
gear. With the selector in this position dur-
i ng driving, 1st gear is automatically en-
gaged if the speed is below about 10
km.p.h. (6 m.p.h.) or during kick-down below
50 km.p.h. (30 m.p.h.).
No upshifting takes place with the selector
l ever in the "L" position.
The "L" position is used for
1. Obtaining immediate manual down-
changing
2. Providing powerful engine braking when,
for example, going down a steep hill
3. Obtaining a high engine speed, if so re-
quired.
OPERATING INSTRUCTIONS
The "N" position is the neutral position,
that is, no gear is engaged.
The "R" position is used for reversing. Do
not engage "R" position until the car has
stopped.
The "P" position is selected for parking
with or without the engine running. Do not
engage "P" position until the car has stopp-
ed. When parking on a hill, the parking
brake should also be applied.
Driving
Select the position, release the brake and
the car will start rolling slowly. Very rapid
acceleration is obtained by depressing the
accelerator pedal to the floor, kick-down.
The car is stopped in the normal way by
releasing the pedal and applying the foot-
brake. No manoeuvring of the selector lever
i s required.
I f the car has to be extricated from snow,
l oose sand or similar, it can be "rocked"
l oose by moving the selector alternately be-
tween the "R" and "D" positions under
continuous light accelerator pressure.
I f desired, manual shifting can be carried
out to a limited extent. In this case, drive
off with the selector lever in the "L" posi-
tion. To shift up to 2nd gear, move the
selector to "D" position and quickly back
to "L" position. Moving the lever to "D"
position engages 3rd gear.
Shifting down from 3rd to 2nd gear and 2nd
to 1st gear is obtained by moving the
selector lever from "D" position to "L"
position or by depressing the accelerator
pedal to floor, kick-down.
OPERATING INSTRUCTIONS

Do not select the "P" or "R" position when

the car is moving.

Do not select "D", "L" or "R" position at a

higher engine speed than idling when the
car is stationary.

Do not select the "L" position at speeds

above 95, 105 and 112 km.p.h. (60, 65 and
70 m.p.h.) for B 20 A, B and E engines
respectively.

Starting by towing

Place the selector in the "N" position and

pull out the choke slightly. Switch on the
i gnition when the car has obtained sufficient
speed and move the selector to position "L".

Towing

I f necessary, the car can be towed with the

selector in position "N", providing the gear-
box is correctly adjusted and the oil is at
the right level. If a fault in the transmission
is suspected, disconnect the propeller shaft
before towing.
 OPERATING INSTRUCTIONS

Engine braking (B 20 E)
During engine braking the injectors shut off.
At about 1 000 r.p.m. they are cut-in again
in order to provide a smooth runover to
i dling speed. If the engine has not reached
about 1 700 r.p.m. before engine braking
starts, the fuel is not cut off.
If the engine is cold, the speed limits are
raised 300 r.p.m.

Braking Towing loop, front Towing loop, rear

When you drive your car in the rain or I f the vehicle is to be towed, the tow line I f the vehicle is to be used for towing, the
through pools of water, even when you are must not be attached to the bumpers, but tow line should be attached to the rear tow-
washing your car, the brake discs and should be fixed to the towing loop on the i ng hook located under the spare wheel
brakes linings may be splashed with water front axle member, see picture above. Dur- well. See picture above .
and this may alter the friction properties i ng towing, the tow line should be kept
of the brake linings. evenly stretched.
Braking, however, will quickly dry out the
brake linings, but sometimes a certain
delay in the braking effect will be noticed.
I f you drive long distances in the rain or
snow slush, you should depress the brake Note: Certain countries have regulations on max. speed when towing.
pedal now and again to heat up the brake
li nings and thus dry them. This should also
be done when you drive the car immedia-
tely after washing it.
TECHNICAL DESCRIPTION

Engine compartment B 20 A and B 20 B

1. Charging relay
2. Expansion tank
3. Alternator
4. Flap housing for air preheating
5. Carburettor (B 20 A)
6. Air cleaner (B 20 A)
7. Air cleaner (B 20 B)
8. Carburettors (B 20 B)
9. Oil filler cap
1 0. Ignition coil
11. Distributor
1 2. Oil dipstick
1 3. Starter motor
1 4. Windscreen washer motor and fluid con-
tainer
1 5. Data plate
1 6. Brake servo
17. Fuel filter
1 8. Brake fluid container
1 9. Reversing light relay (Starter relay
BW 35)
20. Relay, elec. heated rear window
21. Step relay, fullbeam-dipped headlights
22. Steering box
23. Battery
24. Radiator
 TECHNICAL DESCRIPTION

Engine compartment B 20 E

1. Radiator
2. Temperature sensor, induction air
3. Expansion tank
4. Charging relay
5. Air cleaner
6. Pressure sensor
7. Alternator
8. Cold start relay
9. Relay for fuel pump
10. Main relay for fuel injection
11. Throttle switch
1 2. Cold start valve
13. Inlet duct
14. Auxiliary air regulator
1 5. Temperature sensor, coolant
1 6. Oil filler cap
17. Injectors
1 8. Pressure regulator
1 9. Ignition coil
20. Distributor
21. Windscreen washer motor and fluid
container
22. Data plate
23. Starter motor
24. Brake servo
25. Oil dipstick
26. Brake fluid container
27. Relay for reversing lights
(starter relay BW 35)
28. Relay for elec. heated rear window
29. Step relay for fullbeam-dipped
headlights
30. Relay for extra lighting
31. Fusebox
32. Steering box
33. Battery
TECHNICAL DESCRIPTION
ENGINE
The engine is a four-cylinder, water-cooled
carburettor unit with overhead valves.
The cylinder block is made of special alloy
cast iron and is cast in a single unit. The
cylinder liners, which are surrounded by
cooling jackets, are machined directly in the
block. The cylinder head has separate inlet
and exhaust ports, one for each valve.
Lubricating system
Engine lubrication is taken care of by a gear
pump located under the crankshaft in the
sump. The pump is driven by a gear from
the camshaft.
From the pump the oil is forced through the
oil filter and then along oilways to the
various lubricating points. A relief valve is
built into the oil filter and prevents the oil
pressure from reaching excessively high
values. The oil filter is of the full-flow type,
that is, all the oil passes through the filter
before continuing on to the engine lubricat-
i ng points.
Fuel system (not B 20 E)
On certain markets the vehicle is fitted with
an evaporative control system which coun-
teracts fumes from the carburettor and fuel
tank.
Air preheating (not B 20 E)
The engine is equipped with thermostatically
controlled air preheating. This ensures that
the temperature of the induced air is main-
tained constant, thus counteracting ice for-
mation and reducing the warming-up period
after cold starting.
 TECHNICAL DESCRIPTION

Fuel system (B 20 E)

The B 20 E engine is fitted with an electro-

nic fuel injection system.
This system includes an electronic control
unit (8) which converts the impulses from
the various sensors in the engine to con-
trol signals which regulate the four solenoid-
actuated fuel injectors (16). The control sig-
nals influence the opening times of the
injectors and thereby the amount of fuel
i njected.
The mixture of fuel and air is modified the
whole time according to the conditions
under which the engine is running. Engine
speed is governed by the triggering cont-
acts (15) in the distributor, the operating
temperature by the sensor (17) for the cool-
ant, the temperature of the induced air by
the sensor (1) and the engine load by the
pressure sensor (7) which is connected to
the inlet duct. In addition, the control unit
i s provided with information concerning the
position of the throttle valve by means of
the throttle valve switch (4). This informa-
tion is "computerized" in the control unit Principle of operation, fuel injection 1 2. Fuel filter
and re-transmitted in the form of control system B 20 E 1 3. Electric fuel pump
1 4. Pressure regulator
i mpulses to the injectors.
Fuel is injected into the inlet ports in the 1 5. Triggering contacts in distributor
1. Temperature sensor for induction air
cylinder head just before the intake valves. 1 6. Injectors
2. Air cleaner
The fuel is delivered to the injectors via 1 7. Temperature sensor for coolant
3. Throttle
an electric fuel pump (13) which maintains 4. Throttle switch 1 8. Auxiliary air regulator
a constant pressure of 2 kp/cm 2 (30 p.s.i.) 1 9. Idling adjusting screw
5. Cold start valve
i n the fuel line with the help of a pressure 6. Inlet duct
regulator (14). 7. Pressure sensor
On certain markets the car is fitted with a 8. Control unit (electronic) Partial vacuum in inlet duct
system to check fuel evaporation from the 9. Battery Fuel at atmospheric pressure
fuel tank. 1 0. Fuel tank Fuel under 2 kp/cm 2 (30 p.s.i.)
11. Fuel filter overpressure
TECHNICAL DESCRIPTION
Exhaust emission control
Your Volvo is fitted with exhaust emission
control, that is, a system which as a result
of better mixing and distributing of fuel and
air provides a more complete combustion
and thereby cleaner exhaust gases.
On the B 20 A engine, the exhaust emission
control is obtained through the carburettor
which is specially designed for this purpose.
On the B 20 B engine, the exhaust emission
control is provided partly through the car-
burettors and partly by means of a special
i nduction manifold provided with throttles
and a preheating chamber, see illustration
above.
On the B 20 E, the exhaust emission control
i s provided by the electronic fuel injection
system.
When driving at low speeds, the throttles
are closed so that the fuel-air mixture is
forced to pass the preheating chamber.
When higher output is required, the thrott-
l es open so that the fuel-air mixture flows
directly to the cylinders.
Cooling system
The cooling system is of the sealed pres-
sure type and incorporates a circulation
pump. A special expansion tank prevents
air from circulating with the coolant as this
would cause corrosion in the cooling system.
On certain markets the fan is driven via a
slip coupling which permits a max. fan speed
of approx. 3500 r.p.m., resulting in a lower
noise level and increased output.
POWER TRANSMISSION
Clutch
The function of the clutch is to transmit the
power from the engine to the gearbox. The
clutch is of the single dry plate type. Pres-
sure on the pressure plate is obtained from
a diaphragm spring which in its turn is
controlled by the clutch pedal via the throw-
out yoke.

Gearbox
The gearbox has synchromesh on all the
forward gears. Since the gearbox is fitted
with helical gears and the gear lever is rub-
ber-insulated, excellent sound insulation is
obtained.
Automatic transmission
As an alternative, Volvo can be fitted with
a BW 35 automatic transmission. In principle
it consists of two main components - a
hydraulic torque converter and a hydraulic-
ally operated epicyclic gearbox with a
control system. The converter serves as a
clutch and as an extra gear between engine
and gearbox.
TECHNICAL DESCRIPTION
Overdrive
For certain markets, the Volvo 1 42, 144 de
Luxe and Volvo 1 42, 144 Grand Luxe models
are fitted with an overdrive. With the over-
drive, it is possible to reduce the engine
speed while maintaining road speed. This is
l ess wearing on the engine and reduces
fuel consumption at the same time.
TECHNICAL DESCRIPTION
Propeller shaft
The propeller shaft, which is the connecting
l i nk between the gearbox and the rear axle,
i s divided into two sections. The forward
section is flexibly mounted at its rear end in
a rubberized ring.
Final drive
Engine torque is transmitted via the prop-
eller shaft to the rear wheels through the
rear axle. The rear axle is of the hypoid
type, that is, the drive pinion lies below the
centre line of the drive shafts.
Differential lock Rear axle
On certain markets, a differential lock can The rear axle is carried on two support
be obtained as extra equipment. A rear axle arms the front ends of which are bolted to
with a differential lock automatically trans- the body. The rear axle casing is secured
mits the tractive power to the wheel having to the support arms by means of levers.
the best road grip when a wheel begins to Two torque rods are journalled on the cas-
spin. Except for the differential unit, the rear i ng and the body. A torque rod prevents
axle is similar in design to a conventional l ateral movement of the body and rear axle
rear axle. i n relation to each other.
Do not rotate a jacked-up rear wheel if
the other rear wheel is still on the ground.
Due to the differential unit, there is still
drive on the wheel in contact with the
ground. Rotating the jacked-up rear wheel
would thus move the other rear wheel and
may cause the car to topple off the jack.

FRONT END AND STEERING
Front end
The car has independent front suspension.
The front suspension units are mounted on
a strong box member. The member is bolted
firmly to the front section of the body. The
front wheels are journalled in tapered roller
bearings. The front springs consist of coil
springs in which telescopic shock absorbers
are fitted. The car is provided with stabi-
l izers secured to the lower control arms and
to the body.
Steering
The steering is of the cam-and-roller type.
Movements of the steering wheel are trans-
mitted via the worm on the steering column
to the roller on the pitman shaft, which in
turn operates the wheels through a linkage
system.
TECHNICAL DESCRIPTION
HEATING SYSTEM
The heating system is a combined warm
and fresh air system. The incoming fresh air
i s blown by a fan through the cell system
of the element into the vehicle. By means
of the various ventilation controls, the fresh
air can be warmed up and directed to suit-
able places in the car.
From there the air passes out of the car
through a number of extractor vents below
the rear window. This system provides good
ventilation in the vehicle as well as effective
demisting of the rear window and side
windows. The rear window is also electri-
cally heated.


TECHNICAL DESCRIPTION

ELECTRICAL SYSTEM Wiring diagram B 20 A and B 37 = Windscreen wipers

38 = Windscreen washer
1 = Turn indicators 32 cp
The electrical system is of the 12-volt type 39 = Solenoid for overdrive
and is fitted with a voltage-regulated alter- 2 = Parking lights 5 W 40 = Interior light 10 W
3 = Dipped headlights 40 W
nator. The starter motor is operated by 41 = Switch for heater
means of the ignition switch. This switch is 4 = Fullbeam headlights 45 W 42 = Switch for windscreen wipers and washer
also the main switch for the rest of the 5 = Horn 43 = Rheostat for instrument panel lighting
electrical system. The cables to the head- 6 = Distributor 44 = Lighting switch
li ghts, parking lights and interior lighting, 7 = Ignition coil firing order 1-3-4-2 45 = Ignition switch
however, are not controlled by the ignition 8 = Battery 12 V, 60 Ah 46 = Cigarette lighter
switch but can be switched on and off 9 = Starter motor 1 h.p. 47 = Door switch, right
10 = Reversing light switch on gearbox
without the ignition key being in position. 48 = Switch for parking brake control
11 = Warning lamp for headlight fullbeams, 1.2 W 49 = Fuel level indicator unit
1 2 = Step relay for fullbeam and dipped headlights 50 = Reversing lights 15 W
and also headlight flasher
51 = Brake stop lights 25 w
1 3 = Horn ring
52 = Rear lights 5 W
14 = Alternator 12 V, 35 Ah
53 = Licence plate lighting 2X5 W
15 = Relay for reversing lights
54 = Switch for overdrive
16 = Fusebox
55 = Brake warning contact
17 = Charging regulator
56 = Switch for start block and reversing lights
18 = Brake stop light contact BW 35
19 = Flasher relay and switch for warning flashers 57 = Switch for glove locker light
Lighting 20 = Warning light for parking brake, 1.2 W 58 = Electrically heated rear window
21 = Warning light for oil pressure, 1.2 W 59 = Switch for electrically heated rear window
The front lighting on the vehicle consists of 22 = Warning light for battery charging 1.2 W 60 = Side marker lights (U.S.A.)
two headlights (full and dipped beam) toge- 23 = Connector 61 = Relay for electrically heated rear window
ther with two turn indicators and a park- 24 = Glove locker light 62 = Connector unit for instrument
i ng light. The Volvo 142, 144 Grand Luxe 25 = Warning light for overdrive, 1.2 W 63 = Warning buzzer for ignition (U.S.A.)
have also two foglights. 26 = Switch for headlight flasher and turn 64 = Door switch, left
At the rear, the lighting consists of two tail i ndicators
65 = Terminal board
li ghts, turn indicators, brake warning lights 27 = Fuel gauge 66 = Clock
and reversing lights. There are also two 28 = Voltage regulator
li ghts for the rear number plate. 29 = Temperature gauge
Differences may occur for different markets.
On certain markets the car is fitted with 30 = Oil pressure sender
marker lights mounted on the side of the 31 = Switch for overdrive, on transmission SB = Black Y = Yellow
mudguards. 32 = Warning light for flashers, 1.2 W BR = Brown R = Red
The interior lighting consists of a roof light 33 = Instrument panel lighting, 2X3 W GR = Grey GN = Green
and one in the glove compartment. 34 = Temperature gauge BL = Blue W-R = White-Red
Concerning replacement of bulbs, see pages 35 = Lighting for heater controls W White BL-Y = Blue-Yellow
52, 53, 54, 55 and 56. 36 = Heater


TECHNICAL DESCRIPTION

Wiring diagram B 20 E 34 = Temperature gauge 70 = Relay for start valve

35 = Lighting for heater controls 71 = Pressure sensor
1 = Turn indicators 32 cp 36 = Heater 72 = Throttle valve switch
2 = Parking lights 5 W 37 = Windscreen wipers 73 = Cold start valve
3 = Dipped headlights 40 W 38 = Windscreen washer 74 = Temperature sensor
4 = Fullbeam headlights 45 W 39 = Solenoid for overdrive 75 = Temperature sensor
5 = Horn 40 = Interior light 1O W 76 = Injection valves
6 = Distributor 41 = Switch for heater 77 = Triggering contacts
7 = Ignition coil firing order 1-3-4-2 42 = Switch for windscreen wipers and washer 78 = Electronic control unit
8 = Battery 12 V, 60 Ah 43 = Rheostat for instrument panel lighting 79 = Spark plugs
9 = Starter motor 1 h.p. 44,, = Lighting switch 80 = Fuel box
1 0 = Reversing light switch on gearbox 45 = Ignition switch 81 = Foglights
11 = Warning lamp for headlight fullbeams, 1.2 W 46 = Cigarette lighter 82 = Relay for foglights
1 2 = Step relay for fullbeam and dipped headlights 47 = Door switch, right 83 = Switch for foglights
and also headlight flasher 48 = Switch for parking brake control
1 3 = Horn ring 49 = Fuel level indicator unit Differences may occur for different markets.
1 4 = Alternator 12 V, 35 Ah 50 = Reversing lights 15W
SB = Black
1 5 = Relay for reversing lights 51 = Brake stop lights 25 W
BR = Brown
1 6 = Fusebox 52 = Rear lights 5 W
GR = Grey
1 7 = Charging regulator 53 = License plate lighting 2X5 W
BL = Blue
1 8 = Brake stop light contact 54 = Switch for overdrive
W = White
1 9 = Flasher relay and switch for warning flashers 55 = Brake warning contact
Y = Yellow
20 = Warning light for parking brake, 1.2 W 56 = Switch for start block and reversing lights
BW 35 R = Red
21 = Warning light for oil pressure, 1.2 W
57 = Switch for glove locker light GN = Green
22 = Warning light for battery charging 1.2 W
58 = Electrically heated rear window W-R = White-Red
23 = Connector
BL-Y = Blue-Yellow
24 = Glove locker light 59 = Switch fo r electrically heated rear window
25 = Warning light for overdrive, 1.2W 60 = Side marker lights (U.S.A.)
26 = Switch for headlight flasher and turn 61 = Relay for electrically heated rear window
i ndicators 62 = Connector unit for instrument
27 = Fuel gauge 63 = Warning buzzer for ignition (U.S.A.)
28 =Voltage regulator 64 = Door switch, left
29 = Temperature gauge 65 = Terminal board
30 = Oil pressure sender 66 = Clock
31 = Switch for overdrive, on transmission 67 = Fuel pump
32 = Warning light for flashers, 1.2 W 68 = Main relay for fuel injection
33 = Instrument panel lighting, 2X3 W 69 = Relay for fuel pump
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
BRAKES
The brake system is of the two-circuit type
with disc brakes all round. The system is
provided with a tandem-type master cylinder
and a directly-operating booster cylinder.
When the brake pedal is depressed, the
master cylinder is operated mechanically
via the booster cylinder, this increasing the
pedal force about three times. The brake
pressure is transmitted hydraulically from
the master cylinder through the brake to the
wheel cylinders. The pistons in these are
then pressed outwards and apply the brake
pads. The pressure lines to the rear wheel
brakes are provided with a reducer valve
which prevents locking of the rear wheels.
The principle of the two-circuit system is
that both the front wheels are connected to
one rear wheel, that is, should there be a
failure in one of the circuits, there is always
braking power on both front wheels and the
other rear wheel. So at normal pedal pres-
sure the braking effect of one of the circuits
i s 50 %, but when pedal pressure i s i n-
creased, about 80 % of the full braking
power can be obtained in the one circuit.
This provides maximum safety and prevents
l ateral dragging and rear-end lurching. With
the engine stopped, the booster assists the
braking a further two or three times after
which the pedal pressure must be increased
about three times in order to obtain a brak-
i ng power corresponding to the braking
power available with the engine running.
The parking brake operates the rear wheels
mechanically as the brake discs have also
been designed as brake drums in order to
i ncorporate the shoes for the handbrake.

GENERAL
Before the vehicle was delivered from the
factory it was subjected to a very thorough
i nspection. Your dealer, in his turn, carried
out a further delivery inspection in accord-
ance with the specifications of the Volvo
Factory. In addition to this there is a service
i nspection after 2 500 km (1 500 miles) when
the oil in the engine, gearbox and rear axle
is changed. Subsequent servicing of the ve-
hicle should follow the routine in the service
book which is based on service inspections
every 10 000 km (6 000 miles). The simplest
way to provide the vehicle with the servic-
i ng it requires is to have all the servicing
done by a Volvo workshop. You will then
have the work specified i n the service
book carried out in accordance with recom-
mended prices and the workshop stamp in
the service book will show when the vehicle
was serviced.
When the car was being designed, particular
attention was given to the "safety details"
(e.g. front end, brakes and steering). They
are calculated to withstand the severest
stresses with a wide safety margin. How-
ever, if you use your car for hard driving,
you should take the precaution of checking
these parts for fatigue cracks during the
SERVICING
useful lifetime of the car, for instance, when
the parts concerned are being reconditioned.
I f you prefer to carry cut out the simpler
servicing procedures yourself or if you are
sometimes obliged to have them done by a
workshop outside the Volvo organization,
this chapter contains same advice as to
when and how they should be carried out.
For the sake of convenience, the servicing
procedures have been summarized in a
maintenance scheme in the next two pages.
SERVICING

MAINTENANCE SCHEME

I n the maintenance scheme below the servic- Some of the work must be carried out by
i ng procedures have been given certain skilled mechanics or requires the use of
numbers which refer to the detailed descrip- special tools and these have been marked
tions on the following pages. 0.

Operation Operation

LUBRICATION 13. Change oil in rear axle with diffe-

rent lock
1. Lubricate body
1 4. Check oil level in steering box
2. Check oil level in engine
1 5. Check brake fluid level
3. Change oil in engine
ENGINE
4. Carburettors, filling oil in
damping cylinders 1 6. Servicing of crankcase ventilation

5. Check oil level in gearbox 1 7. Change oil filter

6. Change oil in gearbox 1 8. Clean fuel filter B 20 A and B

7. Check oil level in overdrive 1 9. Change fuel filter B 20 E

8. Change oil in overdrive 20. Clean foam plastic sleeve

9. Check oil level in automatic trans- 21. Change air cleaner B 20 A

mission
22. Change air cleaner B 20 B
1 0. Check oil level in rear axle
23. Change air cleaner B 20 E
11. Change oil in rear axle
1 2. Check oil level in rear axle with 23a. Change foam plastic filter for gas
different lock evaporative control system

24. Check valve clearances

 SERVICING

I n addition to the servicing procedures men- a) lighting, including brake warning light
tioned in this scheme you should regularly b) turn indicator lights
check the following from the point of view c) horn
of traffic safety:

Operation Operation .

25. Carry out compression test BRAKES

26. Check fan belt 37. Check the brakes
27. Check coolant level 38. Change servo cylinder filter and
overhaul the brakes
28. Change coolant
29. Check spark plugs
FRONT END
30. Check distributor contact breakers
39. Check front wheel alignment
31. Check ignition setting
40. Check ball joints, steering rods etc.

ELECTRICAL SYSTEM WHEELS AND TYRES

32. Check electrolyte level in battery 41. Check tyre pressure
33. Check state of charge of battery
34. Check headlight alignment BODY
42. Washing

POWER TRANSMISSION 43. Polishing

35. Check clutch yoke travel 44. Anti-rust treatment

36. Check propeller shaft 45. Cleaning


SERVICING

LUBRICATION

Chassis maintenance

To simplify maintenance of your Volvo, the

vehicle has been equipped with ball joints,
steering rods and propeller shafts of such
a construction that they do not require re-
gular lubrication. This has been possible due
to the fact that points that normally require
l ubricating have been packed with very dur- 1 Lubricating the body No. Lubricating point Lubricant
able grease at the factory and then carefully 1. Bonnet catch Paraffin wax
To avoid rattle and unnecessary wear, *2. Bonnet hinges Oil
sealed, thus obviating the need for subse- the body should be lubricated once a 3. Ventilator window catches
quent lubrication. year. The hinges on the bonnet, doors and hinges Oil
However, to ensure that these parts are and luggage compartment lid as well as 4. Catches, doors Paraffin wax
5. Door lock outer sliding
functioning properly, it is necessary to in- door stops should be lubricated every surfaces Paraffin wax
spect their seals and rubber sleeves tho- 1 0 000 km (6 000 miles). During the win- Lock oil
roughly after every 10 000 km (6000 miles) 6. Sun-roof wind deflector Oil
tertime, the locks in the door handles 7. Door handle lock buttons
or at least once a year. Paraffin wax
and luggage compartment lid should *8. Luggage compartment
Oil should be changed or the oil level also be given a reliable anti-freeze to hinges Oil
checked after every 10 000 km (6 000 miles) 9. Luggage compartment lock Oil
prevent them from freezing up. Key hole Silicon oil
i n accordance with the lubricating chart at *10. Door checks Lock oil
the end of the book. The measures taken in *11. Door hinges Grease
this inspection are also to be found in the 12. Front seat slide rails Paraffin wax
and catches and oil
l ubricating chart. 1 3. Window lifts Oil and grease
Always use only first-class lubricant of a Locks Silicon grease
well-known make. The right lubricants in the (Accessible after door up-
right quantity at the right time will increase holstery panels have been
removed)
both the lifetime and the reliability of your * Lubrication is included in the 10 000 km
car. (6000 miles) inspection.

42
 SERVICING

the lower mark, but on the other hand, it
should not be above the upper mark
since oil consumption will then be ab-
normally high. If necessary, top up by
filling through the oil filter hole on the
rocker arm casing with new oil of the
same type already in the engine.
3 Changing the engine oil
With a new or reconditioned engine, the
oil should be changed after the first
2 500 km (1 500 miles). Subsequent oil
changing is according to the intervals
given below. The intervals will depend
to a great extent on the type of oil used.
For engine lubrication, oil grade "For
Service MS", is to be used. As far as
viscosity is concerned, multigrade oil is
recommended. These oils are better suit-
ed for demanding driving conditions, for
example continuous driving i n city
traffic with incessant stopping and start-
i ng or with lengthy idling periods.
For engine oil with viscosity SAE 10 W-30
(multigrade), 10W-40, I0 W-50 or 20W-
50, the oil should be changed every
10 000 km (6 000 miles) or at least once
a year. If engine oil with viscosity SAE
10W (singlegrade), 20/20W or 30 is
used, the oil should be changed every
5 000 km (3 000 miles), or at least twice
a year.
At very low temperatures (below -20 ° C
= -4 ° F) multigrade oil SAE 5 W-20 is
recommended. However, this oil should
not be used when the temperature is
continuously above 0 ° C (32 ° F).
The old oil is drained off by removing the
drain plug on the sump. Draining should
take place after driving when the oil is
still warm.

Viscosity Temperature range Oil change intervals Oil capacities

Oil grade km (miles) 1 )

2 Check the oil level in the engine SAE 10W -30

The oil level in the engine should be SAE 10 W-40 all year round 1 0 000 (6 000) No oil filter
checked each time the fuel tank is filled. SAE 10 W-50 or at least once 3.25 litres (5.72 Imp.pints
The check should be carried out with the SAE 20 W-50 at all temperatures a year =6.86 US pints)
above -10 ° C (14° F)
engine switched off but warm and, in "For Service MS"
order to obtain comparable values, about
below -10 C (14 F)
one minute after the engine has been SAE 10 W
° °
5000(3000) With oil filter
20/20 W between -10 C and
°

stopped. Wipe the dipstick before mea- 30 +30 C (14 and 90 F)

or at least twice 3.75 litres (6.60 Imp.pints
a year =7.91 US pints)
suring. The oil level should be between "For Service MS above 30 C (90 F)
the two marks on the dipstick. It must 1) Change the oil after the first 2500 km (1 500 miles) during running-in.
never be permitted to go down below

43
SERVICING

4 Carburettors
At each oil change check that the oil
l evel in the centre spindle of the car-
burettors is about 6 mm (1/4 ") from the
top of the spindle. If it is not, fill up with
oil ATF (transmission oil).
5-6 Gearbox without overdrive (M 40)
The oil in the gearbox should be check-
ed after every 10 000 km (6000 miles).
The oil level should be up to the filler
hole. If necessary top up with recom-
mended oil. After every 40000 km (25000
miles) the oil in the gearbox should be
changed. In the case of a new or recon-
ditioned gearbox the oil should also be
changed after the first 2 500 km (1 500
miles). The old oil should be drained off
i mmediately after the vehicle has been
run while the oil is still warm.
7-8 Gearbox with overdrive (M 41)
For cars fitted with an overdrive, the of
l evel should be checked and the oil
changed parallel with similar procedure
for the gearbox. The overdrive and the
gearbox have a common oil level and oil
filler hole. Make sure when topping-up
that the oil runs over into the overdrive.
The oil is drained out by removing the
gearbox drain plug and the cap for the
overdrive oil strainer.
At each oil change the oil filter of the
overdrive should be cleaned. This should
be done by a Volvo workshop.

Oil grade Viscosity Oil capacity Oil grade Viscosity Oil capacity

Gear oil SAE 80 0.75 litre Engine oil SAE 30 or 1.6 litres
Automatic Transmission Fluid (ATF) At temperatures 1.3 Imp.pints Multigrade 2.8Impints
continuously above 1.6 US pints SAE 20 W-40 3.38 US pints
alt. 30 ° C (86 ° F)
SAE 90
Engine oil SAE 30

44
 SERVICING

9 Automatic transmission BW 35 1 0-11 Rear axle 1 2-13 Differential lock

The oil in the automatic transmission
should not be changed but the oil level
should be checked every 10 000 km
(6 000 miles). The filler pipe with graduat-
ed dipstick is to be found under the
bonnet just in front of the cowl.
N.B. The dipstick has different gradua-
tion marks for a warm and cold trans-
mission. When the oil level is being
checked, the car should be standing
l evel. With the engine idling in position
"P", the level should be between the
upper and l ower graduation marks on the
dipstick. When topping-up is necessary,
use only Automatic Transmission Fluid,
Type F.
I f this oil is not available, Type A or
Dexron may be used.
The dipstick should be wiped with a
nylon cloth, paper or chamois leather.
Cloths which leave fluff on the dipstick
must be avoided.
The oil level in the rear axle should be
checked after every 10 000 km (6000
miles). The oil level should be up to the
filler hole. If necessary top up with the
recommended oil. The oil in the rear axle
should be changed after the first 2 500
km (1 500 miles). The old oil is drained
off by removing the bottom plug. After
this only the oil level need be checked
and topping-up with recommended oil
carried out if required.
The oil should then be warm and the
magnetic plug must be well cleaned. It
i s of great importance to the lifetime of
the final drive that particles and im-
purities from running-in are removed.
Cars fitted with a differential lock are
delivered from the factory with a rear
axle oil according to the American
Military Standard MIL-L-2105 B provided
with an additive for rear axles with diffe-
rential lock. A similar type of oil should
be used for subsequent topping-up and
changing. Oil level checking and oil
changing are to be carried out at the
same intervals and in the same way as
for a rear axle without differential lock.

Oil grade Oil capacity Oil grade Viscosity Oil capacity

Automatic Transmission 6.3 litres SAE 80 1.3 litres

Fluid, Type F 11.0 Imp.pints Rear axle oil At temperatures 2.3 Imp.pints Rear axle oil MIL-L-2105 B with additive
(If unavailable, Type A 13.0 US pints acc. to continuously 2.7 US pints for differential lock.
or Dexron) MIL-L-2105 B below-10 °
C
(+14 F), SAE 80
0

45


SERVICING

1 4 Steering box
The oil level in the steering box should
be checked after every 10 000 km (6000
miles). The oil level should be up to the
filler plug. If necessary, top up with new
oil. As a rule, the oil in the steering box
does not need to be changed except dur-
i ng overhauling. Should the oil for any
reason need to be changed, the old oil
should be sucked up by means of an oil
syringe which is inserted down into the
filler hole.

ENGINE

1 5 Brake fluid 1 6 Crankcase ventilation

The brake system is provided with two The engine is provided with positive
brake fluid containers with a common crankcase ventilation which prevents the
filler hole. The brake fluid level should gases in the crankcase from being re-
be checked at regular intervals and l eased into the atmosphere. Instead, they
should be between the "Max" and "Min" are sucked into the intake manifold and
marks. take part in the combustion process
whereupon they are blown out through
Oil grade Viscosity Oil capacity the exhaust pipe together with the other
combustion gases. Every 40 000 km
(25 000 miles) remove and clean the
Hypoid oil SAE 80 0.25 litre Use only brake fluids conforming to specification
All year round 0.44 lmp.pint 70R3 for the hydraulic brake system. SAE 70 R 3 nipple (2), the hoses (1 and 3) and the
0.52 US pint (J 70 B) or SAE J 1703 can be used. flame protector (4). Rubber hoses should
also be replaced if they are in a poor
condition.

1 7 Oil filter
The engine is fitted with a full-flow type
oil filter, which means that all the oil
passes through the filter on its way from
the oil pump to the various lubricating
points. Impurities in the oil are collected
i n the filter and gradually block it. For
this reason, the filter must be changed
every 10 000 km (6 000 miles). Scrap the
old filter then.
I f the oil filter is replaced without the
engine oil being changed, the engine
should be topped up with 0.5 litre (1 pint)
of oil.
1 8 Fuel filter (B 20 A and B 20 B)
The fuel filter should be cleaned after
every 10 000 km (6000 miles). Loosen
the screw, remove the cover and the
filter and clean them. Check that the
gasket is not damaged and make sure
that it seals properly when the cover
with filter is re-fitted.
1 9 Fuel filter (B 20 E)
The fuel filter is located under the car
close to the fuel tank. This filter is to be
changed after every 20 000 km (12 500
miles). The filter is replaced as one
complete unit.
Clean the fuel lines and the surrounding
components before carrying out the
change. When changing the filter, pinch
SERVICING
the fuel lines to prevent fuel from runn-
i ng out. Notice when fitting the new filter
that the arrow on the filter housing is to
point in the direction of flow. Filter re-
placement should be carried out by an
authorized Volvo workshop.
20 Air cleaner with foam plastic sleeve
Cars intended for markets where driving
conditions are particularly dusty are pro-
vided with an air cleaner fitted with a
foam plastic sleeve. This sleeve is nor-
mally washed or changed every 20 000
km (12 500 miles). After every 80 000 km
(50000 miles) the paper filter must also
be changed.
The foam plastic sleeve is removed from
the air cleaner and washed in paraffin
(kerosene), fuel oil or warm water mixed
with a washing agent. Squeeze the
sleeve until it is clean and then rinse it
i n clean water. When the sleeve is dry,
dip it in engine oil SAE 30. Squeeze it
i n oil and remove excess oil by rolling
the sleeve in a clean cloth. Re-fit the
sleeve.
47
SERVICING
21 Air cleaner (B 20 A)
The air cleaner insert should be replaced
every 40 000 km (25 000 miles). At the
same time the packing and the three
bolts should be changed. Replacement
should be more frequent when driving
regularly on dusty roads. When fitting
the new air cleaner insert, make sure
that the thermostat body for the intake
air is not damaged.
N.B. The insert must not be damp or
oiled.
22 Air cleaner (B 20 B)
The 'air cleaner consists of a plastic
cover with replaceable paper insert. The
i nsert should be replaced every 40 000
km (25 000 miles). With continuous driv-
48
i ng in dusty conditions, it may be ne-
cessary to change the cleaner more
often. No kind of cleaning whatsoever
should be carried out between the above
i ntervals.
To replace, disconnect the hose clamp
for the air preheating unit and also the
clips holding the air cleaner cover.
The insert is then accessible for removal.
Make sure when fitting the top section
that the thermostat body for the intake
air is not damaged.
Replace the air cleaner with a new one
every 40 000 km (25 000 miles). The
cleaner should be replaced more often
if you are driving regularly on dusty
roads. No cleaning of any kind is to be
carried out between the above-men-
tioned intervals.
To change the cleaner, remove the ex-
pansion tank, the hose between the
i ntake manifold and cleaner and undo
the attaching bolts. The cleaner can now
be lifted out.
23 Air cleaner (B 20 E)
Replace the air cleaner with a new one
every 40 000 km (25000 miles). The
cleaner should be replaced more often
i f you are driving regularly on dusty
roads. No cleaning of any kind is to be
carried out between the above-mention-
ed intervals.
To change the cleaner, remove the ex-
pansion tank, the hose between the in-
take manifold and cleaner and undo the
attaching bolts. The cleaner can now be
lifted out.
 SERVICING

23a Evaporative control system*

The foam plastic filter for the evapora-
tive control system should be changed
every 40 000 km (25000 miles). This
should be done by an authorized Volvo
workshop.

24 Valves
The valve clearance should be checked
after every 1 0 000 km (6000 miles).
The check should be carried out in a
workshop.

25 Compression test
To get some idea of the condition of the
engine, a compression test should be
carried out after every 10 000 km (6000
miles). This test should preferably be
carried out in a workshop.
26 Fan belt
The belt tension can be checked by
pressing in the fan belt at a point mid-
way between the alternator and the fan.
It should be possible to press down the
belt there about 10 mm (3/8") with normal
pressure (7 kp = 15 Ib).
The check can suitably be carried out in
a Volvo workshop.
` Only certain markets
27 Check the coolant level
The cooling system must be well filled
with coolant and not leak if it is to
operate at maximum efficiency. Check
the coolant level when filling up with
fuel. The level should be between the
" Max" and "Min" marks on the expan-
sion tank. The check should be carried
out with particular thoroughness when
the engine is new or the cooling system
has been empty.
Do not remove the filler cap other than
for topping-up with coolant. Frequent re-
moval may prevent coolant circulation
between the engine and the expansion
tank during engine warming up and cool-
i ng.
Topping up with coolant
Top up with coolant by filling the expan-
sion tank when its level has gone down
to the "Min" mark. Use all the year
round a mixture of 50 % reliable anti-
freeze (or corresponding) and 50
water. Top up to the "Max" mark.
NOTE. Do not top up with water only.
Water by itself reduces both the rust-
protective and anti-freeze qualities of
the coolant. It can also cause damage to
the cooling system if ice should form in
the expansion tank.
NOTE. In very warm countries where
there is little risk of frost, water can be
used without anti-freeze.

49
SERVICING
28 Changing the coolant
The coolant retains its properties for
approx. 2 years when it should be chang-
ed. A suitable time to do this would be
i n the autumn to preclude any damage
by frost during the coming winter. To
drain the cooling system, open the drain
tap located on the right-hand side of the
engine and disconnect the hose connec-
ted to the bottom of the radiator. The
expansion tank is emptied by removing
i t from its brackets and lifting it to a
sufficient height so that the coolant can
flow into the radiator.
Before filling with new coolant, flush the
entire system with clean water.
The cooling system is filled with coolant
through the filler opening on top of the
radiator. When this is being done, the
heater control should be set to max.
50
heat to ensure that the entire system
i s filled.
Fill the radiator to the top and fit on the
cap. Then fill the expansion tank to the
" Max" level or slightly above this.
Run the engine for a short period, switch
off the ignition and allow the engine to
cool. Check that the radiator is full and
that the coolant in the expansion tank is
at "Max". If necessary, top up the sys-
tem.
29 Check the spark plugs
The spark plugs should be removed
and checked every 10 000 km (6 000
miles). If necessary change the plugs.
Tightening should preferably be done
with a torque wrench. When fitting new
plugs, be sure to fit the right type.
B 20 A
Bosch W 175 T 35 or corresponding
B 20 B (normal driving)
Bosch W 200 T 35 or corresponding
B 20 B (hard driving)
Bosch W 225 T 35 or corresponding
B 20 E
Bosch W 225 T 35 or corresponding
When changing the plugs, check that
the suppressor connectors are in good
condition. Cracked or damaged connec-
tors should be replaced.
30-31 Ignition system
The distributor contact breaker gap and
the engine ignition timing should be
checked every 10 000 km (6000 miles).
All adjusting work should be done by a
workshop with the proper equipment.
The distributor is one of the most sensi-
tive units in the engine and careless
handling can lead to decreased engine
output and high fuel consumption or
even serious damage to the engine.
 SERVICING

Fuel
Fuel with an octane rating of at least 97 (ROT*) should be used for the B 20 A and B 20 E
engines. For the B 20 B engine fuel with an octane rating of 100 (ROT*) is primarily recom-
mended. When driving chiefly on highways, fuel with an octane rating of min. 97 (ROT*)
can be used for the B 20 B engine. On certain markets where it is difficult to get fuel
with these ratings, the engine can be adjusted accordingly.

* ROT Research Method

Special instructions when working on the electronic fuel injection system

1. Never let the engine run without the
battery being connected.
2. Never use a high speed battery charg-
er as a starting aid.
3. When using a high speed charger to
charge the battery in the vehicle, the
battery should be disconnected from
the rest of the electrical system.
4. The control unit may not overheat
above +85 ° C (185 ° F). The control
unit must not be connected up (the
engine started) when the ambient tem-
perature exceeds +70 ° C (158 ° F).
(With paintwork, etc., when the vehicle
i s being stove-heated, it may not be
driven out of the oven, it must be
conveyed out. If there is risk of tem-
peratures exceeding 85 ° C (185 ° F),
the control unit must first be remov-
ed.)
5. The ignition should be switched off
before connecting up or disconnect-
i ng the control unit.
6. For all work with fuel lines, great
care must be taken to ensure that no
dirt enters the system. Even small
dust particles can jam injectors.
Any work to be done on the electronic
fuel injection system should be carried
out by an authorized Volvo workshop
which has the proper equipment for do-
i ng this.
ELECTRICAL SYSTEM
32 Check the battery electrolyte level
To ensure that the battery functions pro-
perly, the electrolyte level should be
checked regularly. A suitable time to do
this is when the fuel tank is being filled.
The electrolyte level should be 5-10 mm
(3/16-3/8") above the top of the cell pla-
tes. If the level is too low, top up with
distilled water. Never add too much di-
stilled water since this can cause the
acid to splash over and possibly dam-
age the engine compartment. Never
check the electrolyte level by lighting a
match. The gases formed in the cells are
highly explosive.

51
SERVICING

33 Check the state of charge of the battery

The state of charge of the battery should
be checked after every 10 000 km (6 000
miles). The check is made with the help
of an hydrometer which shows the spe-
cific gravity of the battery acid (this
varies with the state of charge of the
battery). See page 66. At the same time,
check the lead terminals and terminal
studs to make sure that they are tight,
coated with grease and that the battery
i s firmly fixed. If necessary, wipe the
l ead terminals and terminal studs clean
with a cloth or brush with a wire brush
and smear them.
34 Check headlight alignment
The alignment of the headlights should
be checked in a workshop after every
1 0 000 km (6 000 miles). Remember that
the section of the road lit up by the
headlights can vary depending on the
l oad in the vehicle.
This car is fitted with an alternator.
When changing the battery or when
carrying out work involving the electrical
system, the following should be ob-
served.
1. A battery connection to the wrong ter-
minal will damage the rectifiers. Be-
fore the connections are made, check
the polarity of the battery with a volt-
meter.
2. If extra batteries are used for starting,
they must be properly connected to
prevent the rectifiers from being dam-
aged.
The negative lead from the auxiliary
battery for starting must be connec-
ted to the negative terminal stud of
the car battery and the positive lead
from the auxiliary battery for starting
to the positive terminal stud.
3. If a rapid charger is used for charg-
i ng the battery, the car battery leads
should be disconnected.
A rapid charger may be used as an
aid- in starting (does not apply to
B20E), but should be switched off
when being fitted and the leads dis-
connected. The rapid charger must
never be used as an auxiliary unit for
starting.
4. Never disconnect the battery circuit
(for example, to change the battery)
while the engine is running, as this
will immediately ruin the alternator.
Always make sure that all the battery
connections are properly tightened.
5. If any electrical welding work is to be
carried out on the vehicle, the earth
l ead and all the connecting cables of
the alternator must the removed. The
welding unit should be placed as near
the welding point as possible.

Replacement of bulbs
To obtain maximum lighting effect and to
forestall the chances of lights going out, the
headlight bulbs should be changed every
year, suitably during the autumn.
The replacement of bulbs in the various light-
i ng units is shown on the following pages.
Make sure when fitting lamps that the guide
pin on the socket fits into its corresponding
recess.
When fitting headlight bulbs, do not touch
the glass with your fingers. The reason for
this is that grease, oil or any other impuri-
ties can be carbonized onto the bulb and
damage the reflector.

52
 SERVICING

Replacing the bulbs for the front

parking lights

Remove the two Philips screws which hold

the glass. The bulb is now accessible for
changing.

Replacing the bulbs for instrument

lighting and heater control lighting

Owing to the location of the bulbs, their

replacement should be carried out by a
Volvo workshop.

Replacing the bulbs for the rear

flashers, parking lights, stop lights
and reversing lights

Remove the two Philips screws which hold

the glass. The bulbs can now be removed
by pressing them inwards and turning them
slightly anti-clockwise at the same time. The
top bulb is the flasher, the one under that is
the reversing light, the next one under that
the stop light and the one at the bottom the
rear light. Make sure that the sealing strip
fits well against the glass when it is re-fitted.

53
SERVICING

Replacing the bulbs for the front

parking lights

Remove the two Philips screws which hold

the glass. The bulb is now accessible for
changing.

Replacing the bulbs for instrument

lighting and heater control lighting

Owing to the location of these bulbs, their

replacement should be carried out by a
Volvo workshop.

Replacing the bulbs for the rear turn

i ndicators, parking lights, stop lights
and reversing lights

Remove the two Philips screws which hold

the glass. The bulbs can now be removed
by pressing them inwards and turning them
slightly anti-clockwise at the same time. The
top bulb is the turn indicator flasher, the one
under that is the reversing light, the next
one under that the stop light and the one at
the bottom the rear light. Make sure that the
sealing strip fits well against the glass when
re-fitted.

54
 SERVICING

Replacing the headlight bulbs

The headlight bulbs are replaced from inside

the engine compartment in the following
way:
1. Remove the contact for the bulb holder.
2. Remove the rubber sleeve.
3. Remove the spring which fixes the lamp
holder in the correct position.
4. Lift out the bulb holder with the bulb
complete as one unit. When fitting the
bulb holder spring into the insert, make
sure that the guide pin engages in its
notch.
Do not touch the bulb with your hand.

1 2

Replacing the bulbs for the side

marker lights*

Remove the two Philips screws which hold

the glass. The bulb can now be removed by
pressing it inwards and turning it slightly
anti-clockwise.
3 4
* Concerns only certain markets

55
SERVICING
Replacing the bulbs for the licence
plate light
The two bulbs for the licence plate light
are mounted on a holder located under the
l uggage compartment locking device.
Loosen the two screws which hold the glass
and remove it. The bulb is now accessible
for changing.
Replacing the bulb for the glove
l ocker
The bulb is located under the dashboard
above the glove locker door. To replace the
bulb, first press it in slightly and then turn
i t anti-clockwise.
56
POWER TRANSMISSION
35 Checking the clutch yoke play
To avoid risk of the clutch slipping, the
clutch yoke free travel should be check-
ed and adjusted if necessary every
1 0 000 km (6000 miles).
36 Check the propeller shaft
After every 10 000 km (6000 miles) or
once a year the rubber seal on the
spline shaft and the universal joints
should be checked. If the rubber seal is
damaged, it should be replaced and the
new seal filled with molybdenum dis-
ulphide grease.
BRAKES
37 Check the brakes
After every 10 000 km (6000 miles) the
vehicle should be taken to a Volvo
workshop for a check on the function of
the brakes.
38 Replacing the booster cylinder air filter
and overhauling the brakes
Every third year or 60 000 km (36 000
miles) the car should be taken to a
Volvo workshop for replacement of the
booster cylinder air filter.
The brake system seals should also be
replaced at the same time.
FRONT END
39 Check the front wheel alignment
Correct front wheel alignment is of vital
i mportance for the steering of the ve-
hicle. Faulty adjustment can mean heavy
wear on the tyres. For this reason, have
the front wheel alignment checked re-
gularly at your local Volvo workshop
every 10 000 km (6 000 miles). If the ve-
hicle has been in collision involving
heavy impact and it is suspected that
the front end may have been affected,
take the vehicle to a Volvo workshop
for a check on the front wheel alignment
as soon as possible. Volvo workshops
have special measuring equipment for
this purpose and can carry out this
control very quickly. The front wheel
alignment angles are shown on page 67.
40 Check the ball joints, steering rods, etc.
After every 10 000 km (6 000 miles) the
vehicle should be taken to a workshop
for a check on the front end concerning
excessive play in the ball joints, steering
gear, etc.
After every 10 000 km (6000 miles) or
at least once a year, the ball joint seal
should also be checked for damage and
l eakage. When new seals are fitted they
should be filled with the recommended
grease.

WHEELS AND TYRES
General
The car is fitted with pressed steel
wheels. All wheels are accurately ba-
l anced. The tyres are tubeless and and
have the following sizes (wheel size
within brackets):
When changing tyres and with transfer
from summer to winter tyres, the car
should be fitted with the same type as
delivered from the factory.
Changeover from radial tyres to diagonal
tyres should be avoided.
Rapid links cannot be fitted since the
space between the brake calipers of the
disc brakes and rims will not permit this.
SERVICING
41 Check the tyre pressure
Make a habit of checking the pressure
i n the tyres regularly. The simplest way
to do this is to check the pressure at a
service station when filling up with fuel.
Sea page 67 for the correct air pressure.
Do not forget the spare wheel when
checking the air pressure.
During driving, the temperature of the
tyre rises and also the air pressure in
relation to the speed of the vehicle and
i ts load. Normally the air pressure should
only be checked when the tyres are cold.
When the tyres are warm, a change in
pressure should take place only in those
cases when air must be pumped in the
tyres. The total pressure for a 1 65 S-15
tyre must not exceed 2.1 kg/cm 2 (30
p.s.i.). Tyres with size 1 65 S are intend-
ed for speeds up to 1 75 km.p.h. (110
tread pattern is not less than 1 mm
m.p.h.).
(1/32"). If it is less than this figure, the
The various tyre sizes are intended for
tyre must be changed. Certain makes
the following max. speeds:
have a so-called "tread-wear indicator",
6.85 S 15 - 175 km.p.h. (110 m.p.h.) that is, narrow strips which show up
1 65 SR 1 5 - 1 80 km.p.h. (112 m.p.h.) when there is only about 1.5 mm (1/16")
Excessively low air pressure is one of tread left on the tyre. This is to warn the
the most common reasons for tyre wear. owner that serious thought should be
I f the pressure is too low, the tread given to changing the tyre.
shoulders bear the entire load and wear Be careful when parking the car next to
down very quickly. Tyres which are the pavement not to damage the tyres
i nsufficiently inflated also result in dif- against the pavement kerb.
ficult steering and high fuel consumption.
Excessively high air pressure means tyre
wear along the centre of the tread. It al-
so tends to make travelling less comfort-
able. At regular intervals check the tyres
for damage, abnormal wear and for any
small stones which may have fastened
i n the tread pattern. Check also that the
57
SERVICING

Changing a wheel

The spare wheel is stowed in a recess to

the right in the luggage compartment. The
jack and tool kit are kept next to the spare
wheel. Before the vehicle is jacked up, the
parking brake should be applied and one of
the gears engaged.

Removing
Unscrew the wheel cap. On the Volvo
1 42, 144, the cap is levered loose.
Loosen the wheel nuts 1/2-1 turn with
1 2 the help of the box spanner. All the nuts
have right-hand threads which are loosen-
ed by turning them in an anti-clockwise
I
direction.
nsert the lifting arm of the jack i n the
appropriate jack attachment of the wheel
to be changed. Jack up the side of the
car far enough to lift the wheel off the
ground.
Unscrew the wheel nuts completely and
lift off the wheel. Be careful when lifting
.off the wheel that the threads of the
studs are not damaged ,,

3 4

58

BODY
42 Washing
Fitting
1. Fit the hub cap on the wheel rim from
the inside of the rim and clean the con-
tact surfaces between wheel and hub.
2. Lift on the wheel.
Tighten the nuts until the wheel makes,
good contact with the flange.
3. Lower the vehicle and tighten the nuts
alternately.
4. Fit the wheel cap. Do not rotate the rais-
ed wheel if the car is fitted with a differ-
ential lock as this will also move the
other rear wheel on the ground, so that
the car may topple of the jack.
SERVICING'
dry carefully with a soft clean chamois
The car should be washed often since l eather. Use different leathers for the
such things as dirt, dust, dead insects, windows and 'the remainder of the car,
tar spots, etc. usually adhere firmly to otherwise using the same leather can
the body and may damage the paint- cause greasy smears on the --windows.
work. Washing also helps to counteract When washing the car, remember to
rusting. During the winter, special care clean the draining holes i n the doors and
should be taken to ensure that all road bottom rails.
salt residue is washed off as soon as
possible, otherwise corrosion can occur. Note. When washing the car in a wash-
When washing the car, make sure that it i n g bay, the ventilation controls should
i s not exposed to direct sunlight since be closed. In certain cases, the air in-
this can cause drying patches. Begin by take for the car heater should be cov-
softening up the dirt on the underside of ered.
the body with a jet of water and use if
necessary a soft brush. Then rinse down
the whole body with a light jet until the
dirt has loosened up. After this, wash off
the dirt with a sponge using plenty of
water. Start on the roof of the vehicle
and work down the body. Use preferably
l ukewarm but not hot water.
A washing agent can be used to faci-
litate washing. Special washing agents
are now available on the market - even
dish-washing fluids can be used.
A suitable mixture is about 5-10 cI
(111/2-31/2 fl. ozs.) of fluid dish washer
to 10 litres (2.2 Imp. galls=2.6 US galls)
of water. Asphalt spots and tar pittings
can easily be removed with white spirit
or equivalent, but this should be done
after the washing.
When a washing agent is used, the car
should be well rinsed down with clean
water afterwards. Begin with the roof of
the car and work down the body. Then
59
SERVICING
'43 Polishing (waxing)
The vehicle does not need polishing
until. the surface finish begins to lose
i ts l ustre and normal washing is no
l onger sufficient to make it shine again
and remove the layer of dirt on the sur-
face. Under normal conditions it is suffi-
cient to polish. the vehicle a couple of
ti mes a year on condition that it is care-
fully looked after and thoroughly washed
as soon as it has become dirty or dusty.
Before the vehicle is polished, 'it should
be carefully washed and dried to avoid
scratches on the paintwork .
Before applying wax, make sure that the
surface is absolutely clean.
I t may often be necessary to use white
spirit for cleaning.
Waxing should neither be considered as
a substitute for polishing nor as a ne-
cessary protection for the paintwork
against unfavourable weather. For the
most part waxing is not necessary until
one year after delivery of the car.
60
Touching-up surface finish damage
The touching-up of any extensive damage
to the synthetic finish requires the use of
special equipment and skill, so that the re-
pairing of any such damage should be en-
trusted to a Volvo workshop. Minor damage
caused by flying stones, etc. and small
scratches can, however, be attended to by
the owner himself.
Damage caused by flying stones requires
i mmediate treatment if rusting is to be
avoided. Always make a habit, therefore, of
checking the finish regularly and carrying
out touching-up if required. Volvo dealers
can supply you with suitable touching-up
paint in tins or spray bottles. Always make
sure that you get the right colour. Touching-
up is as follows:
1. If flying stones should penetrate to the
metal of the bodywork, the damaged sur-
face is to be scraped completely clean
with a penknife or similar. If, however,
the paintwork is. not damaged by stones,
then all that is needed is light scraping
to remove the dirt.
2. In the event of severe damage due to
flying stones, it is necessary to treat the
spot concerned with anti-rust primer. The
primer should cover completely the scrat-
ched and the edges rubbed off.
3. When the anti-rust primer has dried, ge-
nuine Volvo paint is applied. Stir the
paint well or shake the spray bottle
thoroughly before use. Apply several thin
coats of the paint, allowing it to dry
thoroughly between each application.
Chromed parts
Chromium-plated and anodized parts should
be washed with clean water as soon as they
become dirty. This is particularly important
if you drive on gravel roads which are
treated with chemicals to keep the dust
down or in the winter when salt is used to
melt the snow. After the car has been wash-
ed, apply wax or anti-rust preparation.
44 Anti-rust treatment
Your Volvo is anti-rust treated at the
factory.
I nspection and any touching-up of the
anti-rust protection should be done at
regular intervals and at least once a
year. The enclosed body sections should
also be anti-rust treated by means of
spray application at least once a year.
I f any touching-up of the anti-rust pro-
tection is necessary, this should be done
i mmediately to prevent moisture from,
seeping in and consequently damaging it.

45 Cleaning
Cleaning the upholstery
The woven fabric upholstery can be
cleaned with a vacuum cleaner or brush.
Stains should be removed before they
are allowed to dry.
Wipe up the stain as much as possible
before applying spot remover. This can
be done with a damp cloth or similar.
Use a dry cloth to suck up the spot
remover and repeat the treatment. Norm-
ally many stains can be removed with
soap and water or detergent, after which
the spots treated are washed with water.
I f carbon tetrachloride-petrol (equal parts
carbon tetrachloride and chemically pure
petrol) should be used, it should be
allowed to evaporate before the stain is
treated with water. Always work on a
stain from the outside-in to avoid its
spreading.
Here are a few tips on suitable stain
removers for some different types of
stains.
Stains on leather and plastic can be
cleaned with water or mild detergent.
Water can be used to remove the follow-
i ng stains: blood (cold water), milk, tea,
soft drinks, coca-cola and beer.
Stains made by berries, fruit, coffee and
vomitings can be removed with water if
done immediately.
Carbon tetrachloride-petrol is used to
remove the following stains: asphalt, oil,
grease, chocolate, ice-cream, chewing
gum, shoe polish, lipstick, butter and
margarine.
Urine stains can be treated with 5
ammoniac and washed with water. This
should be repeated if necessary.
Cleaning the floor mats
The floor mats should be removed at
l east twice a year and cleaned. In winter-
ti me with the prevalence of snow and
dirt they should be taken out and dried.
Sweep thoroughly the area covered by
the mats, since any water and dirt there
can cause rusting. Stains on the mats
can be removed with an appropriate
detergent and water.
SERVICING
BEFORE A LONG-DISTANCE TRIP
I f you are thinking of travelling abroad with.
your car or taking a l ong journey, you
should have the car checked at a Volvo
workshop. You will enjoy your journey better
if you know that your car is in perfect trim.
I rritating incidents can be avoided as well
as expensive and time-absorbing stoppages.
Wherever you go there should be a Volvo
workshop within easy call to attend to your
car if required.:
However, it is always a good idea before
making a trip to ensure that, at least on a
minor scale, you have with you a compre-
hensive touring kit. This is particularly * the
case if you anticipate widely varying con-
ditions as regards climate, roads and the
prevalence of much dust. Many workshops
stock special kits for this purpose. Re-
member when filling up with fuel to observe
the existing fuel recommendations. If you
prefer to look over your vehicle yourself,
the following hints are worthwhile noting:
1. Check the brakes, front wheel alignment
and steering gear.
2. Check the engine and drive units with
regard to fuel, oil, coolant leakage.
3. Examine the tyres carefully. Replace worn
tyres.
4. Check that the engine is running per-
fectly and that the fuel consumption is
normal.
5. Examine the state of charge of the bat-
tery and clean the terminals.
6. Check the tool equipment.
7. Check the lighting.
61

SERVICING
COLD WEATHER
When cold weather is on the way, it is time
to think of the winter, servicing of your car.
The first night of frost can come as a very
unpleasant surprise unless preventive precautions have been taken. _,
J ..
Engine cooling system
A good quality anti-freeze should be used
all the year round. Thus, the cooling system
should always contain water plus anti-freeze
and rust inhibitor, even during the summer.
For changing the coolant, see page 50. If
the coolant has to be topped up during the
winter, do not use only water as water by
i tself weakens both the anti-frost properties
as well as the rust-proofing effectiveness. of
the coolant. It is a good idea when topping-
up with coolant to have the concentration
checked.
Experience has also shown that extremely
weak anti-freeze solutions (10-25 %) are
very unfavourable from the point of view of
rust protection. For this reason, the quan-
tity of anti-freeze should amount to about
50 % of the coolant, that is, 4.3 litres (7.5
I mp. pints=9 US pints), this lowering the
freezing point to -35 ° C (-31 F).
Radiator spirit is not recommended as an
anti-freeze agent since it evaporates at nor-
mal engine temperature.
62
Engine lubricating. system
During the winter multigrade oil or engine
oil SAE 10 W should be used for the engine
lubricating system. At very low temperatures
(below -20 ° C = -4 ° F) multigrade oil
SAE 5W-20 is recommended. These oils
reach the lubricating points in the engine.
more easily at low temperature and also
facilitate cold starting. See page 43.
Electrical system
.The electrical system in the vehicle is sub-
jected to greater stresses -during the win-
ter than during the warm summer months.
The lighting and starter, motor are used
more and since the capacity of the battery
is also considerably lower at low air tempe-
rature, the state of charge must be checked
more often and, if necessary, the battery
charged. If the battery voltage is excessively
l ow, there is risk of the battery being dam-
aged by frost.
Brake system
the brakes are
During very cold water
subjected to splash and condensation water
which can result in the parking` brake freez-
i ng up -if left on.
When you park the car, do not apply the
'parking ,brake but engage first gear or
. reverse and if possible place blocks behind
the wheels. See also page 25.
Windscreen washer
Just as anti-freeze is added to the cooling
system during the winter to prevent frost
damage, anti-freeze should also be added to
the water container for the windscreen
washers. This is particularly important be-
cause the windscreen during the winter fre-
quently becomes dirty and is often splashed
with water which rapidly freezes and thus
necessitates the frequent use of the wind-
screen washer and wipers. Your Volvo
dealer can supply you with suitable anti-
freeze for this purpose.
Anti-freeze for door locks
A frozen door lock is one of the most irri-
tating things that can happen to a car-
owner. Many valuable minutes early in the
morning can be wasted warming up keys
and melting ice in locks. Remember this in
good time and lubricate the locks in ad-
vance with some suitable anti-freeze agent.
Such agents are now available in small
handy tubes which can easily find room in a
handbag or coat pocket.

WHEN THE ENGINE STALLS
OR WILL NOT START
The information given below is only intended
to serve as a guide in localizing and tempor-
arily correcting minor faults. After having
carried out any such measures, have them
checked and adjusted by an experienced
mechanic.
The engine does not start although the
starter motor turns it over at normal speed
1. Check to make sure there is fuel in the
tank.
2. (B 2C A and B 20 B.) If the engine is hot,
start the engine with the accelerator
pedal fully depressed.
3. (B 20 E.) Check to make sure the fuel
pump is functioning properly. This is
done by turning the ignition key to driv-
i ng position. This will run the pump for
1 to 1.5 seconds. If the pump does not
function, check to make sure that the
pump fuse is not blown.
4. (B 20 E.) Attn. Do not touch the accelera-
tor pedal if the engine is cold. If the
engine is hot, start it with the accelerator
pedal depressed halfway. Avoid repeated
short attempts at starting. Instead, let the
starter motor run a little longer (max. 15
-20 seconds) at each try.
5. With damp weather, when flashover may
occur, wipe the spark plug isolators
clean. Release the distributor cap and
wipe it dry.
Check to make sure that the ignition
l eads are properly fitted in the distributor
head and ignition coil. I 1. That one of the ignition leads has
6. (B 20 A and B 20 B.) Check to make sure
that the fuel pipe connections to pump
and carburettor do not leak and that fuel
reaches the carburettor.
7. (B 20 E.) Check to make sure that all
contacts for sensors and injectors are
properly fitted.
8. If the engine turns over without starting,
there may be too much fuel in the cy-
l i nders, with damp plugs as a result.
Screw out the plugs and wipe them dry.
Check the electrode gap.
If the engine still does not start
1. Remove the ignition lead from each plug
i n turn. Hold the end of the lead about
1/4 from the cylinder block while turning
round the engine with the ignition switch-
ed on. If there is a strong spark, the
fault is probably in the spark plugs, so
these should be changed .
2. If only a weak spark is obtained or none
at all, check to ,sea whether the ignition
l eads are properly i nserted in the distri-
butor and ignition coil.
3. Remove the distributor cap, check and
clean all contact surfaces. Check that the
contact breakers close properly when
the engine is turned round. If the contact
breaker arm shaft binds, oil it very spar
i ngly.
If the engine misfires, the reason can be:
eldointhsrbuc-veofmth
spark plug.
2. That one or more of the spark plugs is
coated with soot or oiled up, in which
case the plug concerned should be clea-
ned or changed and the spark plug gap
adjusted.
3. That the distributor tap and rotor arm
are cracked or damaged.
4. That one of the ignition leads is in a poor
condition.
5. That the contact breaker gap in the distri-
butor is insufficient or non-existent.
6. That the contact breakers are badly burn-
ed.
How to start your car downhill
Switch on the ignition, pull 'out the choke if
required, engage 3rd gear or even 4th and
l et the car roll downwards with the clutch
pedal depressed. When the speed is up to
1 5-20 km.p.h. (9-12 m.p.h.), and not be-
fore, release the clutch pedal slowly.
Being towed: Secure the towline to the tow-
ing loop. The car is towed at an even speed
i n 2nd gear. Try starting as suggested in
the previous paragraph.
63


PECIFICA TIONS

MEASUREMENTS AND WEIGHTS

4640 mm 182.7„ Permissible total weight 1 700 kg (37 l b.)
Length `
Width 1735 mm 68.3 Permissible load (without driver) 380-430 kg'
Height unladen (ready to drive) 1 455 mm 57.3" (836-947 lb.)
2620 mm -1 03.0V' depending upon
Wheelbase
Ground clearance, full load 1 25 mm o o.-4 4.9"
vehicle type '
1350 mm ' 53.1 " Permissible axle pressure , front 800 kg (1760 lb.)
Track, front
rear 1 350 j nm 53.1 " rear 950 kg (2090 lb.)
9.25 m 30'4" Permissible roof load 1 00 kg (220- lb.)
Turning circle;
Weight, ready, to drive 1 240/1320 kg (2730/2905 lb.) Maximum permissible trailer weight 1 200 kg (2640 lb.)

ENGINE
Type designation Volvo B 20 A Volvo B 20 A Volvo B 20 B Volvo B 20 B Volvo B 20 E
Output (DIN) at r.p.m. 82 h.p./4700 82 h.p./4700 1 00 h. p./5500 100 h.p./5500 1 20 h.p./6000
Output (SAE) at r.p.m. 90 h.p./4800 90 h.p./4800 118 h.p./5800 118 h.p./5800 1 30 h.p./6000
Max. torque (DIN) at r.p.m. 1 6 kpm/2300 116 lb.ft. 1 5.5 kpm/3500 112 lb.ft. 17 kpm (123 lb.ft.)/3500
Max. torque (SAE) at r.p.m. 1 6.5 kpm/3000 119 lb.ft. 17 kpm/3500 1 23 lb.ft. 1 8 kpm (130 lb.ft.)/3500
Number of cylinders 4 4 4 4 4
88.9 mm 3.5" 88.9 mm 88.9 mm (3.5")
Bore
Stroke 80 mm
it
80 mm 3.15 80 mm (3.15")
1.99 litres 1.99 litres 1.99 litres
3.15
Displacement 1.99 litres 1.99 litres
Compression ratio 8.7:1 8.7:1 0.3:1 9.3:1 1 0.5:1
Overhead Overhead Overhead Overhead Overhead
Valves
Valve clearance, warm and cold inlet and exhaust
0.40- 0.45 . mm 0.016"-0.018" 0.50-0.55 mm 0.020-0.022 0.40-0.45 mm (0.016-0-018",)
700 r.p . m. 800 r.p.m. 800 r.p.m. 900 r.p.m.
I dling speed (warm engine) 700 r.p.m.
(700 r.p.m. = BW 35 (700 r.p.m. = BW 35 (800 r.p.m. = BW 35
autom. transmission) autom. transmission) autom. transmission)


SPECIFICATION

Output and torque diagram Fuel system

Carburettor, B 20 A, type . Horizontal ..
designation Zenith-Stromberg.
175 CD 2 SE
B 20 B, type' Horizontal
0

designation SU-HIF 6
(o n vehicles with
Zenith-Stromberg 175 2CSDE)

Ignition system
Firing order 3-42 1-
I gnition setting
stroboscope setting
with vacuum
regulator disconnected
B 20 A 21 23 ° B.T. D.C. .
(at 1500 r.p.m.)
B 20 B 10 ° B.T. D..C.
(at 0-800 r.p.m.)
B 20 E 1 00 B.T.D.C.
(at 700-800 r.p.m.)
Spark plugs, B 20 A Boschs W 175 T-35*
B 20 B, normal driving Bosch W 200 T 35*
hard driving Bosch W 225 T.35*
Cooling system B 20 E Bosch W 225 T 35*
Spark plug gap (0.028-0,032") m
Type Positive pressure Tightening torque . 3.5-4.0 kpm (25-29 l b-ft.)
(0.7 kp/cm 2 =10 p.s.i.) Distributor, direction of rotation Anti-clockwise - ,
closed system 0.4-0.5 mm (0.016-0.020)
Thermostat, begins to open at 82 ° C (180 ° F) Contact breaker gap .
fully open at 90 ° C (195' F) or corresponding


SPECIFICATIONS

ELECTRICAL SYSTEM POWER TRANSMISS I ON

Voltage 12V Clutch
Battery, type Tudor 6 EX 4F o.p.*
Capacity 60 Ah Clutch release arm play 3 mm (approx. 1/8")
Electrolyte, specific gravity 1.28
Recharged at 1.21
Alternator, rated output 450 W
max. current 35 A
Gearbox
Type designation M 40 M 41 BW 35
Reduction ratios: 1st speed 3.13:1 3.13:1 2.39:1
2nd speed 1.99:1 1.99:1 1.45:1
X con-
3rd speed 1.36:1 1.36:1 1:1
verter
4th speed 1:1 1:1 -
Lamp bulbs (12 V) Power Socket Number ratio
(with overdrive) - 0.79:1 -
P 45 T Reverse 3.25:1 3.25:1 2.09:1
Headlights 45/50 W 2
Foglights 55 W Pk 22 s 2
Parking lights, front 5 W S8.5. 2
rear 5 W Ba 15s 2
Flashers, front and rear 32 cp Ba 15 s 4 Rear axle
Stop lights 32 cp Ba 15 s 2
Reversing lights 32 cp Ba 15 s 2 Type Hypoid bevel gear
License plate light 5 W S8.5 2 Reduction ratio 4.1:1 4.3:1 4.1:1
Side marker lights 5 W Ba 15 s 4
I nterior lighting 10 W S8.5 1
Glove compartment light 2 W Ba 9 s 1
I nstrument lighting 3 W W 2.2 d 2 Speeds in km.p.h. (m.p.h.) at 1 000
Lighting, heater controls 1.2 W W 1.8 d 3
engine r.p.m.
Clock light 2 W Ba 7 s 1
Warning lamps: Rear axle 4.1:1 4.3:1
charging 1.2 W W 1.8 d 1 Gearbox M 40
turn indicators 1.2 W W 1.8 d 1
parking brake 1.2 W W 1.8 d 1 1 st speed 9.1 (5.7) 8.7 (5.5)
headlights 1.2 W W 1.8 d 1 2nd speed 1 4.3 (9.0) 1 3.7 (8.5)
oil pressure 1.2 W W 1.8 d 1 3rd speed 21.0 (13.0) 20.0 (12.5)
overdrive " 1.2 W W 1.8 d 1 4th speed 28.6 (17.9) 27.7 (17.0)
emergency warning flashers 1.2 W W 1.8 d 1 4th speed + overdrive - -
elec. heated rear window A 1.2 W W 1.8 d 1 Reverse .8.8 (5.5) 8.4 (5.3)
P


SPECIFICATIONS

FRONT WHEEL ALIGNMENT CAPACITIES

WHEELS AND TYRES Fuel tank 58 litres

(12.76 Imp, galls=15.31 US galls)
Tyre size, standard Cooling system 1 0 litres
(2.2 Imp. galls=2.6 US galls)
1 42/144 Radial 165 SR 15 (of which expansion tank 0.6 litre
1 42/144 de Luxe Radial 165 SR 15 =1 Imp. pint, 1.3 US pints)
(For U.S.A. diagonal 6.85 S 15) Oil capacity,
1 42/144 Grand Luxe Radial 165 SR 15 engine, at oil change 3.25 litres
(5.72 Imp. pints = 6.86 US pints)
Wheel size i ncl. oil filter 3.75 litres
(6.60 Imp, pints=7.91 US pints)
1 42/144 4 1/2 J 1 5 FH gearbox (M 40) 0.75 litre
1 42/144 de Luxe 5 J 15 FH (1.32 Imp. pints=1.58 US pints)
1 42/144 Grand Luxe 5 J 15 FH (M 41) 1.6 litres
(2.81 Imp, pints=3.38 US pints)
(BW 35) 6.3 litres
Tyre pressures
(11.09 Imp. pints= 13.29 US pints)
Tyre size 1 6.85 S 1 5 (U.S.A.) I 1 65 SR 15 rear axle 1.3 litres
(2.28 Imp. pints=2.74 US pints)
Pressure kp/cm2 steering gear 0.25 litre
Front Rear Front Rear
(p.s.i) , cold tyres (0.44 Imp. pint=0.53 US pint)
1 -3 persons 1.5 (21) 1.6 (23) 1.8 (26) 1.9 (27)
Full load 1.6 (23) 2.1 (30) 1.9 (27) 2.2 (31)
TOOL KIT
With prolonged driving at speeds above 140 km.p.h. (90
m.p.h.) the pressure should be increased in the 6.85-15 The tool kit contains:
tyre by 0.3 kp/cm 2 (4.5 p.s.i.). This also applies to the Wheel nut and sparking plug spanner, tommy bar, pliers,
1 65 SR 15 tyre when driving at speeds near that of the maxi- adjustable spanner, Philips screwdriver, plain screwdriver.
mum for the vehicle. Maximum pressure must not, however,
exceed 2.3 kp/cm 2 (32 p.s.i.) and 2.5 kp/cm 2 (36 p.s.i.) resp.
LUBRICATING CHART

Symbols Notes to lubricating chart (1/4") from the edge of the spindle. Use
oil ATF, (transmission oil).
Brake fluid Note 1. The wheel bearings are packed at
Grade: SAE 70 R3 the factory with a special type of grease Note 7. Change the oil filter every 10 000
SAE 70 R3 (J 70 B) or SAE J 1703 intended to last the entire lifetime of the km (6 000 miles). See page 47.
can also be used bearings. In connection with such work-
shop operations involving uncovering the Note 8. Check the oil level when filling the
Rear axle oil wheel bearings, the bearings should be tank. Concerning oil changing, see page 43.
Grade: Hypoid oil cleaned and then lubricated with high-class,
durable grease according to the instructions Note 9. Check every 10 000 km (6 000
Viscosity: See page 45 miles) that the oil reaches up to the filler
in the service manual. Except on the above
occasion, subsequent adding or changing of plug. Concerning lubricant for rear axle with
Special lubricants l ubricant is not required. differential lock, see page 45.
See resp note The rear wheel bearings are lubricated, so
change of lubricant is unnecessary. After
the bearings have been removed, however
Light engine oil they should be lightly greased with wheel
bearing grease.
Engine oil
Grade: For Service HS Note 2. Check that the oil reaches up to
Engine oil: Multigrade the filler plug. Use hypoid oil SAE 80 all
See also page 43 year round.
Note 3. Check that the fluid reaches up to
the MAX mark.
Note 4. Lubricate the felt wick under the
rotor and fill a few drops of light engine
oil into the lubricating cup.
Note 5. Check every 10 000 (6000 miles)
that the oil reaches up to the filler plug.
Concerning oil change, see page 44.
N.B. The type of gearbox will decide the
type of lubricant to be used.
Note 6. At every engine oil change check
that the oil level in the centre spindle of
the carburettor(s) reaches up to about 6 mm


Lubricate
after every
LUBRICATING CHART Lubricate
after every

Wheel bearings. Wheel bearings

Note 1 Note 1

Steering box Note 6

Note 2 Carburettor(s)

Brake fluid Oil filter

container
Note 7
Note 3

Distributor Engine
Note 4 Note 8

Gearbox Rear axle

Note 5 Note 9

Wheel bearings.
Wheel bearings
Note 1 Note 1

Oil capacities
Engine excl. oil filter approx. 3.25 litres ( 5.72 Imp. pints = 6.86 US pints)
i ncl. oil filter approx. 3.75 litres ( 6.60 Imp. pints = 7.91 US pints)
Gearbox, M 40 approx. 0.75 litre ( 1.32 Imp. pints = 1.58 US pints)
M 41 approx. 1.6 litres ( 2.81 Imp. pints = 3.38 US pints)
BW 35 approx. 6.3 litres (11.09 Imp. pints = 13.29 US pints)
Rear axle approx. 1.3 litres ( 2.28 Imp. pints = 2.74 US pint
Steering box approx. 0.25 litre ( 0.44 Imp. pint = 0.53 US pints)