ElectricalSystem

Section

Grcups

(excl.Wiring Diagrams)

and
lnstruments
242/244/245

Repairsand
Maintenance

1976-

Battery
Alternator
Starter Motor
lgnition System
Lights
Std. Equipment
Instruments

31
32
33
34
35
36
38

Content of Manual
Group31: Battery
Generalinfomation

GrouD32: Altrnator
Specifications

N e wF e a l u r e s . . . . . . . , , , ,
D e s c r i p t i.o. .n. . . . . . . . . .
ServiceDiagnosis
Checo
k f c h a r g ' nsgy s t e m
........... .....
ServiceProcedures
Specialinstructions
for work on alternator
equipment.........

A 1-A12

5
6
7

12

Group33: StarterMotor
GeneralInfomation
SparePartslllustration
SpecialTools

22
23
24

Group34: lgnitionSystem
Specificarrons
L u b r a c a t. i.o. .n. . . . . . . .

32
32
33

lllusration
Bre8kerlss
Electronic
lgnitionSysrem
General
ServiceProcedures:
Replacing
distriburor
Replacing
impulsesender

81 816

39

Group35: Lights
Specifications
Headlamps
Front lights

43
44
?t5

Lights,242 and 244, DL and GT

46
47

Lights, 245

Group36: StandardElectricalEquipment
,$
49
50
52

Switches

Bulb FailureWarningLight
Tailgate Window Wiper and Washer. 245

WindshieldWiper Assembly

GrouD38: Instruments
InstrumentCluster
WarningLights
Replacinginstrument

Testingfuel gaugesand tank levelsenderc

AddilionalInlomalion

A1 A8

NOTE:All references
to model240 in thismanualalsoapplyto DL,GL and GT.

TP 11402t2
3000.03.80
Printedin lJ.S.A.

53
53
54
55
56
58
61

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
1 . 1 4 0 .- . . . - . . . . . . . . . . . V e r yL i t l l P
e o w eLr e t l
andmajorengine
e li ys c h a r g e d
electrical
componnts 1 . 1 0 . . .- . . - . . . - . . . . . . . C o m p l e tD
'(80"F)

water,Thenflushwilhcleanwater.Be sureventcaps
are tight so no solutiongels into cellsto neulralize
the acid.
Alsowashbatlerycarrierand holddowns.

o
O

General
Lack ot eleclrolylecauses prcmaturelailure of batteriestasierlhan anythingelse,Plalesexposedlo ai
delefioralerapidly.Check electrolylslevel fiequenlly,
especially
in hot weatherwhenevaporalion
asmore
likely.
Filldeslilledwateronlyto the battery,neveracid. Howsvsr, any watsr is batterthan no waler. Batlerylife is
extnddby usingthe pureslwaler available.

CheckingBanery
The mostcommonwayto checkbatterychargeis wilh a
hydrometer.
lt measures
specificgravitywhichis a directmeasure
of percenlage
sulphuric
acidintheelectro'
lyl6.As batlerydropslromchaedto discharged
condition,acidleaveslhesolulionandenterslheplates.This
causesa decreasein specilicgravity.
Prolonging
batterylile is tusl a matlerol oeveloping
goodhabilsol leslingandmainienance.
Adirtybattery
discharges
ilsel{:acid
corrosion
anddirtaclas conductors. Corrosionaroundbatlerypostseats awaycopper
cableterminals.
A dartybatleryshould
b movsdandscrubbed
witha
solutionoJ bakingsoda and wateror ammoniaand

bolts.Tighlboltswillstrain
Donolovenighten
holddorvn
the battery.Checkbanerycase for cracks.
when charged,a batterygivs off hydrogenand oxygen,a mbdurewhichis highlyexplosive.
Keepopen
llamesaway Aom batleryand never disconnecta
chargerby removingthe connectional the batterypost.
tho ground
Guad againslsparksby disconnecling
it
lest.
Be
caretul
nol lo lel
cablelirst andconnecting
lhe
battery
tools or other meial objeclsfall across
terminals.
Neve. take rcadings right atter adding water. Water
mustlilst be mixedwilh eleclrolyle.
This is done by
charging
thebattryor runningit onlhe carfor a couple
Takeelecvollte fromeachcell andcomparereadings,lt
lowerthanolhercsllsitsplates
onecellis0,030ormore
lo
are not holdingchargeand il mightbs ncessary
(0.0501or
dry
replacethe batlery.
charged)
ll batlerychcksgood by the specilicgravilytest,il
mightstillb6 necessary
lo makea highraledischarge
lest,duplicaling
lhe stanermotordemands.
SeeGroup
33, SlarterMolorandEleclrical
testspecilicaiions.
loadon bailerylongerthan
ncessary,
Donotmaantain

Group31
Battery

Banery
WARNING!
Caution
We wouldliketo strcssthe importance
ot not havjng
openllamesor spa*s in the vicinityof the batterybcauseol theexplosive
gaswhichlonnsin 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 mustbeattowed
lo
thawoulbetoreconnecling
up thejumbercabtes.(A
flal batterylrcezesal -10"C. (15"F.))

Useof JumperCables

SENO
ING CAL

RECEIViNG
CAR

os itive

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

N e g a ti v e
Terminal

-The senderbalteryenginemuslbeswitched
off.The
receiverbatterymainswilchmustb off.Thebodies
ofbothlhecarsmuslnotbeinconiaclwithachother
(risk oJ sparksfoming whenthe cablesare connectedup.)
1. Connect
the redcablefromsenderbatteryplusterminallo receiving
batterypluspost.
2. Connectone
endoflheblackcabte
to agroundpoint
somedistancelrom lhe receivingbatlery.Suitabty
lhe receivingbanery'sgroundconnectionshould
alsobe on the bodyor on the engine.
-Slart thecarof lhesenderbatteryandidteit at about
1500rpmfor severalminules.
-Starl the car of the receiverbattery.

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

Gtoup31
Battery

CABLES

Specifications

Group32
Alternator
Specifications
Alternator

13.0-15.0V

Tlpe

Output
\,4.,

sppFd

55 Amps
225 t/s

..

= 13500rpnr

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

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

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

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

Description

o
1. &ush holdor
2. M6gn6iizingDiodes
3. Slip ng 6ndshield
4 Bcrmd (slrien diodas)
-.
T1. allernaror rs a th'e" pl'ase sld. Lonnpcl.d a
_
l
_
e
'
i
e
'
q
F
c
l
r
'
rs burl rnro
s o
nar n9 un r. lhe
"nd
shield and consisls of six silicon diodes. Aso ho{rsed
n rhe slip rng end shield are three so called mag
ne /rng dodFs. wl_cl repd rhP rred via ll"e vor;9.

A 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 .
tionary main coil(stator).The rotor is a 12 pole clawpole rype w,rh rl"e l,ed Lo' 'ed ac oss lwo slip rings.
Since the ahernator outpul s self-limited(max. 55
amps),a simplereguatoris used. t conlrolsthe vo tage

Gtoup 32
Ntomator
Specitications

Design

NewFeatures

A newtypeSEValtemator
(SEVP/N71655302)
is now
beingslockedunderVolvoP/N 5462893.The new
allemalorcan be identiliedby a blackplasticdaode
guardand a molddwiringhamessassembly.(See
PiclureBelow).Whenreplacingthe olderstyleSEV
allernalor
withthe newversion,lwominorchangeslo
lheoldwiring
hamessarercquired.
Reterto lhe instructionsbelow.

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

I
I
2, Carelully
tapetheold in-carwiingharnessconnector piugas shown.
Theconnectorplug
iromlhe newmoldedalternalor
harnessshouldbe pluggedinlothe regulalor.
Nole: Do not underany circumslances
cut anyoJ
the old leadssincetheymay be neededfor
Juturealtemalorinstallations.

Gtoup 32
Altemator

Design

Altomator

When $e ignition is switchedon, current nows

throughthe chargingwarninglamp ro terminalD+
on the voltageregulator.
Viathe regulaior,
rhe current
rs conducredrhroughthe roror corlro ground.

02s-0,40mm
Voltagaregularor
Regubtorcontactfor
3. Springrensioner
2.

ower conro! range

Regulalorcontacl tor
upper contol range

4.

Spring upper seciion:

lf the vohage ises in spite of thig rhe armature on

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

5Wr

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

lo0o500060007ooo

AIIEBNAIOR BPM
f:j9
Arrmatoroutputcurue
A = amps
RM = ahernator
speed/mi.ute
Thealternator
maximumoutpuiis55 amps.Topspeed
is 13500rpm.

Group32

Diagnosis

ServiceDiagnosis
Condition:

Warning lamp does not light with engine off.

Action

Possiblecause

Testlamp(12 volts2 wattstbetweenB+ and61/D+

on alternatorlights.
Test lamp betweenB+ and 61/D+ doesnot light.
Test lamp between61/D+ and groundlights.
Testlampbetween61/D+ andgroundgivesa weak
light.Removethe plug at the regulatorand connect
an ammeterbetweenB+ and DF on the alternator.

Warninglamp burnedout or opencircuitto D+ on

regulator.
Positivediodeshorted.

O amp

Worn brushes,oxidizedslip ings on breakagein rotor

2-2-5 amps

Open ckcuit in regulatoror in lead DF from regulator

to DF on alternator,

Condition:

oi'

Warninglamplightswith engineoftor running.

Action

Possiblecause

Disconnect
the plug at the regulator
lamp
Control
still lights.
Warninglampgoesout-Re installtheplugi. the rcgulatorandconnectan ammeterbetweenB+ and D+

CircuitshortedbetweenD+ ontheregulatorand
61/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.

Condition:

Warninglamp lights with 6ngin6off bu1starts to give a weak light

whenngineis running.

Actionr
TestlampbeiweenB+ and61/D+ on the alternator
wirh the enginerunningl
Doesnot light,
Givesa weak light.

Possiblecause
resistance
Transition
in thecharging
circuitor in the
leadto the waminglamp.
(overcharging
Defective
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

I
0.

Diagnosis

Check ol charging system

Generalorientation
Connectionsat altemator
FEDwlFE. TO CHAFGTNG
CONTROL
LIGTIT

ir

iiJ"
t

FEDor aRowri

ro
D

PLUGAT ALTERNATORWITHWIFE
LOOMTO VOLTAGE
FEGUIATOF

o
'1.,,

o
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
shouldbe in fullychargedand goodcondilionlor the
lesls.
tollowing

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

I
I

than13.0volts:go to A10.
c. Readinglovver

VOLT-I']ETEF

(Refer to sction Tesling the VoltageRegulatol for

chargingrats).

A5
Voltmeter stillto alternator B+ and ground
Switchon blower,rearwindowheaterandheadlighl

\s
\\

BEDor BBOWN

Run engineat 2OOrpm for one minute

Vollagereadingshouldbe lessthan O.7volt lower
a.
b.

GREENof WtllTE

Group32

0)

b. Readinghigherthan14.4volts:go to 410-

Lessthan 0.7 volt: go to A6.

More than O.7 volt: go to A1O.

T
Diagnosb
A6
Connectvoltmeterto alternatorBi and battery plus

Switch on headlighruppe. beams.Run enginear approx. 1500 rpm. Voltmeter readingsho! d be O.O-O.3

a.

Less than 0.3 vok: go ro A7.

b.

I M o r et h a n 0 . 3 v o t :
chck wire from a lernator 8+ io starter motor
to batiery pl(]sfor loose or corrodedconnecton.

Connect voltmeter
gineground

to battery minus and en-

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

-xF

FEDor BFOW{

Voltage reading should be 0.0-0.2 voll.

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
or corroded connectons.

A8
GFEEN
orWHm

Charging system should be correct if all previous 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 alternator.

Runengineat l5OOrpm.

'/.-_'

/l

a.

Vollage readingexceeds0.5 volt ahernatormust

be defectiveand should be replacedor repaired.

b.

Voltage readinglower than 0.5 volt voltage regulator 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 alternaBunengineat 1500 rpm.
a. VoltagereadingexceedsO.5
volt:alternaror
must
be defectiveandshouldbe replacedor repaired.
b. VoltagereadinsbelowO.5 voh: so ro A11.
Priorro this test,carefullycheckthat wiresfrom atternatorto voltageregulatorare in corect order.No
shons,no grounds,no looseconnections.

Atl
Checkrotor circuitresistance
Disconnectwire DF (plud at vohage regulator.Use
ohmmetertocheckrotor resistanc.
Correctresistance
is approx.4 ohms. Howevet dependingon brush conditlon,resistancesof 4-10 ohms might be considered

I 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.

OlIU.UETEB

b.

Botof resistancechecks out lower than approx

rolor is orobablydefectrve.When reDaiflng.checl
rotor resislancedirecrlyonslipringslo venfytautt.

BLACKWIRE

10

Gtoup32

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

Diagnosis

At 2

JUMPEAW|FE
,.-_-\

Full Fielding Test

Thisis alullchargetestol alternator,
airnsdatdefinitety
separating
allernalorproblemsfromvoltageregutator

I
\

D+
REDWIBE

a. Removethe plugat the vollageregulalorandconnecla 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.

(
VOLT-METEF

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
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
batteryandotherelectricacircuitsdue lo
HighVoltage.

\s
\\

GREENor WHIIE

Group 32
Altematot

11

Removingaltenator

SrviceProcedures
Specialinstructionslor work on alternatorequipment
banery.makesurclhal
or installing
1 . Whenreplacing
properpolarityis observed,A misconnectedbaltery
ruinthe r-ectifers.
will immediately
lhe mainckcuitbroken
Neverrunlheallemalorwith
The battery and/or altematorand regulalor leads
whrF lhe engne is
must neverb disconnecled
running.
3 . No attemptshouldbe made to polafizethe al-

lhe
batteryin vehicledisconnct
Whenfastcharging
batterygroundcable.
5 . Whenusingan extra battoryas a starlingaid, connectit in parallel.
the
Whenarc weldingon the vehicle,disconneci
lead
on
the
gound
as
lhe
B+
cableas well
battery
plug
The
voltage
regulalot.
al lhe
alternatorandlhe
the
alwaysbeconnectedcloseto
weldingunitshould

0l

0(

Removingalternator

BI
Removealternator
a.
b.
c.

wires at alternator.
Disconnect
Removebolt for tensionerbar, hex 13 mm
Lift off drive beltsand lower alternaior.

0),
B2
Removealternator and bracket
ALsoremovethe tensionerbar.
Hex 13 mm

12

Group32

cr

Diassembling dItematol

Disassembling
alternator
cl
Removenutand washerfrompulley.Pulloff pulleyand

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

c7
frornthe terminal
Solderloosethe starorconnections

NOTE:Aways use a heat sink whensolderingand

soldering
arounddiodesto preventdamageto

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%.

-.

14

Group32

Testing

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

o
o

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

ct2
Brush holder
Use40 Voh altematingcuiienr.
Correct radng: 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.

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

16

Gtoup32

O
O

,
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
B o s . r 'F r 1 V 3 5 o ' L o i i e s p o n d r nC
g .o a l t h e s L i pr i n q
Assemblethe
end shield bearingseal with N/lolykote.
D o o f o r g . r r o a s a . lr l - es o n n qo r l - - . [ p

aq e_d

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

ct8
InsraLl
rhe brushholder.

cl9
thewasher
fan,spacerandpulley.Position
Installkey,
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

DAr
Hex 13 mm

Cl
D2
Installdrivebelts
Install bolt for tensione. bar. Adjust

Oldallernalor
shown,

18

Group32

f(

Tesnng voltage rcgulator

Testing voltage regulator

-{:-._:

llilN

Charging Regulator
Electronic
charuingregulalorshave now been Introduced as spare parts lor cars which do nol have lhe
thre-teminalclnnection contacton the regulalor.
These nsw regulato|scan be easily identiliedby lhek
grey cover,Theold type regulatorshaveblack covers.

ldentitying the regulEtor

with
Sev P/N72610102
diode(ed
plate)
Magnetizing
diode

Marking

Spot
Blueor
Black
Spol

1259303-4
12593026

SevP/N726-10002

ldentitying the alternator

walhprotectivg
diodeshavea red plateon
Allemators
Thoseallernalorswhichdo not havea red plateon the
diodes.
rearend arefitledwithmagnelizing

r||gnetlzlng Olodo3

Group32
Altematot

Testing vohage rcgulatol

Testing voltage regulator

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

-'l

L JI!
'l

'

Lt-

li.ii!

Wiringdiagramfortssting
voltagregulator

c.

Vohselamp 12 vohs
Conlrollamp 12 vo rs,

0,25-A,1O.r'm

E. Ammeter0 50 amps.
F. Fesuarorresistance
G. Batery 60 amparehours

Voltageregulator
L

D.

2.

-24

20

Fesularorcontacrfor
rowerconrrorrange
FegulalorcontaclJor
upperconlrolEnge

3.
4.

Sprinsrensoner
spring uppersecrion
Sreetspring
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
lemperalure
at 25rc (77"F).
Loadlhealtematorwilh
10-15amps,suchas switching
headlights
on
10ripperbeam,andreadthevollage.
The
voltageshouldstill readbetwen13.1'14.4volts,bul
mustnotdropmorethan,4voltslessthantheunloaded
specification.
For exactvoltageat ambientlemperatures
see diagramsopposite.

.2o

Group32

.4O

r80

0
V

0
0

Testing voltage regulatol

Testing voltage regulator

lon test benchor in vehicle)

Elctronlc Fgulalol!

regulalorshould
be
llvollageisoulsidespecificationlhe
replaced.
lf ihe voltageregulatoris to be tssledmorc
accuhtely,installitin thevehiclewhichshouldlhenb
d vn 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
The
thevollagbetweenB+ andD on thealtemator.
engineshouldbs tumingover al i50O rpm,whichis
approximatelytfie sameas 3000 lpm allernatorspeed
temperature
whenmeasung.Withregulator
atambient
ol approximalely
25'C (7rD the voltageshouldbe
Pleasenotevollagevariations
according
to diagrams.
according
lo ambientlemperalures.

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

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

-20 -10

Gtoup 32

Group33
StarterMotor
GeneralInformation

The starter motor is rnountedon the fiywheel housing

on lhe left side of the erg ne. I is a a pol sers
wound motor. The pinion on the starter motor armature shaft moves axally to engagethe f ywheel r ng
gear. The pinion is controlled by a solenoid.
T J r _ i n gt h e r g nr i o n l e y r o s r a f l r r gp o s r r o nc L l s r r
the soenoid, causingthe armatureln the soenoid to
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. - . . . . . . . . .

Direction of rotation
O!iput

22

Group33
Staftet Motol

.................

Bosch

8 1 0 W (1 . 1
I

12V

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

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

0.0020.0123.1 3.5 tbs

o.o47,0.173
2 . 1 73 . 8 1 b .n
1 . 2 01 . 5 6b .n
0.006-o.oo

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
Be'easevollage.......

M n I Volts
Lessthan1 v.

Brushsping tension.
DEranc" hor p,nron end ro ,ing gear race
F iclondl rorque oI 'olor brakP i no i d l i n gI o q u e . . .
Backlash
C o r n m u r a l om
r . drd-ere' .
Brush min. length

...

r 318"
o.52'

Etecrricaltest specifications

nt,

t:
13
14

ie

\15

\o
\

e 18 17

7 26

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

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.
thecornmutatorend
Remove
thetwo screwsretaining

B3

Lift up the brushes.

Removerhe brushholderbridgelrom the armature
shaft.
The minusbrushesare retainedtogeiherwith the
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
Removerubbr stop and steel washer
Removethe pivotpinfor the pinionlevsr.Lift out armatureassemblyfrom 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 undercut
0.4 mm = 0.008".
lf no machineis available,usa properlygroundlrack-

26

Group33
StarterMotor

Examination

Bto

Bll

Use a "Growler" to check the armature for shorts.

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

812
lJse40VoltsACcufientoravailable
equipmentlo
check
the stalorcoil insulation.

(0
Bt3
Checkend shieldsand brushholdsr.
Replacsworn or damagedparts
No morethan0.005 (O12 mm)bushingplayis perCheckotherpans and replaceif worn or damaged.
The lock ring shouldalwaysb3 rplacedas it might
havebeendamagedor lost its tensionwhen removed,

Group33
StaftetMotor

Installing
bushings

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
poles
poles
lvlark
and housing.The
shouldbe reinstalledin 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
,

..JI-J

28

Group33
Stafte,Motor

Replacingbrushes
Bt 7
Brushes
siroderthan9/ 16 = 14mm shouldbere

",,

-)-:
-"''

1.
2.

Do not allow any soder to Rrndown in the brush

leads.This would stiffen the leads and prohibir
iree movements.

: . -7 . , - 1 1

u;

Solder loosethe brushesfrom their attachments.

Solderon the new brlshes. llse a sufficienty hot

:i,,;
Assembling starter motor +
Bt8
Lubricateas shown- Use Bosch lubricanrsor similar:
I FI 2 V3

$E

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
rng into pace with a fitling puLler.

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.

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
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

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

t.roii.ll

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

Gtoup33
Staftet Motol

_...-!
Specifications

Group34
lgnitionSystem
Specifications
Tvpe .. ... ..
F i r i no
s r d e r. . . . . . . . . . . .
lgnationtiming,vacuumunit disoonnoctd(checkenginespecificalions).
Sparkplugs(Check6nginspcifications)
cap ... ...
Tighreningrorque

Metric
US specs
Ereakerless
electronicignition
13-4-2

0.7-08 mm
20-30 Nm

0.028-0.0032"
15-22 tb.fr

Distributor
Bosch(Check
engine
spscificalions)
... .... ...
lsnitioncoil
EoschNo,

0221 122 006

Bosch No.

0227 100 005

Centrifugalgovernor
Toral advance.distibutor degrees
Advance begins at, distibutor
Distributor rpm at 50 advance
9 ' a d v a n c e. . . . . . . . . . . .
f ' r l la d v a n c e. . . . . . . . . . .

7.2-1O| / s
15.2-14.3t/s
23.3-34.5 r/s
40 t/s

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

5.Oot 10
6 l - l 0 7 m m Frg
79-129 mm Flg
l5O mm Hg

2.44.3 in Hs
3.1-5.1in Hg
5.9 in Hg

Retard,dislributor degrees(doublefor crankshaftdegreed . . .. . . .

R e t a r db e g i n sa t . . . . . . . . . . . . . . . . . . . .
2 0 r e r a r da l ,
Retard ends al
Consull correct specifcations for Model yoar,

II
@(

@l

Lubricating
distributor
permittedis applyinga coupleof
Theonly lubrication
dropsof oil on the felt wick in the centerof the rotor
shaft.

Removedistributorcap and rotor.

Lubricate
felt wick underrororwith a coupleof drops
of light oil.

Bcareful,do not splashanyoilon the impulsssen-

32

Gtoup34
lgnition System

fll

D
0

lr

Group34
lgnitionSystem

33

BreakerlessElectroniclgnition System
General
Two main changes frcm the conventional ignition
1.
2.

The breakerpoinis are replacedby an induction

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

Otherlvisethe designand function is the same as the

conventonar system.

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 impulsesndsrconsistsof:
2.
3.
4.

coil (magnetic pick-up)

armature kotor)
permanent magnet

Stator. coil 6nd pemanent magnet are connectedto

the distributorhousingwhilethe armatureis connected
to the disr butor shaft.

Note1:
Whenusinga distriburor
lester,alsothe electronic
modulemustbeconnecled
in orderto geta distributor

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

34

Gtoup34
lgnitionSystem

Stator and armaturehave as many pole teeth as the

ensin has cylinders.

n(
(

Futiction

Thepermanentmagnetcreatesa magnelc field which

goesthroughthe stator.The rnagneticcirorh is closd
lvhenths poletesth areoppositaeachothe..The magneticcircuitis openwhen lhe poleteeth areseparated.
This mansthat the armature clossand 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.

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

pick-up)
Theimpulsereceived
from the coil(magnetic
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
moduleoutput transistorbreaksthe primarycircuil
inducingsecondary
voltagein the coilto firsthespark
plugs.

ro

The poleteethhavea functionsimilarto that of the

cam bbs in a conveniionaldistributor.

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

NOTE:Ths ignitioncoilisdesigned
specifically
for the
breake ess solid state ignition sysrem.lt is identified
by specifications
andnumberonly andcannotbe replacedby other lype coils.

Group34
lgnition System

35

Diagnosis

ffiH
r!

!;;: :

E
o

i:;E:i

o
o

='E:::;
:!:iii

o
E)

o
o

-9
L
o
(E

ii iii !
..:!5! n

-rri

tia

I t;; :l

. f,-lii=,
f,
giit
:| |

o(

il rd

;:; .:
;
ili t s :

iEEi

i':! i !
ES:: i

!!:::

!
:

tt

o
o
o
-c

l,l El
iil
rlil
l"
llFI

ttll

o
o
IE

36

|l r-l

l,f,-l;;
t
lillii;;l

til Eqil
Gtoup34
lsnition Sysbm

,.(

r-

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
centr {TDC}.
- Thecamswillthenpointobliquetyupand
pulleymark
will b at Oo.

Line up rotor
Turnrotor so markis approx.600frcm markon o|stributorhousing.

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.

A7
Installdistributorcap

e(
@l

A8
Reconnect
P mary wire, vacuumIinestc.

c)A9
Set timing
Referto vhiclespecificatrons.
/./.'

38

Group34
lgnitionSYstem

BeplacingimpulsesEnder

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

io

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

B3
Rsmovethe screwssecuringthe contact.
Removethe
contactby pullingit carefully
straightout.

o
io
84
Remov
thsscrewsretaining
thsimpulsesenderplat6.

Group34
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
impulse
sendet.
Remove
threscrewsandreplace

40

Gtuup34
lgnitionSystem

Replacingimpulsesetd]aii
B9
lnstallation
Attachthe impulssenderto the ptate.
Theconnectorpinsshouldbe ptacedoppositeabovs
the attachmentsar lor ths impulsesnderplate.

Bto
Installimpulsesnder.
Scure it with ths two screws.
hstall sn6p ring.

Btl
Installthe armature.
Thslotshouldbeopposit
the dgeon thedistributor
shaft.
Fit the lock.pinso that the lift facesthe dg on the
distributor shafL
OtheMiss tha lock pin may be sheardoff.

Bt2
hstalt shimsand snap ng.

Gtoup34
lgnkion System

41

Replacingimpulse sendel

813
Rconnect
thewir6 connctor
andtightenthe screw.

Bt4
Installclaspsand vacuumuniL

R15
Installdust cover, rotor and cap,

Bt6
Check distlibutol

i/r
t\

42

Gtoup34
lgnition System

Rotats thg distributor shaft s6v6raltums in both directions

It shouldrotatefreelyandwithout anynoisor sizure.
The only resistancwhich may occur is the littl6
stiffnss causedby the magnetin the impulsosendr
whn the teeth pass each othr.

'v
Specifications

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

USbulbNo.

Powor

Sockel

No.ot bulbs

Balss
Bal5s
8a156
8a15s
Ba15s
Balss
S 8.5

2
2
2
2
2
2
2
2

5Ya"Typ 1
5%" fype 2
SaiedBeam

Headlighls
242,GI

7" rype 2
67
5w4cp
TumSignals,front
1073
21wl32cp
TumSignals,
rear
1073
21wl32cp
Tailljghb
67
5w4cp
Stop Lighls
1073
21wl32cp
Back-upLighls
1073
21wl32cp
SidelvlarksrLights
57
3wlzcp
The followingbulbsmay be obtainedfrom a Volvo dealefi
FositionLights,tiont

Re3r Ash Tray Light

LicensePlateLight
lntsriorLight
Glovs Locker Light
InstrumentPanslLight
ControlPanelLight
Shift PositiongAutom.
EngineCompartmentLight
ControlLamps
Charging
Turn Signals
BrakeFailure
ParkingBrake
Headlights
Oil Pre:sure
Overdrive
WarningFlashers
El. Heated Window
Seat Belts
Bulb Failur

1,2W

1.2W
1 . 2W
15w
1.2W
't.2 w
1 . 2W
1 . 2W
1.2W
1.2W
1.2W
2W
1.2W

Socket
w 't.8d

No of bulbs
,I

s 8.5

2
1 \245:21

Bags
BaTs
w 1.8d

3
3

wt.8d
w 1.4d
w1.8d
w1.8d
wl.8d
w 1.8d
w 1.8d
w 1.8d

wr,8d

w1,8d
Bags
w 1.8d

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

Gtoup35
Lights

43

ServiceProcedures
ReplacingSealedBeamheadlamPs

Turn 1/2 turn to rcmovethe plasticscrews.

Removthe 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 hsadlightalignmnt.

44

Gtoup35
Lights

Models240,DL 2d, and GT

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

@,

D
I

llttt

,ilJlll
i NNER-BqAM
BIA{,
sEAtE
Tvpe1

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

/.rfl

cr
c4
\OLVOPARTS
1 0 3 02 3 0 r 8
( 1 0 36 )

Lights 245

15 l/
rNTERroRLrcHrs

@-

6;>

IC t/

2t t/

<"

5 l,l
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

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

@l

Replacingturn signalswitch(headlightdimmer switch)

Rernove
the two casingsroundrhe sreeringcotumn.
Removethe lwo retainingscrews.
-rd_>fp,rhe wres
to rhe r.w swtcn.Resror..

l_l

Replacinghorn
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,

48

Group36
Standad ElectricaI Equipment

Bulb Fatlurc Warntng System

Replacinglight switch
DI
Disconnectthe defrosrerhosefrom the defrosteroutRemove 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.
The warning lighi should come on.
lf the warning light does noi come on, it is de

E2

Start engrne,
The warning light should go oLrt.
The Bulb FailureWarning light andthe chargrng
control light simultaneously= alternator does
The Bulb FailureWarning light is on after ihe
charging control light has gone out = Sensor

E3

E4
E5

E6
E7

NOTE: llghr switch shouLdbe pLrshedin and

brake pedal not actuated durrng test.
EB

Switchon headlightlower beam.

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

Grou?36
Standard ElectricalEquiqment

49

Bulb FailurcTailgaE

ReplacingBulb FailureWarning Light sensor

F]
F2
F3
F4
F5

Disconnect
the connectorar the SensorUnit.
Removethe SensorUnit.
Installthe replacemenr
Sensorunir.
Re-connect
the connectorto the SensorUnit.
Checkthe functionof the replacement
unit.

Tail gate window wiper and washer,245

Qr

cl

Spare Parts lllustration

50

Group36
Standad ElecticalEquipment

Tailgatewindow Wiperlwasher

Tail gate window wiper, 245

G7
Removing
panel
batterygroundcable.Removelhe
Disconnectlhe
on the insideof the tailgale.
sc.ewsfor lhe wrpermotorproRemove
theretaining
the link arm ai the wipermolor.Foldthe
Disconnect
plate
prctection
asideand lift oul the wrper motor'
at lhe wLpermoand
Markthewires, disconnectthem

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* $itch for p8rt pGition and
@nnctoEfor wirlngh.r6.
l. caeth prk$itch isdefsctiv,only
lhk @nn6ctore3sFblyshouldb.
rplacd,notthe 6mi sipr trDtor.

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

Replacingwiper unit

Removal
Jl

J2
J3
/

52

lnstallation

Disconnest
batterygroundcble
Removeside panel,
Removepanelunderdashboard.
Removedefroster hoses
Removeglove box,
Bemovewiper arms.
Disconnect wipr assembly and lift it out
throughglovebox opening.

Group36
Standard EIecuicaI Equipment

K1

K2

K3

Installwiper assmbly.
Remove device secudng wiper assmbly at
transportand handling.
Install glove box
dsfrostsr hosss
side panels
panel unclerdashboard
Installwiper arms.
Reconnectbattery ground cable,I
Checkfunction.

lGroup38
Instruments
Instrumentcluster
B

Odometer
D
Mile reading
E
Speedometer
F
Left turn signalindica'torlight{green)

Parkins brake reminderlight(red)

High beam indicator(blue)
Brake {aiturewarning light(red)

H
I

Rightturn signalindicator(green)
Oilpressurewarninslisht(red)
Alternatorwarninglightked)

D E F G

c
J

(last figures represents1/ 10 mile)

Trip odometer resst knob
P
Push in to reset
Remlnder light, EGR Service (except Lambda-Sond)
O
Tachometer(certainmodels)
rpm.
thousands
of
engine
Reads
O angp rdnge lor momentdrv Jse. during d' cel-

Red prohibited range.

Bulblailure warning light (yellow,
Temperature gauge
The gauge pointer should normally remain in_
side the green range.

lf the pointer enters the .ed range repeatedly,

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

The red range from R to O representsapprox.

I itels = 2.5 US gals./2 lmp. gals.

Warning lights
These lights will light up when the ignitlon is turned
on. before the ngineis started.This is also to prove
rhar rhe lightr f-nLrioi. The light should go our d'ter
the engine has started.(However,the parking brake
rem nder light will not go out until the parkingbrake

this light tsndgrolnd is open. When the oi pressure

drops below a pre-determinatedvalue, the pressure
sensitivevalveclosesthe circuhand the warn ng light
is illuminated.
Brakefailure

warninslishtked)
Oil pressure

warninglight lredl
lf the lishl comes on during drivlng,the oil pressure
is too low Stop the engine immediaielyand check
the engine oil evel, see page 46. After hard driving,
rhe lignt will come on occdsrondllywle_ rhe "ngrr.
is idling. This is normal, provided it soes oul when
the engin speed is increased.
The warning light for the oil pressurereceivescur.ent
via the ignition switch. lt is groundedthrough a pres. rrh lhp enginF
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
running and at normal pressufe,the circuit lhrolgh

lfthe lighr comes on whiledrivingand the brake peda

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
that one of the br.ke cncuits is oul of fLrnctior.
S h o - l d a ' a u k a . i s ei n a n y o i r h e l w o c ' c - i i s o l r l e
hydraulic brake system, so that $ere is a pressure
difference between the circuits of more than 8 10
kp/cmz 1114-142 psil when the brakes are applied,
this actuatesthe valve and ihe warning light goes on.
The warning lamp remains lighted r.rntilthe fallt n
the brakesysternhas beenconected and the warn ng
vdlvere ser. 9e .e 'elthg rhe wa'n 19 vdve. s"e SeL
tion 5, Brake, Grolp 52.

Gtoup 38

53

lnstrument Cluster

Altemator
warning light(red)

Parkingbrake
reminderlight

lf the light comes on when engine is running,check

the ahernatordrive belt tension as soon as possrble.
The alternator waming light lights up when lhe alternator voltage is ower than the battery voLtage.As
the alternatorvohagerisesand commencesto charge
ihe battery,the warning light goes out, indicatingthat
the alternator is charging.

This light wiL be on when the parking br6ke (hand

br.ke) is set. The parkingbrake lever is situated between ihe lront seats.
The parkingblake reminderlight receivescurent vla
the ign tion swich. When the parkingbr6keis app ied,
t h e w a r n i n 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
ing lamp femainslightedas long as ihe parkingbrake

Reminderlight,
EGRservice(exceptLambda-Sond)

Bulbfailure
warninglight

lf the vehlcle is equ pped with an EGR(ExhaustGas

Be&culation) 15OO0 mile serviceremindef light, as
requiredbytheU.S. Envionmental ProtectionAgency.
the lighi wil come on ar 15000 mile interuals.This
ls a reminderto gei the EGRvalve servlced.The light
wil stay on until .eset by rhe dealer.
NOTE: Warning lights, generally,are lights which il
uminateto indicateth.t a deviceis noi operatrngpro-

T h e l i g h , c o a e s o n i f . 1 y o i r h e ' o l l o w r n q . g l r 1 "i )
one of the lower beams
One of the taillights
one of the license plate lights
one of the take lights {when the brake peda is de

I n d i c a t o 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

50O rpm
lOO0rpm
1750 rpm

Speedometer
readins
31.5 I 2.5 mph

f the spedometerfunct 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
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
instument should also be repaced.
The speedometercan be checkedby rufning it at dffernl speecls.Thefollowing valuesshouldthen applyl

SDeedometerdrive cable
It is rnost important ihat the speedometercabe s
correctlyiitted if the speedomeleris to functon wthout trouble. t is vitaly imporiant thar the cable is nol
benl too sharply.At no point must the radius of a

54

Group38

bend be less than 100 mm (4"). lf it s ess than this,

vibration and noise can occur in the inslrument.The
drive couplingsmust run trle in the outer casing of
the cable. This is checked with

t
,_(

Replacinginstrumentcluster
I
Removethe cove6 roundthe steeringcoturnn.
2. Bemovethe bracketretainingscrews.
Allow the bracketto slip down on the sreerinq

Removsthe retainingscrewstrom the instrumnt

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. Removetachomler
(or blindcover,)
3. Removethreespeedometer
retainingscrews.
Carefullyrcmovethe instrumem.

Replacinginstrumentplate("printedcircuit")
t.
2.
3.
4.
5.

{Remove instrument cluster, see above).

Remove tachometer (or bl;nd coved.
Remove speedometer.
Remove three plate retainingscrews.
Carefullyremove the plate. not damagrngremperature of fuel gauge.

Group38

Gauges

Replacingclock
the batterygroundcable.
Disconnect
Disconnect
the controlpaneland pull it out.
Bemovethe impactguardbY pushingit down.
Removetwo screws.
thewites
outletandclock.lMark
Liftout defroster
beforedisconnectang.
6. Bemovetwo retainingscrews.Beplaceclock
is oppositeoder.
7. Installation
1.
2.
3.
4.
5.

Replacingtemperaturegauge/fuelgauge
1.
2.
3.
4.
5.

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

6. Remove the gauge.

7.

Replacing'uelgauge sendingunit (tankunit)

,5016
1.
2.
3.
4.
5.
6.
7.
8.
9,

t56

Grcup38

Disconnectthe battery ground cable.

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

Gauges

Testing temperature gauge or fuel gauge

lf a lemperalure
orluelgaugeis notwo*ing properly,
the gaugesystemcanbe tesledas lollows:

METHOD
A. Tslingthe voltagesiabilizer.
1- Connect
thetestresistor(panno.9995158-4)tothe
inslrumentwhichis functioning
pfopedy.In other
words,il lhe,uelgaugsis nol functioning
prope y,
disconnect
gaugecablefromthe
the lemperature
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 thefaultyinslrumenl
sender
andconnecithelestsistancebetween
ihe sender
cableandvehicleground.
w,@-19A/2AO,N

pointeris horlzontalor insidethe

2. ll the instrumenl
ma*, thenthesenderis laulty(tolerance
+ poanter
width).Checkthe luel gaugesenderaccordingto
lvanual,Sc-3 240 or 260 se es, Elec.
Servace
(TP ii402 or 11413).lfthe
System& Instrumenls
pointeris oulsidethe lolerancerange,thenlhe instrumentis faulty.
Test resistol
P/N:
(bluecable)Volvo140,160-1976,
9995158-4
240,260

SpareParts
P/N
9999145-7

Resislor
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
conneclion
cablesandlightenup.Cutthopartofthe
resislorcablewhichprojecls.

Group38
Instruments

57

Testingfuelgaugesand tank levelsenders

To avoid unnecessaryrplacemsntgfollowing procedures should be used when checkingcomplainrson
th ful gaugindications.
To check a mastergaugeis needed.This is a gauge
which has corect resistance.

Masteagauge
Obtain a ful gaugetank senderfrom Parts Department ancl check it with an accurate ohm-meter
An extra accuratemaster gauge should stay within
th followinglimhs:
Upperend position{Fulltank}
40ohmst2ohms
Boftom end position {emptyl
282 ohms a 14 ohms
It mightbe a goodideato bsndths movementlimiter
to obtain correct readings.

19?6ModelShorvn

Position
Omm
15mm
84 mm
1 9 1m m

282 t
223 A
98 a
40 t

48 ohms
26.5ohms
14 ohms
5 ohms

NOTE:Checkvehiclespecilicalions.

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

1,7mm

58

Gtoup38
lnstruments

A2
Swhch ontheignition.
Comparefuelgaugo rsadingwith pictureat leftr showing deviation permitted at nd of st.okes.
Correct reading:procad to A3.
Incorrsct reading:proceed to A4.

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 stabilizerand replacethe fuel gaugeThe luel gauge tank sender rcmains as possible

A6
Bemove the tank sender.

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

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

282 I
223 t
98 :t
40 :l

48 ohms
26.5 ohms
14 ohms
5 ohms

Group38

59

Testing fuel gauge

VOLVO
112 BB2
li a cusromerstil complainsin spite all specificalions
a r e w l h n l i m i t s ,t m u s l b e e x p a i n e dt o h m t h a t t h e
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
to drop fasler al full tank.
The expansiontank capacityis approx. 6 liters (qts).
t is slowy fiied with fuel.
When filling f!el. the expanson tank is srill almost
empry when rhe tuel tank has been filled.

It lakes approx.30 minLrtesto fill ihe expansiontank.

This will causethe leve in lhe fuel tank io drop and,
in addition to the fuel used, this mght qive the m
pressionlhe gauge readingis lower than normal and
the gauge incorect.
The p!rcose of the expansiontank is to prevent the
flel tank from releasingfuel in caseswhen lhe tank
has been filled whh cod fuel whrch then heats up

olr
I

olher publicaNOTE:Eadytype illustraled-consult

iionsfor newdesignfuellank specificalions.

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

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

107 366

60

Group38

282 ohms
60 ohms
40 ohms

.l

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

Eo5cn t0332 ?Ol lO2

Boththe main and pump rslays are locatedunder the

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

PJr!!-Er&v
lblF

||lvo 'l2t50D!

tlz3t75l

,03t2 015 0t

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

Ey

r>

CAUTION:Theselwo relaysmustneverbe interchanged.

Group36
Ralays

61

SpecrTlcadors

Maln& PumpRelays
1978/1979lrodels

!2r5337-l

This relay is located underthe dash narthe 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.
bslweenthe
Themounting
bracketistheonlyditference
ea.lyandlateversion.

62

Group36
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)