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ElectricalSystem Section Grcups

(excl.Wiring Diagrams)
and Battery
Alternator
31
32
lnstruments Starter Motor 33
lgnition System 34
242/244/245 Lights 35
Std. Equipment 36
Repairsand Instruments 38
Maintenance 1976-
Content of Manual
Group31: Battery
Generalinfomation

GrouD32: Alt€rnator
Specifications 3
N e wF e a l u r e s . . . . . . . , , , ,
D e s c r i p t i.o. .n. . . . . . . . . . 5
ServiceDiagnosis 6
Checo k f c h a r g ' nsgy s t e m ........... ..... A 1-A12 7
ServiceProcedures
Specialinstructions for work on alternator
equipment......... 12

Group33: StarterMotor
GeneralInfomation 22
SparePartslllustration 23
SpecialTools 24

Group34: lgnitionSystem
Specificarrons 32
L u b r a c a t. i.o. .n. . . . . . . . 32
lllusration 33
Bre8kerl€ss Electronic
lgnitionSysrem
General

ServiceProcedures:
Replacingdistriburor
Replacing impulsesender 81 816 39

Group35: Lights
Specifications 43
Headlamps 44
Front lights ?t5
Lights,242 and 244, DL and GT 46
Lights, 245 47

Group36: StandardElectricalEquipment
Switches ,$
Bulb FailureWarningLight 49
Tailgate Window Wiper and Washer. 245 50
WindshieldWiper Assembly 52

GrouD38: Instruments
InstrumentCluster 53
WarningLights 53
54
Replacinginstrument 55
56
Testingfuel gaugesand tank levelsenderc A1 A8 58
AddilionalInlomalion 61
NOTE:All references
to model240 in thismanualalsoapplyto DL,GL and GT.

TP 11402t2
3000.03.80

Printedin lJ.S.A.
Battery

Group31

GeneralInformalion

(@20'CrANDCHARGE
spEcrFrcGRAVTTY
SpecillcGravltyReadlng
(uselhe mlnlmumflguretor lestlng)
Minimum BatleruCharoe
1 . 2 6 0 . . . . . . . . . . . . . . . . . . 1 0 0C%h a r g e d
1 . 2 3 0 . . . . . . . . . . . . . . . . . .7 5 . /C
. harged
1.200. . . . . . . . . . . . . . . . . . 50%Charged
The Battery 1.170. . . . . . . . . . . . . . . . . . 25 Chaged
andmajorengine 1 . 1 4 0 .- . . . - . . . . . . . . . . . V e r yL i t l l P
e o w eLr e t l
compon€nts 1 . 1 0 . . .- . . - . . . - . . . . . . . C o m p l e tD
electrical e li ys c h a r g e d
'(80"F)

water,Thenflushwilhcleanwater.Be sureventcaps
are tight so no solutiongels into cellsto neulralize
the acid.
Alsowashbatlerycarrierand holddowns.
Donolovenighten bolts.Tighlboltswillstrain
holddorvn
General the battery.Checkbanerycase for cracks.
Lack ot eleclrolylecauses prcmaturelailure of bat-
when charged,a batterygiv€s off hydrogenand oxy-
teriestasierlhan anythingelse,Plalesexposedlo ai

o
gen,a mbdurewhichis highlyexplosive. Keepopen
delefioralerapidly.Check electrolylslevel fiequenlly, llamesaway Aom batleryand never disconnecta
especially in hot weatherwhenevaporalion asmore
chargerby removingthe connectional the batterypost.
likely.
Guad againslsparksby disconnecling tho ground
Filldeslilledwateronlyto the battery,neveracid. How- it lest. Be caretul
nol lo lel
cablelirst andconnecting
svsr, any watsr is batterthan no waler. Batlerylife is

O ext€nd€dby usingthe pureslwaler available.


CheckingBanery
tools or other meial objeclsfall across
terminals.
lhe battery

Neve. take rcadings right atter adding water. Water


The mostcommonwayto checkbatterychargeis wilh a
mustlilst be mixedwilh eleclrolyle.This is done by
hydrometer. lt measures specificgravitywhichis a di-
chargingthebatt€ryor runningit onlhe carfor a couple
rectmeasure of percenlage
sulphuricacidintheelectro'
lyl6.As batlerydropslromchae€dto discharged condi-
tion,acidleaveslhesolulionandenterslheplates.This Takeelecvollte fromeachcell andcomparereadings,lt
causesa decreasein specilicgravity. onecellis0,030ormore lowerthanolhercsllsitsplates
are not holdingchargeand il mightbs n€cessary lo
Prolonging batterylile is tusl a matlerol oeveloping
replacethe batlery.(0.0501ordry charged)
goodhabilsol leslingandmainienance. Adirtybattery
discharges ilsel{:acidcorrosion anddirtaclas conduc- ll batlerych€cksgood by the specilicgravilytest,il
tors. Corrosionaroundbatlerypostseats awaycopper mightstillb6 necessarylo makea highraledischarge
cableterminals. lest,duplicaling
lhe stanermotordemands. SeeGroup
33, SlarterMolorandEleclricaltestspecilicaiions.
A dartybatleryshould
b€ €movsdandscrubbedwitha
solutionoJ bakingsoda and wateror ammoniaand loadon bailerylongerthan
Donotmaantain n€cessary,
Group31
Battery 1
Banery

WARNING!

Caution
We wouldliketo strcssthe importance ot not havjng
openllamesor spa*s in the vicinityof the batteryb€-
causeol theexplosivegaswhichlonnsin the battery.
Thereis thus a dangerof sparksfromshodingat lhe
batleryposlswhrchcan causethe gas to ignde.

Prccedures
-Both batteries (senderandreceiving) musthavethe
samevoltage.
-TheAmperageolthesenderbattery mustnotbevery
muchgreaterlhan lhatfor the receiverbattery.
-The battery cellcapsmustbein position (thisreduces
riskol gas igniting).
-lf lhereceiving batleryis frozen,il mustbeattowedlo
thawoulbetoreconnecling up thejumbercabtes.(A
flal batterylrcezesal -10"C. (15"F.))

Useof JumperCables
ING CAL
SENO -The senderbalteryenginemuslbeswitched off.The
receiverbatterymainswilchmustb€ off.Thebodies
ofbothlhecarsmuslnotbeinconiaclwith€achother
(risk oJ sparksfoming whenthe cablesare con-
nectedup.)
1. Connect the redcablefromsenderbatterypluster-
minallo receivingbatterypluspost.
2. Connectone endoflheblackcabte to agroundpoint
RECEIViNG
CAR somedistancelrom lhe receivingbatlery.Suitabty
lhe receivingbanery'sgroundconnectionshould
alsobe on the bodyor on the engine.
-Slart thecarof lhesenderbatteryandidteit at about
1500rpmfor severalminules.
N e g a ti v e -Starl the car of the receiverbattery.
os itive
Terminal

F I T TI N G C A E L E S NOTE!Do not alterthe positionof the cabte


clampsdu ng lhe startingattemptotheMise
lhereis riskof spa*s forming.
Do nol bendoverthe batteryl

-Remove the cablesin precisely


the reverseorderto
flttingthem.

RE]'1OV CABLES

Gtoup31
2 Battery
Specifications

Group32

Alternator

Specifications
Alternator
Tlpe
Output
13.0-15.0V
I
55 Amps
\,4., sppFd .. 225 t/s = 13500rpnr
D r e c t i o no f r o t d to n .. Clockwise
q o r o . e _ g e a l r p r ' 3 r o._. . . . . . . . . 1:2
S I D ' r n g s .r n i - J m d i d m e l e . 3 1 . 5m m
ra: o-r oI o-no 0.O3 mm = O.OO12
Stdtor Loil res stdnce O.14ohm + 10%
F o r o r c o r lr e s r s t a n c e 4.Oohms+ 10%
O-rpu esl 48 Amps at 3000 rpm, 13.2 Vohs and
24oC ambienttemperature

Voltage Regulator
Tlp. .. ...
Colt'o. vordge ol 40OO pr 13.9-14.8Volts
I
Loadru r.rr owo 'wo co.racrs 4511 Amp
C o n t r o lr a n g e ,b e l w e e nu p p e ra n d l o w e r c o n t a c ts e t s . . . . . . . . . . . O O.4 Vohs
3-8 Amps

Description

o
1. &ush holdor
2. M6gn6iizingDiodes
3. Slip ng 6ndshield
4 B€crmd (slrien diodas)

-. A n a r F ' a t o r h a sa r o t a ! . S , r ed . o r l ( r o _ o ralr d . s l d .
T1. allernaror rs a th'e" pl'ase sld. Lonnpcl.d a
F c l ' i e ' rs burl rnro _ l _ es o r ' q tionary main coil(stator).The rotor is a 12 pole claw-
nar n9 un r. lhe "nd
shield and consisls of six silicon diodes. Aso ho{rsed pole rype w,rh rl"e l,ed Lo' 'ed ac oss lwo slip rings.
n rhe slip rng end shield are three so called mag
Since the ahernator outpul s self-limited(max. 55
ne /rng dodFs. wl_cl repd rhP rred via ll"e vor;9.
amps),a simplereguatoris used. t conlrolsthe vo tage

Gtoup 32
Ntomator
Specitications 3
Design

NewFeatures

A newtypeSEValtemator (SEVP/N71655302) is now


beingslockedunderVolvoP/N 5462893€.The new
allemalorcan be identiliedby a blackplasticdaode
guardand a mold€dwiringhamessassembly.(See
PiclureBelow).Whenreplacingthe olderstyleSEV
allernalor
withthe newversion,lwominorchangeslo
lheoldwiringhamessarercquired. Reterto lhe instruc-
tionsbelow.

Afteroldstyleallemaloris removedandin-carhamess
js disconnected,proceedwith the operationsshown
duringinslallation
oJlhe new allernator. .)
1. Conneclin-carharnessleadsto terminals
at backoi
newalternator
as followsi
a. Heavygauge,rcd twin
lead10B+ teminal.
b. Singlered leadto D+/61teminal.
c. Blackleadto D- teminal.

d. Useelecvicallapeto securely
fastengreenDFlead

Nole: Makesure ihe lead is well insulatedand

2, Carelullytapetheold in-carwiingharnessconnec-
tor piugas shown.
Theconnectorplugiromlhe newmoldedalternalor
harnessshouldbe pluggedinlothe regulalor.
Nole: Do not underany circumslancescut anyoJ
the old leadssincetheymay be neededfor
Juturealtemalorinstallations.

Gtoup 32
4 Altemator
Design

Altomator

When $e ignition is switchedon, current nows


throughthe chargingwarninglamp ro terminalD+
on the voltageregulator.
Viathe regulaior,
rhe current 02s-0,40mm
rs conducredrhroughthe roror corlro ground.
Voltagaregularor
Regubtorcontactfor 3. Springrensioner
ower conro! range 4. Spring upper seciion:
2. Regulalorcontacl tor
upper contol range

lf the vohage ises in spite of thig rhe armature on


the voltagecoil is pulledfurtherdown so that rhe upper
contol range contacts close, Thus ihe rotor coil is
grounded at both ends which causesthe voltage ro
d.op rapidly. The cycle is repeated continuouslyso
that the voltage is maintainedconstant.

5Wr

t_-!

When the roior starts rotating,ahematingcurrent is


formed in the stator. Most of the current is recrified
by the positiveand negativediodesand is conducted lo0o500060007ooo

via B+ on the alternatorro the battery.A small part AIIEBNAIOR BPM


Arr€matoroutputcurue f:j9
of the currenr is rectified by the exciter diodes and
is led via 61/D+ to the voltage regulatorand rhen A = amps
to the rotor coil. This cycle is repeateduntil the regu- RM = ahernator
speed/mi.ute
lating voltage has been reached,at which point the
lower controlrange coniactson the voltageregulator Thealternator
maximumoutpuiis55 amps.Topspeed
open and field current must oassa control resistance. is 13500rpm.

Group32
5
Diagnosis

ServiceDiagnosis

Condition: Warning lamp does not light with engine off.

Action Possiblecause
Testlamp(12 volts2 wattstbetweenB+ and61/D+ Warninglamp burnedout or opencircuitto D+ on
on alternatorlights. regulator.
Test lamp betweenB+ and 61/D+ doesnot light. Positivediodeshorted.
Test lamp between61/D+ and groundlights.
Testlampbetween61/D+ andgroundgivesa weak
light.Removethe plug at the regulatorand connect
an ammeterbetweenB+ and DF on the alternator.

O amp Worn brushes,oxidizedslip ings on breakagein rotor


oi'
2-2-5 amps Open ckcuit in regulatoror in lead DF from regulator
to DF on alternator,
o
Condition: Warninglamplightswith engineoftor running.

Action Possiblecause
Disconnectthe plug at the regulator CircuitshortedbetweenD+ ontheregulatorand
61/D
Controllamp still lights.
Warninglampgoesout-Re installtheplugi. the rcg-
ulatorandconnectan ammeterbetweenB+ and D+

Lessthan 2.0 2.5 Ampsl Defective regularor(brcakage).


More than 2.0-2.5 Amps: Circuil shorted between DF on regulatorand DF on

Coil shoned.

I
Condition: Warninglamp lights with 6ngin6off bu1starts to give a weak light
when€ngineis running.
0.
Actionr Possiblecause
TestlampbeiweenB+ and61/D+ on the alternator resistance
Transition in thecharging
circuitor in the
wirh the enginerunningl leadto the waminglamp.
Doesnot light,
Givesa weak light. Defective (overcharging
regulator of thebattery)orde
(insufficient
fectiveahernaior chargingoflhe battery).
Installnew regulator.
Test lamp betweenB+
a n d6 1 / D + :
Doesnot light. Removed regulator defective.
Givesa weak light. Defectivealternator.

Group32
6
Diagnosis

Check ol charging system

Generalorientation

Connectionsat altemator

FEDwlFE. TO CHAFGTNG
CONTROL
LIGTIT

ir
iiJ"
t
FEDor aRowri

ro PLUGAT ALTERNATORWITHWIFE
LOOMTO VOLTAGEFEGUIATOF

o
D '1.,,

Connectionsal voltageregulaior
i d e n l i f c a l i o no f w t r e s n p l u g

_.._.i...t_ REDo. BFOWN


D+
DF
GREENor WHITE

Procedures

Checkdrive bell tehsion


D e f l e d o na t m d p o n t s h o l J db e a p p r o x5. / 1 6 ' ( 8

Gtoup 32
A2
Check batlery condition
A batteryin good conditionshouldbe usedfo' rhe

Checkthat batterYterminalsare cleanand tighl


Reler1o Group31 for checkingbattery.The battery

I shouldbe in fullychargedand goodcondilionlor the


lesls.
tollowing

A3
Switch on ignition
Charginglighton instr!mentpanelshouldilluminaie
go to A4.
a. Light illuminates.
b. Lightdoesnot illuminate:discon.ectplugal vol
rage regulalorand ground red wire D+.
- Light illuminates:
go to 44
Lightdoesnot illuminatercheckwires,control
lightbulb etc.

A4
Connect a voltmeter to alternator B+ and
grouno
All lighlsandaccessodes switchedoff. Runengineal
// approx.2000 rpm for one minute,then read voltage.
a. Voltagereadingcoflecl go to ,q5,
II b. Readinghigherthan14.4volts:go to 410- 0)
II than13.0volts:go to A10.
c. Readinglovver

I I I
(Refer to s€ction Tesling the VoltageRegulatol for
chargingrats).
I \
VOLT-I']ETEF

A5
,

I
Voltmeter stillto alternator B+ and ground
Switchon blower,rearwindowheaterandheadlighl

Run engineat 2OOrpm for one minute

\s
\\
BEDor BBOWN Vollagereadingshouldbe lessthan O.7volt lower

a. Lessthan 0.7 volt: go to A6.


b. More than O.7 volt: go to A1O.

GREENof WtllTE

Group32
I
T
Diagnosb

A6
Connectvoltmeterto alternatorBi and bat-
tery plus
Switch on headlighruppe. beams.Run enginear ap-
prox. 1500 rpm. Voltmeter readingsho! d be O.O-O.3

a. Less than 0.3 vok: go ro A7.


b. I M o r et h a n 0 . 3 v o t :

N ch€ck wire from a lernator 8+ io starter motor


to batiery pl(]sfor loose or corrodedconnecton.

Connect voltmeter to battery minus and en-


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

Voltage reading should be 0.0-0.2 voll.


-xF
a. Less rhan O.2 vok, go to A8.
b. M o ' e l l _ d . 0 . 2v o l r .c h F c kw r e l . o m b a e r y m r - u s
to eng ne ground to alternatorground for
FEDor BFOW{
or corroded connectons.

A8
GFEEN
orWHm Charging system should be correct if all pre-
vious tests have proven satistactory.

Gtoup32
With incorrectsystemtest readings
A9
Re{erence
to A4
{Voltage reading higher than 14.4 volts)
Connectvoltmeter to D+ and B+ on alterna-
tor.
'/.-_'
Runengineat l5OOrpm.
/l a. Vollage readingexceeds0.5 volt ahernatormust
be defectiveand should be replacedor repaired.

I b. Voltage readinglower than 0.5 volt voltage reg-


I ulator should be replaced.Recheck.

At0
Reference to 44
(voltagereadingbelow 13.0 volrs)
of referenoo to a5
(voltagedrop more than O.7 voh)
Connect voltmeter to O+ and B+ on alterna-

Bunengineat 1500 rpm.


a. VoltagereadingexceedsO.5 volt:alternaror
must
be defectiveandshouldbe replacedor repaired.
b. VoltagereadinsbelowO.5 voh: so ro A11.
Priorro this test,carefullycheckthat wiresfrom at-
ternatorto voltageregulatorare in corect order.No
shons,no grounds,no looseconnections.

Atl
Checkrotor circuitresistance
Disconnectwire DF (plud at vohage regulator.Use
ohmmetertocheckrotor resistanc€. Correctresistance

I I is approx.4 ohms. Howevet dependingon brush con-


ditlon,resistancesof 4-10 ohms might be considered

I I
I
R u n e n g i n ea t 1 5 0 0 r p m .
qoror ressrancechecksour coiiect: go to 41r. i
I OlIU.UETEB
b. Botof resistancechecks out lower than approx

rolor is orobablydefectrve.When reDaiflng.checl


rotor resislancedirecrlyonslipringslo venfytautt.
BLACKWIRE Rotor r esr$anceconsrderably
hrgherthan app'ox.
4 ohTs clea' ahernarorbrushesand shp rings.

Gtoup32
10
Diagnosis

JUMPEAW|FE At 2
,.-_-\ Full Fielding Test
( Thisis alullchargetestol alternator,
airnsdatdefinitety
separating allernalorproblemsfromvoltageregutator
I D+
REDWIBE a. Removethe plugat the vollageregulalorandcon-
\ necla jumperwircbetweenD+ andDF as shown.
\--
DF
GREENo. WHIIE

Connect voltmeter toalternator B+ and ground


/a
bower, rear wrndow heater. headighr upper

Run eng ne at 2OOOfpm.


d.
Pe"d, 9" I gr er rhcn 4.O rol,s rndrudrealler
a , d o a \ e o J e r t \ v o l r a g Fr P g u -
lator sho!ld be replaced.
(
Beadings below 14 volts, usually considerably
VOLT-METEF l o s e : i n d i c a r er l - ed l r q n j o ' , n o - l o b . e p a , - o
o r ' e o d n e d r 'r. 1 e .d r o d e >Fo r o s i l p l y a r , a r l r .

CAUTION:Donotrunenginehigherthan 2000RPN4 or
lor lengthlypedod-it coulddamagethe

o
batteryandotherelectricacircuitsdue lo
HighVoltage.

\s
\\

GREENor WHIIE

Group 32
Altematot 11
Removingaltenator

S€rviceProcedures

Specialinstructionslor work on alternatorequipment


banery.makesurclhal
or installing
1 . Whenreplacing Whenfastcharging batteryin vehicledisconn€ct lhe
properpolarityis observed,A misconnectedbaltery batterygroundcable.
will immediately ruinthe r-ectifers. 5 . Whenusingan extra battoryas a starlingaid, con-
Neverrunlheallemalorwith lhe mainckcuitbroken nectit in parallel.
The battery and/or altematorand regulalor leads Whenarc weldingon the vehicle,disconneci the
must neverb€ disconnecled whrF lhe engne is battery gound cableas well as lhe B+ lead on the
running. alternatorandlhe plug al lhe voltage regulalot.The
3 . No attemptshouldbe made to polafizethe al- weldingunitshould alwaysbeconnectedcloseto the

0l

Removingalternator 0(

BI
Removealternator
a. Disconnect wires at alternator.
b. Removebolt for tensionerbar, hex 13 mm
c. Lift off drive beltsand lower alternaior.

0),

Removealternator and bracket


B2 cr
ALsoremovethe tensionerbar.

Hex 13 mm

Group32
12
Diassembling dItematol

Disassembling
alternator
cl
Removenutand washerfrompulley.Pulloff pulleyand

o Bemove brush holder retaining screws.


Remove blush holder.

C3
Remove nuts and bolts connecting akernator end

Remove front end shield from stator and rear end

Pressout rotorlrcm lronl endshield.


Note:oldtypeshown.

Gtoup32
Testing

Removethe screws retainingthe fronl ball bea.ing.


Press out ihe bearing.

tu,* C6
Femove nuts for p us diode plate.Lift up and bend
0
c7
frornthe terminal
Solderloosethe starorconnections 0
NOTE:Aways use a heat sink whensolderingand
arounddiodesto preventdamageto
soldering

alternator
Test of disassembled
C8

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

O
c9
Test stator coil resistance.
Connectthe iest instiurnentacrossthe phase termi

Conect resistance:O.14 ohm + 1O%.

-.

Group32
14
Testing

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

o
o Test rotor coil resistance.
Connect the test instrument across rhe slip rings.
Corect resstance 4.O ohms + 10%.
cl l

Sllp rngs which are burned or damaged should be


turned in a athe. use tail stock.
S l i p r n g m i n i m l m d i a m e i e rs 3 1 . 5 m m = 1 . 3 ' .
Use a dia indicatorto check out-of-round.max mum
0.03 mnr = 0.OO12".

ct2
Brush holder

Use40 Voh altematingcuiienr.


Correct r€adng: indeiinite
C h e c kt h a t m i n i m l m b r u s he n g t hi s 1 4 m m = O . 5 5 ' .

Group32
15
Replacingdefective rectifier diodes
ct3
Diodes
Test rhe diodeswith

NOTE:AlthoughBoschtestingequipmentis shown,
similarequipmenlis availabbfromdomeslic
manulaqurers.

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

Greasethe drive end ball bearinswith srease Bosch


c15 O
Ft1V4 {orequivale.t).
InstaI bearng assemblyin the driveend bearlngshield.

Gtoup32
16
,

Assembling altemator

c16
Pressdrive end bearings h i e d o n t o t h e r o t o f .
lnstal rhe spacernng.

cl7
Greasethe slip rlng €nd shield bearing wth grease
g .o a l t h e s L i pr i n q
B o s . r 'F r 1 V 3 5 o ' L o i i e s p o n d r nC
end shield bearingseal with N/lolykote. Assemblethe

D o o f o r g . r r o a s a . lr l - es o n n qo r l - - . [ p aq e_d

-oro-e
A s s e m b l ea l t e r n a r o rc o m p o l e l t \ . rcrarrlg
screws to 3.6 4.3 lb.ft. = 5.G-6.9 Nm and nuts to
3 . 3 4 . 3 L b . f t=
. .4.5-6.0 Nm.

ct8
rhe brushholder.
InsraLl

cl9
fan,spacerandpulley.Position
Installkey, thewasher
andlorquethe nutto 29 lb. tt. = 40 Nm.

c20
Teston a lest benchbeforeinstallalion.

Gtoup 32
17
lnstalling ahenatot

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

Installing alternator
DI
Installaltemator with bracket and tensioner
0
DAr
Hex 13 mm

Cl
D2
Installdrivebelts
Install bolt for tensione. bar. Adjust
f(

Oldallernalor
shown,

Group32
18
Tesnng voltage rcgulator

Testing voltage regulator

-{:-._:

Charging Regulator

llilN Electroniccharuingregulalorshave now been Intro-


duced as spare parts lor cars which do nol have lhe
thr€e-teminalclnnection contacton the regulalor.
These nsw regulato|scan be easily identiliedby lhek
grey cover,Theold type regulatorshaveblack covers.

ldentitying the regulEtor

with Marking
Sev P/N72610102
diode(ed
plate) Spot 1259303-4
Magnetizing Blueor
diode Black
Spol 12593026
SevP/N726-10002

ldentitying the alternator


Allemators diodeshavea red plateon
walhprotectivg

Thoseallernalorswhichdo not havea red plateon the


rearend arefitledwithmagnelizingdiodes.

r||gnetlzlng Olodo3

Group32
Altematot
Testing vohage rcgulatol

Testing voltage regulator

(Ontest benchor in vehicle)


EI
Connect the regubror to an alternator n good con-
dition.

E -'l

L JI!
L-
t-
H 'l

'
D
Wiringdiagramfortssting
voltag€regulator
li.ii!

0,25-A,1O.r'm
0
E. Ammeter0 50 amps.
Voh€selamp 12 vohs F. Fesuarorresistance
c. Conlrollamp 12 vo rs, G. Batery 60 amparehours Voltageregulator -
L Fesularorcontacrfor 3. Sprinsrensoner (
D. V
rowerconrrorrange 4. spring uppersecrion
2. FegulalorcontaclJor Sreetspring
upperconlrolEnge Lowerseclioni
Br meta spfng

Runthealternatorat 5000rpm(alt.speed)or2500rpm
(enginespeed)for 15seconds.Readthevoltageonthe
voltmeler.
Wilhno loadon lhe allernatof,
thevollmeler
shouldread13.1-14.4 voltswilhthe regulator
ambient
lemperalureat 25rc (77"F).
Loadlhealtematorwilh
onheadlights
10-15amps,suchas switching
10ripperbeam,andreadthevollage. The
0
voltageshouldstill readbetwe€n13.1'14.4volts,bul
mustnotdropmorethan,4voltslessthantheunloaded
specification.
For exactvoltageat ambientlemperatures
agramsopposite.
see di- 0
-24 .2o .4O r80

Group32
20
Testing voltage regulatol

Testing voltage regulator

lon test benchor in vehicle)

llvollageisoulsidespecificationlhe regulalorshouldbe
replaced. lf ihe voltageregulatoris to be tssledmorc
accuhtely,installitin thevehiclewhichshouldlhenb€
d v€n for approx,45 minulesat speedabove30 mph.
The €asonlorlhe diving is to letlhe regulator obtain
cofiecl wo*ing temperature.
NOTE:Thevehiclemustbedriven.lt isnotsufficient iusl
to havethe engineidling.
lmmediately after,or prelerably
duringdriving,measure
thevollag€betweenB+ andD on thealtemator. The
engineshouldbs tumingover al i50O rpm,whichis
approximatelytfie sameas 3000 lpm allernatorspeed
whenmeasung.Withregulator atambienttemperature
ol approximalely 25'C (7rD the voltageshouldbe
El€ctronlc F€gulalol! according to diagrams. Pleasenotevollagevariations
according lo ambientlemperalures.

-20 -10 0 +to +20+30 +{o +50+60 oc


0 + l r i +32 +tO +68+85 +lo4fl22 +140oF

Gtoup 32
Group33

StarterMotor

GeneralInformation

0 (

The starter motor is rnountedon the fiywheel housing


0 (

on lhe left side of the erg ne. I is a a pol€ ser€s


wound motor. The pinion on the starter motor arma-
ture shaft moves axally to engagethe f ywheel r ng
gear. The pinion is controlled by a solenoid.
T J r _ i n gt h e r g nr i o n l e y r o s r a f l r r gp o s r r o nc L l s r r
the soenoid, causingthe armatureln the soenoid to
b e d r a w n I ; n d l h e s l a r r e .p i no n r o e _ g d g er h e . i . 9
gear on the engine flywheel/drive plate. When the
armatLrrehas moved a ce.tain distance,the contacts
for ihe main curfent closeand the starterrnotor starts
running.

f'(
Specifications
D e s i g n a t i o. n. - . . . . . . . . . ................. Bosch 12V
I
Direction of rotation
O!iput 8 1 0 W (1 . 1
I

Group33
22 Staftet Motol
Mechanicaltest specificat;ons
A r m a r u r ee n d I ' o a l .. .. 0.01 O.03mm 0.0020.012-
Brushsping tension. t4 t6 N 3.1 3.5 tbs
DEranc" hor p,nron end ro ,ing gear race 1.2-4.4mn o.o47,0.173
F iclondl rorque oI 'olor brak- 25 40 Ncm 2 . 1 73 . 8 1 b .n
P i no i d l i n gI o q u e . . . IrL l8 Ncm 1 . 2 01 . 5 6b .n
Backlash 0.3-0.5 mm 0.006-o.oo
2.12
r . drd-ere' .
C o r n m u r a l om ... 33.5 mm r 318"
Brush min. length 13mm o.52'
Etecrricaltest specifications

1-.5 Volrsard 30 50 Amps 9 7 1 3 0. / s s80O7800 rpm

90 Volts a d I85 220 A-ps 1 1 . 52 2 . 5t / s 1050 1350 rpm

7 Vohqa_d 400 490 Aaps ... 0 r/s O rpm

C-r ir rokage M n I Volts


Be'easevollage....... Lessthan1 v.

nt,
t:
o 13
14
ie \15
\o
\
7 26 e 18 17

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

3 T.minorlor bd!.ry reod


9. Coniedion l.dd ro rield

Group 33
Staftet Matol 23
-T

Specialtools
Renoval, disassembly

SpecialTools

EF 2122 Sleeve 6nd drifl for inst.lins cnclip


EFAL 3 Smoothing drift
FG 2649/ 1 Sr.oothing drift
EF 2649 Drift for installingbushing

ili
0
ServiceProcedures

Removal
0 (

Disconnectthe battery ground cable.

Disconnectthe leads from the staner motor.

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

tl

I (
Disassembly

8l
Rernovethe two screws retainingthe cover-

Gtoup 33
24 starter
Motor
Disassembly

B2
Bemovelock ring and spacerrings.
thetwo screwsretaining
Remove thecornmutatorend

B3
Lift up the brushes.
Removerhe brushholderbridgelrom the armature
shaft.
The minusbrushesare retainedtogeiherwith the

o brushholderbridge.
The plus brushesstay with the field coils.

B4
Removethe nLrtconneclingthe field coil to the so_

Removerhe screwsrerarni"gthe so eroid to the prno'

Remove the solenoid.

B5
Remove ihe stator assembly from ihe pinion end

Group33
StafterMotor 25
Examination

B6
Removerubb€r stop and steel washer
Removethe pivotpinfor the pinionlevsr.Lift out ar-
matureassemblyfrom the piniondrive shield.

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

Examination

B8
Checkthe armaturefor damagssand wear.Replace
the armarLrre
if the shaft is worn or warped.
Turnthe commutatorin a latheif it is scorsd,pitted

Minimumdiameteris 33 mm = 1.3OO.
Max.permittedout-of-roundis 0.08 mm = O.0OO32'.

0 (

B9
UseaMicaundsrcutter to undercut0.4 mm = 0.008".
lf no machineis available,us€a properlygroundlrack-

Group33
26 StarterMotor
Examination

Bto

Bll
Use a "Growler" to check the armature for shorts.
Switch on and hold a hacksawblade close to the ac
mature. lf the blade vibrates in any position,one of

c
the following faults can exist:

- commutator shorted

Replaceihe rotor if faulty.

812
lJse40VoltsACcufientoravailable
equipmentlo
check
the stalorcoil insulation.

(0
Bt3
Checkend shieldsand brushholdsr.
Replacsworn or damagedparts
No morethan0.005 (O12 mm)bushingplayis per-

Checkotherpans and replaceif worn or damaged.


The lock ring shouldalwaysb3 r€placedas it might
havebeendamagedor lost its tensionwhen removed,

Group33
StaftetMotor
Installing
bushings

T Bt4

m-
Beforeinstallation,new bushingsshouldbe immersed
in oil, Bosch 01 1 V 13 or similar,for at least 1/2
hour.OtherwisetheirseNicetime willbe considerably

The bushings are made to correct dimensionsand


must not be machined.Any machiningwill block the
pore holeswhich in turn obstructsthe lubricatingabil

Use Bosch specialtool EF 2649 to pressout the old


bushing.
Clean the hole and remove any burrs.
Use same aosch tool to press in the new bushing.

Replacingfield coil
Bt5
lvlarkpoles and housing.The polesshouldbe rein- (
stalledin exactpositions.
Placethe siatorin a clampingdevice,BoschEFAW9
or similar,and slackenthe pole screws.
Removethe statorfrom the clampingdevice.
Removepolesand field coils.

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

, 1

..JI-J

Group33
28 Stafte,Motor
Replacingbrushes
Bt 7
-)-: ",, siroderthan9/ 16 = 14mm shouldbere
Brushes
-"''
1. Solder loosethe brushesfrom their attachments.
2. Solderon the new brlshes. llse a sufficienty hot

Do not allow any soder to Rrndown in the brush


leads.This would stiffen the leads and prohibir
iree movements.
: . -7 . , - 1 1

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

F
@
il &,
llnrr.LnJl

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

Group33
StarterMotor 29
AssmW

820
lnstall steel washer and rubber stoo.

821
Install solenoid. @ (

o (

822

{(

{(

823
Installbrushholderbridgeand brushes.

Gtoup33
StarterMotor
Install commuralor end shield.
Installthetwo long screwsthat hold rhe staner motor

825
Installspacerwashersand lock ring.Thearmatureend
play should be 0.002-0.006- = O.05-O.3 mn
Installsufficient amount of washersto keep the end

o playwithin theselimits.
Attach the smallcoveroverlhe shaftend.

Installing starter motor

Connect the starter motor leads.


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

Fi!. L0. Sb'l r hor.r t.roii.ll


L Fr.n 6ct..r 3. To fi.ld windiig
2. Fron isnition *irct' 1. To ilnnion .oil

Gtoup33
Staftet Motol
_...-!

Specifications

Group34

lgnitionSystem

Specifications
II
Metric US specs
Tvpe .. ... .. electronicignition
Ereakerless
F i r i no
s r d e r. . . . . . . . . . . . 13-4-2
lgnationtiming,vacuumunit disoonnoct€d(checkenginespecificalions).
Sparkplugs(Check6ngin€sp€cifications)
cap ... ... 0.7-08 mm 0.028-0.0032"
Tighreningrorque 20-30 Nm 15-22 tb.fr
Distributor
Bosch(Check engine
spscificalions)
@(
... .... ...

lsnitioncoil
EoschNo, 0221 122 006 @l
Bosch No. 0227 100 005

Centrifugalgovernor
Toral advance.distibutor degrees
Advance begins at, distibutor 7.2-1O| / s 430-600 rpm
Distributor rpm at 50 advance 15.2-14.3t/s 910-1100 lpm
9 ' a d v a n c e. . . . . . . . . . . . 23.3-34.5 r/s 1 4 O U 2 O 7rOy m
f ' r l la d v a n c e. . . . . . . . . . . 40 t/s 24OOtpm

Retard,dislributor degrees(doublefor crankshaftdegreed . . .. . . . 5.Oot 10


R e t a r db e g i n sa t . . . . . . . . . . . . . . . . . . . . 6 l - l 0 7 m m Frg 2.44.3 in Hs
2 0 r e r a r da l , 79-129 mm Flg 3.1-5.1in Hg
Retard ends al l5O mm Hg 5.9 in Hg
Consull correct specifcations for Model yoar, (

Lubricating
distributor

Theonly lubrication permittedis applyinga coupleof


dropsof oil on the felt wick in the centerof the rotor
fll
shaft.

Removedistributorcap and rotor.


Lubricate felt wick underrororwith a coupleof drops
of light oil.

B€careful,do not splashanyoilon the impulsssen-

Gtoup34
32 lgnition System
D
0

0
lr

Group34
lgnitionSystem 33
BreakerlessElectroniclgnition System

General

Two main changes frcm the conventional ignition

1. The breakerpoinis are replacedby an induction


type impulse sender.
2. An electronicmodulehas been added.lt is wired
betlveen distributorand ignition coil. lt amplifies
the impulsesbefore sendingthem on to the ig-

Otherlvisethe designand function is the same as the


conventonar system.
(
{

SpecificFunctionlnformation
0l
1. lmpulsesender
It is locatedin the distributorwhere the breakerpoints

Insreadof closingard openingan eLecrriccircuit. rhe


m p u l s es e n d e ' o p e n sa n d . l o s e s a m a g n e r i cc i r c u r r .
This inducesimpulsesin a coil (or magnetic pick-up).
The impulses€ndsrconsistsof:

2. coil (magnetic pick-up)


3. armature kotor)
4. permanent magnet
Stator. coil 6nd pemanent magnet are connectedto
the distributorhousingwhilethe armatureis connected
to the disr butor shaft.
n(
Note1: Stator and armaturehave as many pole teeth as the
Whenusinga distriburor
lester,alsothe electronic ensin€ has cylinders. (
in orderto geta distributor
modulemustbeconnecled

Note 2:
When makingCylinderBalancstesting,most instru
mentsrequirethat a specialadapterbe used(or the
enginewill die).

Gtoup34
34 lgnitionSystem
Futiction

Thepermanentmagnetcreatesa magnelc field which


goesthroughthe stator.The rnagneticcirorh is clos€d
lvhenths poletesth areoppositaeachothe..The mag-
neticcircuitis openwhen lhe poleteeth areseparated.
This m€ansthat the armature clos€sand opens the
magneticfield while it is rot8ring This generatescllr
rent pulsesin the diskibutor coil {magneticpick-up).
Vacuumand centdfugalcontrol of lhe dming is per
formedsimilarto the conventional distributor.

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

Theimpulsereceived from the coil(magnetic


pick-up)
in the distributoris convertedand reinforcedin the
electronicmoduleand governsthe outputtransistor
whichin turn governsthe ignitioncoil primarycircuit.
When the pole teeth are in front of each other, the

ro moduleoutput transistorbreaksthe primarycircuil


inducingsecondary
plugs.
voltagein the coilto firsthespark

The poleteethhavea functionsimilarto that of the


cam bb€s in a conveniionaldistributor.
NOTE:Ths ignitioncoilisdesigned specificallyfor the
breake ess solid state ignition sysrem.lt is identified
by specificationsandnumberonly andcannotbe re-
For 240 S6d6, a 1,o g r6istor is l@t6d on thoiirewart placedby other lype coils.

Group34
lgnition System 35
Diagnosis

ffiH r! ^

!;;: :
i:;E:i
E
o ii iii !
..:!5! n

o
o
='E:::;
:!:iii o(
o
-rri
€(

E)
o tia ! :
o I t;; :l
-9 . f,-lii=,
giit
f, ;:; .:

iEEi
;
ili t s :
1
L
o :| | I i':! i ! !

(E
o il rd ES:: i
!!:::
:
a

tt
,.(
o l,l El
o
o
iil
l"
rlil
llFI
r- |
-c
o tt-
ll

o |l r-l
o
l,f,-l;;
t
IE
o
lillii;;l
til Eqil
Gtoup34
36 lsnition Sysbm
Replacingdistribut$

ServiceProcedures

Replacingdistributor
AI
Disconnect
hightensionleads(orcapl primsrywire
andvacuumhoseat the distributor.

Removeattaching bott and tift oft distributor.

A3
Rotate crankshaft until No. 1 pisron is at top oeso
cent€r {TDC}.
- Thecamswillthenpointobliquetyupand pulleymark
will b€ at Oo.

Line up rotor
Turnrotor so markis approx.600frcm markon o|s-
tributorhousing.

Install distributor
Pushdistributorinto positionin engineblock.Check
that rnarkon rotor and mark on distributorhousino
lineup. Installdislnbutorretsiningboft,hex 13 mlrl-.

Group34
lgnhionSystem
A6
Install dust cover
Removerotor,fit dust cover,and r€-inst6llrotor.

Installdistributorcap
A7
e(
@l

A8
Reconnect
P mary wire, vacuumIinestc.

c)-
A9
Set timing
Referto v€hiclespecificatrons.
/./.'

Group34
38 lgnitionSYstem
BeplacingimpulsesEnder

Replacingimpulsesender

Ramoval
Unclaspthe lock clasps.
Bemovecap. rotor and dust cover,

Removevacuumunit anclclasps.

io Caution:
The retainingscrewshave ditterentlengthsand if im,
pnoperlyplacedcan projectand damagsmovingparts.
Theretore,alwaysplace the screwslogelher with the
componenl to whichtheybelong.

B3
Rsmovethe screwssecuringthe contact.
Removethecontactby pullingit carefully
straightout.

o
io
84
Remov€
thsscrewsretaining
thsimpulsesenderplat6.

Group34
I lgnitionSystem
Replacng impulse 'endel

Removesnap ring and shims

B6
Lift off the armatureand the smalllock Din.

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

88
thr€escrewsandreplace
Remove impulse
sendet.

Gtuup34
40 lgnitionSystem
Replacingimpulsesetd]aii

B9
lnstallation
Attachthe impuls€senderto the ptate.
Theconnectorpinsshouldbe ptacedoppositeabovs
the attachmentsar lor ths impulses€nderplate.

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

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

Bt2
hstalt shimsand snap ng.

Gtoup34
lgnkion System 41
Replacingimpulse sendel

813
R€connect
thewir6 conn€ctor
andtightenthe screw.

Bt4
Installclaspsand vacuumuniL

R15
Installdust cover, rotor and cap,

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

Gtoup34
42 lgnition System
'v
Specifications

Group35
Lights
Specifications
Llghts,12 V USbulbNo. Powor Sockel No.ot bulbs
Headlights
244-245
DL4DWagon' 5Ya"Typ€ 1
5%" fype 2
S€aiedBeam
Headlighls
242,GI 7" rype 2 2
FositionLights,tiont67 5w4cp Balss 2
TumSignals,front 1073 21wl32cp Bal5s 2
TumSignals, rear 1073 21wl32cp 8a156 2
Tailljghb 67 5w4cp 8a15s 2
Stop Lighls 1073 21wl32cp Ba15s 2
Back-upLighls 1073 21wl32cp Balss 2
SidelvlarksrLights 57 3wlzcp S 8.5 2
The followingbulbsmay be obtainedfrom a Volvo dealefi
Socket No of bulbs
Re3r Ash Tray Light 1,2W w 't.8d ,I
LicensePlateLight 2
lntsriorLight s 8.5 1 \245:21
Glovs Locker Light Bags I
InstrumentPanslLight BaTs 3
ControlPanelLight 1.2W w 1.8d 3
Shift PositiongAutom.
1 . 2W wt.8d
EngineCompartmentLight 15w
ControlLamps
Charging w 1.4d l
Turn Signals 1.2W w1.8d 2
BrakeFailure 't.2 w w1.8d 1
ParkingBrake 1 . 2W wl.8d 1
Headlights 1 . 2W 1
Oil Pre:sure w 1.8d 1
Overdrive 1.2W w 1.8d I
WarningFlashers w 1.8d I
El. Heated Window 1.2W wr,8d 1
1.2W w1,8d ,I
Seat Belts 2W Bags 1
Bulb Failur€ 1.2W w 1.8d 1

Gtoup35
Lights 43
ServiceProcedures

ReplacingSealedBeamheadlamPs

Turn 1/2 turn to rcmovethe plasticscrews.


Remov€the he.dlightrim.

Turn the chromedring slightlycounterclockwise.


Removethe chromedring and lift out the headlamp
unit.
Disconnectthe socket contact.

q,:1,>.

Feconnect socket contact, install headlampunit,


chromed ing and rim.

Headlightalignment

lJssthe wo Bcrswsto adjudths hsadlightalignm€nt.

Gtoup35
44 Lights Models240,DL 2d, and GT
flril
ii:,- :.;
iit;:::,4)

@,

D llttt
I ,ilJlll
i NNER-BqAM
BIA{,
sEAtE Tvpe1

K
OUTER
BEAIq,5 3/4"
SEALED
BEAfi TYPE2
l1\\\i
Models240, DL 4d and DL 5d

Group35
45
U9hE,242,244,DL & GT

2
q3>

@L
tr

@(
Irj? *s*.1-.. . @(

30

a
fr

J,l

t4
I
/.rfl
cr
c4

\OLVOPARTS
1 0 3 02 3 0 r 8
( 1 0 36 )
Lights 245

15 l/

@- rNTERroRLrcHrs
6;> IC t/

5 l,l
2t t/
€<" USBUL8No,l0/t

I
0
5 l,l 4 cp, LISBULB
flo.67 t

Group35
Lights
Group36

StandardElectricalEquipment

Replacingignitionswitch

Removenose insulationpane and cefter side panel.


Disconnect-theterminal block for the ignition swrch.
Use a stubby screwdriver to remove the ignition

A2
I
Atlach the new ignition swLtch,
Connect the terminat btock.
Re-instal panels. @l
Replacingturn signalswitch(headlightdimmer switch)

Rernovethe two casingsroundrhe sreeringcotumn.


Removethe lwo retainingscrews.
-rd_>fp,rhe wres
to rhe r.w swtcn.Resror..

Replacinghorn l_l
CI

Disconnectthe battery ground cable.Turn and lift off


the lock pins. Remove the grille.
Disconnectthe wires at the horns.

C2

Attach the wires as shown.


lnstallthe gr lle and reconnectthe battery gro!nd ca,

Group36
48 Standad ElectricaI Equipment
Bulb Fatlurc Warntng System

Replacinglight switch
DI

Disconnectthe defrosrerhosefrom the defrosterout-

Remove the screws retainlngthe defroster outlet.

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

D3
Disconnect the switch from the terminal
block.
Connectthe new switch.
lnstallswitch,defrosteroutet, switchhandleandde-

Checking Bulb Failure warning light operation


NOTEiBuLbFaiure Warninglight may come on if con
nected bulbs current draw ls disiorted.A short ndi
cation may sometimes occur, when headlightsare
switchedon, dependingon vaiation in "starting"time

Switch on €ninon. E3 Switchon headlightlower beam.


The warning lighi should come on. The Waming light should be out.
lf the warning light does noi come on, it is de The Bulb FailureWarninglighl ison, butallbulbs
lor lower beam, parking lighl, laillighl,efc., are
E2 Start engrne, functioning= Sensor is defeclive.
The warning light should go oLrt. E4 Switch off headlighl lower beam.
The Bulb FailureWarning light andthe chargrng E5 B e m o v ef u s e N o . 1 l o r 1 2 .
control light simultaneously= alternator does The waming lighl shoud come on. f not = Sen
sor is defective.
The Bulb FailureWarning light is on after ihe Re-connectfuse.
charging control light has gone out = Sensor E6 Switch off ight.
E7 Depressbrake pedal.
NOTE: llghr switch shouLdbe pLrshedin and The warning light should be out. lf it comes on
brake pedal not actuated durrng test. and both brake lights function, it is defective.
EB Switch off igniton.

Grou?36
Standard ElectricalEquiqment 49
Bulb FailurcTailgaE

ReplacingBulb FailureWarning Light sensor

F] Disconnect the connectorar the SensorUnit.


F2 Removethe SensorUnit.
F3 Installthe replacemenrSensorunir.
F4 Re-connect the connectorto the SensorUnit.
F5 Checkthe functionof the replacement unit.

Tail gate window wiper and washer,245 Qr (

Spare Parts lllustration

cl (

Group36
50 Standad ElecticalEquipment
Tailgatewindow Wiperlwasher

Tail gate window wiper, 245

G7
Removing
Disconnectlhe batterygroundcable.Removelhe panel
on the insideof the tailgale.
Remove theretaining sc.ewsfor lhe wrpermotorpro-

Disconnectthe link arm ai the wipermolor.Foldthe


prctectionplate asideand lift oul the wrper motor'
Markthewires, disconnectthem
and at lhe wLpermo-

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

Replacingbrushes

Fold rhe retaining bracket asde.


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

Gtuup36
Standard ElectricalEquipment 51
WindshieldWiper

Windshieldwiper assembly

CoNNEcroRAssEMBLY

Includ* $itch for p8rt pGition and


@nn€ctoEfor wirlngh.r6.
l. ca€eth€ p€rk$itch isdefsctiv€,only
lhk @nn6ctore3s€Fblyshouldb.
r€plac€d,notthe 6mi€ sip€r trDtor.

A s S P A R EP A R T S
AVAILABLE

Replacingwiper unit

Removal lnstallation
Jl Disconnestbatterygroundc€ble K1 Installwiper ass€mbly.
Removeside panel, Remove device secudng wiper ass€mbly at
Removepanelunderdashboard. transportand handling.
J2 Removedefroster hoses K2 Install glove box
Removeglove box, dsfrostsr hosss
J3 Bemovewiper arms. side panels
/ Disconnect wip€r assembly and lift it out panel unclerdashboard
throughglovebox opening. K3 Installwiper arms.
Reconnectbattery ground cable,I
Checkfunction.

Group36
52 Standard EIecuicaI Equipment
l-
Group38
Instruments
Instrumentcluster
Odometer D Parkins brake reminderlight(red) Rightturn signalindicator(green)
Mile reading E High beam indicator(blue) H Oilpressurewarninslisht(red)
B Speedometer F Brake {aiturewarning light(red) I Alternatorwarninglightked)
Left turn signalindica'torlight{green)

A B c D E F G

c
J K L N o P
lf the pointer enters the .ed range repeatedly,
(last figures represents1/ 10 mile) checkcoolantleveland fan bek tension,see page
Trip odometer resst knob 49.
Push in to reset P Overdriveindicator(green)
Remlnder light, EGR Service (except Lambda-Sond) Lights when overdrive is engaged.
Tachometer(certainmodels) O Fuelgauge
Reads thousands of engine rpm. The fueltank capacityis approx 60 lhers= 15.8
O angp rdnge lor momentdrv Jse. during d' cel- U S s a l s . l 1 3 . 2l m p . s a l s .

Red prohibited range. 1/2


Bulblailure warning light (yellow,
o Temperature gauge
The gauge pointer should normally remain in_ The red range from R to O representsapprox.
side the green range. I itels = 2.5 US gals./2 lmp. gals.

Warning lights

These lights will light up when the ignitlon is turned this light tsndgrolnd is open. When the oi pressure
on. before the €ngineis started.This is also to prove drops below a pre-determinatedvalue, the pressure
rhar rhe lightr f-nLrioi. The light should go our d'ter sensitivevalveclosesthe circuhand the warn ng light
the engine has started.(However,the parking brake is illuminated.
rem nder light will not go out until the parkingbrake
Brakefailure
warninslishtked)
Oil pressure
lfthe lighr comes on whiledrivingand the brake peda
warninglight lredl c a _b e d e p e s s e df - f t h e ' t h a - r c r m d l i l i s d ni d i , d l i o r
lf the lishl comes on during drivlng,the oil pressure that one of the br.ke cncuits is oul of fLrnctior.
is too low Stop the engine immediaielyand check S h o - l d a ' a u k a . i s ei n a n y o i r h e l w o c ' c - i i s o l r l e
the engine oil evel, see page 46. After hard driving, hydraulic brake system, so that $ere is a pressure
rhe lignt will come on occdsrondllywle_ rhe "ngrr. difference between the circuits of more than 8 10
is idling. This is normal, provided it soes oul when kp/cmz 1114-142 psil when the brakes are applied,
the engin€ speed is increased. this actuatesthe valve and ihe warning light goes on.
The warning light for the oil pressurereceivescur.ent The warning lamp remains lighted r.rntilthe fallt n
via the ignition switch. lt is groundedthrough a pres- the brakesysternhas beenconected and the warn ng
s u r a s a n s t r v ev a l v eo n r l e F n S r n eW
. rrh lhp enginF vdlvere ser. 9e .e 'elthg rhe wa'n 19 vdve. s"e SeL
running and at normal pressufe,the circuit lhrolgh tion 5, Brake, Grolp 52.

Gtoup 38
53
lnstrument Cluster

Altemator Parkingbrake
warning light(red) reminderlight
lf the light comes on when engine is running,check This light wiL be on when the parking br6ke (hand
the ahernatordrive belt tension as soon as possrble. br.ke) is set. The parkingbrake lever is situated bet-
The alternator waming light lights up when lhe al- ween ihe lront seats.
ternator voltage is ower than the battery voLtage.As The parkingblake reminderlight receivescurent vla
the alternatorvohagerisesand commencesto charge the ign tion swich. When the parkingbr6keis app ied,
ihe battery,the warning light goes out, indicatingthat t h e w a r n i n gl i g h ti s g r o u n d e d
b y l h e s w i t c h . T h ew a r n
the alternator is charging. ing lamp femainslightedas long as ihe parkingbrake

Reminderlight, Bulbfailure
EGRservice(exceptLambda-Sond) warninglight
lf the vehlcle is equ pped with an EGR(ExhaustGas T h e l i g h , c o a e s o n i f . 1 y o i r h e ' o l l o w r n q . g l r 1 "i )
Be&culation) 15OO0 mile serviceremindef light, as
requiredbytheU.S. Envionmental ProtectionAgency. one of the lower beams
the lighi wil come on ar 15000 mile interuals.This One of the taillights
ls a reminderto gei the EGRvalve servlced.The light one of the license plate lights
wil stay on until .eset by rhe dealer. one of the take lights {when the brake peda is de
NOTE: Warning lights, generally,are lights which il
uminateto indicateth.t a deviceis noi operatrngpro- I n d i c a t o rl i g h t s .9 q " r a l . a e l g l ' r s w h . h ' u r r n d r o (
to indicate that a device is operating.

Testing speedometer and odometer assembly

lf speedometeror odometer s not functioning, ihe


reason may be a fault in Lnslrumentor speedometer
cable or the worm gear in the transmission,or ln the

f the sp€edometerfunct ons while the odometerdoes


not, or vice'versa, the instrument is deiective and
should be replaced.No attempt should be made to
repar rne Insvumenr.
W h e _b o r hs p e e o o n e r e ' a nodo o ne , e ' { o p f - n c o n
t
ing,the fault ls probablyin speedometercableor gear.
Disconnectspeedomeiercable f.om instrumeni and
see if it can be roiated,
ChecL rhe cable and the drive dt the trdnsmission ,_(
C h e c l r h e d n v eL o - p n g s ' o l a l e e a s . l ' f r r . a - s h F
Speedometer readins instument should also be repaced.
50O rpm 31.5 I 2.5 mph The speedometercan be checkedby rufning it at df-
lOO0rpm fer€nl speecls.Thefollowing valuesshouldthen applyl
1750 rpm

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

Group38
54
Replacinginstrumentcluster

I Removethe cove6 roundthe steeringcoturnn.


2. Bemovethe bracketretainingscrews.
Allow the bracketto slip down on the sreerinq

Removsthe retainingscrewstrom the instrum€nt

3. Disconnect speedometer cable,


Grip the reve.seside of the speedometer and
pressthe Instrument up,oul until the snaplock
at the instruments upperedge releases.
5. Lift out the instrumentand disconnect the rer
m;nalblockon the reverceside.

Replacingtachometer

1 . (Removeinstrumentcluster,see above).
2. Removethree retainingscrews,
3. Carefullyremovethe instrument. The terminats
can easilybe damaged.
4. Installtachometer(or cove, as shown.

Replacingspeedometer assembly

t . Removeinstrumentcluster,see above,
2. Removetachom€ler (or blindcover,)
3. Removethreespeedometer retainingscrews.
Carefullyrcmovethe instrumem.

Replacinginstrumentplate("printedcircuit")

t. {Remove instrument cluster, see above).


2. Remove tachometer (or bl;nd coved.
3. Remove speedometer.
4. Remove three plate retainingscrews.
5. Carefullyremove the plate. not damagrngrem-
perature of fuel gauge.

Group38
Gauges

Replacingclock

1. Disconnect the batterygroundcable.


2. Disconnect the controlpaneland pull it out.
3. Bemovethe impactguardbY pushingit down.
4. Removetwo screws.
5. Liftout defroster thewites
outletandclock.lMark
beforedisconnectang.
6. Bemovetwo retainingscrews.Beplaceclock
is oppositeoder.
7. Installation

Replacingtemperaturegauge/fuelgauge

1. Removeinslrument
clusler.
2. Remove tachometer (or blind cover).
3. Remove speedometer.
4. Remove instrument.
5. Remove two retaining nuts on the instrument

6. Remove the gauge.


7.

Replacing'uelgauge sendingunit (tankunit)


o
,5016

1. Disconnectthe battery ground cable.


2. Unfold the mat in the luggage compartment.
3. Remove cover and disconnectground wne.
4. Disconnectthe wire at the sendingunit terminal.
5. Disconned the return hose at the sendrngunrl.
6. Disconnectand move aside the breather hose.
7. Use tool 9995016 to remove rhe sending unat.
8. Installthe new sendingunit with a new gasket.
Installationis opposite order.

t-
9,

Grcup38
56
Gauges

Testing temperature gauge or fuel gauge

lf a lemperalure
orluelgaugeis notwo*ing properly,
the gaugesystemcanbe tesledas lollows:
METHOD
A. T€slingthe voltagesiabilizer.
1- Connect thetestresistor(panno.9995158-4)tothe
inslrumentwhichis functioning pfopedy.In other
words,il lhe,uelgaugsis nol functioning
prope y,
disconnect the lemperaturegaugecablefromthe
sensorand connectthe test resistorbelweenthe
sendercableandvehicleground.
2. 140,160-1974 240,260
The pointershouldnowbe horizontal
(tolerance
+ pointerwidlh).
lf the inslrumenlpolnterpointsoutsidethe toleF
ence range,thenthe voltagestabilizeris faulty.It
lhe instrumentpoinfer is within the tolennce
range!continuewilh SlepB.
B. Testingthe gaugeandsender.
1, Disconnect
lhecable!o thefaultyinslrumenlsender
andconnecithelest€sistancebetween ihe sender
cableandvehicleground.
w,@-19A/2AO,N
pointeris horlzontalor insidethe
2. ll the instrumenl
ma*, thenthesenderis laulty(tolerance + poanter
width).Checkthe luel gaugesenderaccordingto
Servace lvanual,S€c-3 240 or 260 se es, Elec.
System& Instrumenls (TP ii402 or 11413).lfthe
pointeris oulsidethe lolerancerange,thenlhe in-
strumentis faulty.
Test resistol
P/N:
9995158-4 (bluecable)Volvo140,160-1976,
240,260
SpareParts
P/N Resislor
9999145-7 100 1W5%140,160-1974
240,260
Replacing the resistor
Disconnect the cablesand openthe holder.Place
lhe newresislorin the holderandallowthe rcsistor
conneclions to projectlrom lhe holder.Insedthe
conneclioncablesandlightenup.Cutthopartofthe
resislorcablewhichprojecls.

Group38
Instruments 57
Testingfuelgaugesand tank levelsenders

To avoid unnecessaryr€placemsntgfollowing proce-


dures should be used when checkingcomplainrson
th€ fu€l gaug€indications.
To check a mastergaugeis needed.This is a gauge
which has corect resistance.

Masteagauge
Obtain a fu€l gaugetank senderfrom Parts Depart-
ment ancl check it with an accurate ohm-meter
An extra accuratemaster gauge should stay within
th€ followinglimhs:
Upperend position{Fulltank}
40ohmst2ohms
Boftom end position {emptyl
282 ohms a 14 ohms
It mightbe a goodideato bsndths movementlimiter
to obtain correct readings.
Position
Omm 282 t 48 ohms
19?6ModelShorvn
15mm 223 A 26.5ohms
84 mm 98 a 14 ohms
1 9 1m m 40 t 5 ohms

NOTE:Checkvehiclespecilicalions.

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

1,7mm A2
Swhch ontheignition.
Comparefuelgaugo rsadingwith pictureat leftr show-
ing deviation permitted at €nd of st.okes.
Correct reading:proca€d to A3.
Incorrsct reading:proceed to A4.

Gtoup38
58 lnstruments
Testing fuel gauge

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

0
44
Test operation of voltage stabilizer
To do this,usea new voltageslabiizerto test gauge

puli straightout so the


To replacevoltagestabilizer,
threepinscomeloosefromtheretainers-

A5
lf mis-readingpercistsin spite of operationsaccording
ro 1 and 2 above. re install the ordinaryvoltage sta-
bilizerand replacethe fuel gauge-

The luel gauge tank sender rcmains as possible

A6
Bemove the tank sender.

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

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

0mm 282 I 48 ohms


15 mm 223 t 26.5 ohms
84 mm 98 :t 14 ohms
40 :l 5 ohms

Group38
59
Testing fuel gauge

VOLVO
112 BB2

li a cusromerstil complainsin spite all specificalions It lakes approx.30 minLrtesto fill ihe expansiontank.
a r e w l h n l i m i t s ,t m u s l b e e x p a i n e dt o h m t h a t t h e This will causethe leve in lhe fuel tank io drop and,
e x p a n s o nt a n ki n s i d ei h e f u e l t a n kc a u s e st h e r e a d i n g in addition to the fuel used, this mght qive the m

olr
to drop fasler al full tank. pressionlhe gauge readingis lower than normal and
The expansiontank capacityis approx. 6 liters (qts). the gauge incorect.
t is slowy fiied with fuel. The p!rcose of the expansiontank is to prevent the
When filling f!el. the expanson tank is srill almost flel tank from releasingfuel in caseswhen lhe tank I
empry when rhe tuel tank has been filled. has been filled whh cod fuel whrch then heats up

NOTE:Eadytype illustraled-consultolher publica-


iionsfor newdesignfuellank specificalions.

Testingtemperaturesensor

The sensoris checkedby heatingh in water and read-


ing resistanceand temper.ture.
Besistancemay deviate :t 10%.
.l
50oc = 122oF 282 ohms
loooc = 212oF 60 ohms
12OoC= 24AoF 40 ohms
t
107 366

Group38
60
Specifrcations

Additional Information

Mainand PumpRelayApplication

1974/1975lrodelg

Eoth pump and main relay are the sarhe.


They are locatedin the enginecompanment,
They are inlerchangeable.

.1975/192Models

Boththe main and pump rslays are locatedunder the


dash nearlhe hood relsasecable,
Eo5cn t0332 ?Ol lO2 The pumprslayis easiv dislinguished lromlhe main
relay by a heavy gauge yellow wire in its mulliplug
(#87),whichgoeslo luel pump.
I
In most cases, lhe pump relay ls fitted with a whils
v plasticplug.

PJr!!-Er&v

lblF tlz3t75l ||lvo 'l2t50D!

torP oa lla ,03t2 015 0t

!!F.!..d.. Ey r>

CAUTION:Theselwo relaysmustneverbe inter-


changed.

Group36
Ralays 61
SpecrTlcadors

Maln& PumpRelays

1978/1979lrodels

!2r5337-l
This relay is located underthe dash n€arthe hood
releasecable.

192/1979Models

gs!g:99!4-e,g
a2

This r6lay is localedunderthe hood near the batlery,


Volvo#1235013-8.
Both rolaysus€ th€ same Volvonumber.
Themounting bracketistheonlyditference
bslweenthe
ea.lyandlateversion.

Group36
62 Relays
llatioml
Instihrtetot
AUIOONYT
sElvtGt
EXCEU.EilCE

VOI-VO
SUPPOBTS
VOLUIITARY
rrrEcMt{tc
cEn FtcAfl 0rl
8YTHE lt.t.t.S.t.
(U.s.A.only)

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