SERVICE MANUAL - Volvo Amazon Picture Gallery
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1. SERVICE Part 9 91 94 INSTRUMENTS HEATER SYSTEM P 120 CONTENTS Group 91 Instruments Description el eer rere TT Timer sce 1 Combined instrument 1 Fuel gauge including tank fitting 2 opeedometer 4 TOS EE IEEE IIa 2 Temperature gauge 3 pressure contact 3 Windscreen Wiper 4 Repair instructions Replacing the combined instrument 4 Checking the fuel gauge 4 Replacing the fuel gauge dial 5 Replacing the tank fitting 5 Adjusting speedometer 5 Checking the speedometer cable 5 Replacing the speedometer cable 6 Temperature gauge testing and removing the sensollubItW cari muse gree 6 Replacing the temperature gauge dial 6 Windscreen wiper replacing the wiper blades 6 Group 94 Heater system Descripllon mom RM ee 7 Heater early production 7 Heater late production 8 Heater control valve 8 Repair instructions Heater early production 10 Heater late 10 Replacing the heater controls 11 Replacing the warm air tunnel 11 Specifications in 1 oo RT a 1 P 120 GROUP 91 INSTRUMENTS2. d dB FE 6 6 EE ee SP SSS ERT DGEIN VOCE RO Ro ROG eee do ee ee aa i e Ne ee PP Ld a OO SSS SEE umo APRES 8 ee es eR oP Se SSE SS ee ee a Se E SUR BOO OU ER RO m n ORO ers eres Fes Fe SS mam SS ee ee ROB POR ones een eed RA RA RS R SOROR SO RODEO RU QR a eS ETETETT rrr BbnsRARBRBRREDEERPETPEUNTETPEUEHEUTTSTPERME TOC PCP PCL eee Ee BAS hak BERTRESSBEPEPERTERETRRE PPP PHT LE L E E SE SPAS CER PS ee SS BBRREPBSSSSEBEBENERBERME oS eee se ee ee ER RNENEMEESEFT 4s4CSCABREGAGSERERGORGGEERGGGEEGOERRGCEEOROR OG EON ee 9A o OA ARRA RERR
3. DESCRIPTION Fig 1 Instruments and controls Control for windscreen wiper and washer Choke control Lighting switch Direction indicator switch with headlight flasher Ignition switch with starter contact Cigarette lighter Controls for heater and ventilation system DUDU GL PS Ol COMBINED INSTRUMENT The combined instrument incorporates the speedo meter temperature gauge fuel gauge four warning lamps and two instrument lighting bulbs The com 2 9 7 6 4 bined instrument is illustrated in Fig 2 and 3 E 7 Speedometer a SAO DEN 2 Fuel gauge Wo 12 AEN Temperature gauge Charging control lamp Trip meter Warning lamp for full beam headlights Warning lamp for direction indicators fM Mileometer z Warning lamp for oil pressure 10 371 Instrument lighting 3 Combined instrument reverse side gt P 120 FUEL GAUGE The fuel gauge has two main parts These consist of the tank fitting and the actual dial on the instru ment panel The tank fitting consists of a float which through a lever is connected with a contact arm which slides over an electrical resistor rheo stat Any alteration of the fuel level in the tank will cause either a smaller or larger part of the resistor windings to be in circuit The instrument dial has two coils one in series with the rheostat in the tank fitting and one connected directly to earth Th
4. ES Ey n UE WE nm xo L d 4 pn T P ely i ETE Fig 16 Replacing wiper blade L Y P 120 GROUP 94 HEATER SYSTEM DESCRIPTION Early production Fig 17 Heater 1 2 3 4 5 6 7 8 9 Defroster nozzle Air intake Nut for attaching bolt Defroster nozzle Fan motor Controls Rubber gaiter Cell system Distribution housing 10 Rubber hose 11 Shutter 12 Heater control valve 13 Casing 14 Spiral reinforced hose P 120 Late production Defroster nozzle Controls Air intake Rubber gasket Attaching bolt Fan rotor Oa di e gt The heater illustrated above consists of the follow ing main parts air intake welded to the body water separator fan housing with fan and motor cell system distribution housing including shutters heater control valve and controls Fig 19 shows the flow of the cold air and hot air respectively to the defroster and space around the feet when the fan is switched on and the shutters are fully open 9 8 Heater Electric motor Cell system Shutter lever for outgoing air Shutter lever for defroster air Attaching bolt Heater control valve HEATER CONTROL VALVE The heater control valve is one of the main parts of the heater The purpose of the valve is to con trol the supply of heated coolant to the cell system of the heater This supply is controlled by the valve in two ways both manually by means of the heater contro
5. EMPERATURE GAUGE The temperature gauge consists of a sensor unit and a dial These are connected to each other by means of a copper pipe with a very small inter nal diameter In order to protect it from external damage and to prevent sharp bends the pipe is provided with a pleated protective covering and on late production vehicles an addiditional plastic covering The sensor unit consists of a small container lt is partly filled with a mixture of volatile liquids principally consisting of ether As the coolant temperature rises this liquid is pro gressively transformed into gas This gives rise to an increase in pressure which is transmitted through the above mentioned copper pipe up to the flat tubular spring in the temperature gauge dial The spring then tends to straighten itself out and at the same time transmits a movement to the lever which through a suitable reduction actuates the pointer of the instrument OIL PRESSURE CONTACT The function of the oil pressure contact is shown in Fig 8 The contact is adjusted to a predetermined breaking pressure When the engine oil pressure is above this value the oil pressure warning lamp is out In the right hand part of Fig 8 the oi pressure is so low that the spring overcomes the force operat ing on the other side of the diaphgram The con tact rivet is then pressed down against the contact plate with the result that the warning lamp lights The adjusting screw of the con
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7. and automatically through a thermostat arrangement The function of the heater control valve is shown in Fig 21 Fig 19 Arrangement and function of the heater system The direction and volume of the air flow are regu lated with the controls AIR and DEFR The tempe rature of the air is regulated with the control TEMP GE Fig 20 Heater control valve 1 Sensitive coil for thermostat When the heater control is moved downwards the lever on Fig 21 is thereby pulled upwards the valve is opened and coolant supply to the cell system begins The air passing through the cell system is thereby heated up and then conveyed to the lower part of the heater in which the shutter arrangements and sensitive coil of the thermostat are placed When the air flowing through has reached a particular temperature the mixture of volatile liquids in the sensitive coil of the ther mostat begins to vaporize This gives rise to an P 120 STANGT Closed VARMT Warm OPPEN Open FLAKT Fan KALLT Cold 1 HT p Se Fig 21 Simplified sketch of heater control valve function 1 Thermostat 9 Lever for heater control 3 Valve increase in pressure which causes the thermostat of the heater control valve to expand This expan sion results in the valve restricting the coolant supply to the cell system thereby reducing the heat transmitted to the air flowing through The thermostat then loses some of its expansio
8. ble to manufacture a template with a bending radius of 100 mm 4 as shown in Fig 12 Note also that late production speedo meter cables and instruments are provided with a guide at the connecting points see the arrows on Fig 14 Concerning replacement of speedometer gears see Part 4 43 and the specifications on page 12 P 120 DY FT 2 PYE VOLVO 101 379 Fig 11 Removing the tank fitting MIN R 100 VOLVO 101 380 Fig 12 Template for fitting speedometer cable Fig 13 Speedometer cable connection early production VOLVO 101382 Fig 14 Speedometer cable connection late production 9 b P 120 Replacing the complete speedometer cable 1 Screw off the cap nut on the instrument Re move the rubber grommet from the cowl wall and pull the cable through 2 Release the necessary retaining clips and unscrew the cap nut on the gearbox connec tion 3 When fitting the new speedometer cable handle it in such a way that there is no risk of damaging the driving cable or outer covering When replacing a complete speedometer cable no extra lubrication of the driving cable is normally necessary 4 Thread the speedometer cable through the rubber grommet 5 Connect the speedometer cable both to the instrument and gearbox 6 Fit the rubber grommet in position Fit the necessary retaining clips and make sure that the bending radius at any point is not less than that permitted see und
9. bout 80 km p h 50 m p h 6 40 S 15 Tyres Speedometer gears Rear axle ratio Number of teeth Large gear Small gear Theoretical percentage Ratio error of mileometer 4 55 1 11 50 5 17 3 4 1 ae The percentage error in the above table is calculated for a rolling radius of 328 mm 1229 27 which is a standard value established by AB Volvo for this size of tyre at a vehicle speed of about 80 km p h 50 m p h 9 12 l References to Workshop Bulletins SSPEARS RCE mab dbhAEERRERPRTRBESDSENTERTSETDBEREEASm BERRREARRETRZARERSARRTSRSRSRSSSEREESARRRSRAAZEASHARAZR ARARRARHARZRRRRZRRRRRRSTARRRSSARRARSHABSARSRBSSAABAA RESRARSRAdARARSSSASEEIREENENNR m eateciRebiSRAASRRBENARPEEA HEHFFEREREBSEHWESTEEEHER ATERTSESERSEMSPmEEMUSTFMSERHRESEMHNPMEBEESTMETRRPATEMEMEREBRRMEBEERMBHARRRHERSERBRREASRBERHEBSRRRREN REG mpra IIIJ CEES EEIEIE PRACRASERARSRPRERPEPRESRETESETEUSNEEMSERAREARESRASERMAESM FSS SS FS ESSE ROO ROSOR S NGA UGG OUS GEC U GG ROAD NGA LUCCA HEERES meee ert temei eee iiaeia ee ee ee 4 4 2 nd eT TS ee PR M RRRR RA ARRA RE ARE sassa PRP Pee RR ARR A AR RA AR m de RR Re aq qp Pees
10. clips are undamaged Any damaged parts should be renewed The thermostat can be removed after its casing has been taken off When removing first drain off sufficient coolant so that the thermostat comes above the water level HEATER late production The heater is removed and fitted as a complete unit as follows 1 Drain out the coolant 2 Remove the rubber hoses on the heater control valve and cell system 3 Unhook the control cables from the shutters and heater control valve Remove the defroster hoses 4 f there is a parcel shelf remove it in order to facilitate removing the heater control valve 5 Remove the fan motor does not apply to late production where only the lead has to be dis conected 6 Remove the heater attaching nuts 7 Lift out the heater Be careful not to damage the copper pipe of the heater control valve Dismantling 1 Unscrew the screws which hold the heater halves together and separate them 2 Lift out the cell system and remove the pro tective cardboard 9 10 Fig 22 Dismantling the heater Checking the cell system Clean the cell system externally and lower it under pressure max 1 2 kg cm 17 b sq in into water heated to about 70 80 C 160 180 F The joints in the cell system are soldered The con necting points are brazed If any leakage is disco vered the place concerned should be cleaned very thoroughly so that the new solder can flow in properl
11. d text strip comes correctly Tighten the screws and fit the bulb holder 6 Check the function P 120 Adjusting Move up the controls to their closed position Then check the positions of the shutters and heater control valve If they are not fully closed in this position they should be adjusted when the cable coverings at the respective attaching points on the heater or heater control valve are loosened After adjustment has been completed move the controls backwards and forwards a few times to check the function Replacing the warm air tunnel 1 Remove the defroster outlet 2 Lift up and remove the front rubber mat 3 Unscrew the bolt which holds the warm air tunnel 4 When fitting check that the drain hose from the lower part of the heater to the gearbox tunnel has not been ripped off during removal but is in its proper position Before fitting the warm air tunnel also check that the gear lever rubber gaiter is in its proper position i e with the sealing lip against the top of the gearbox tunnel 5 Fit the warm air tunnel 6 Lift in and fasten the rubber mat fit the de froster outlet and connect the hoses P 120 SPECIFICATIONS SPEEDOMETER GEARS 5 90 15 Tyres Speedometer gears Theoretical percentage Rear axle ratio Number of teeth Ratio error of mileometer Large gear Small gear 4 10 1 10 41 5 16 3 2 1 1 56 4 56 1 9 41 5 18 3 6 1 0 7 The percentage error in the abo
12. e current can therefore flow in two direc tions One of these is through the series connected coil of the instrument through the rheostat of the tank fitting to earth alternative 1 and the other is through the coil which is connected to earth alter native 2 When the fuel tank is empty the current flows as described in alternative 1 When filling the tank the current flowing in this way will be reduced due to an increasing part of the rheostat coming into circuit so that a larger part of the current will flow through it directly to the coil connected to earth alternative 2 The pointer on the dial will then move from the Empty position it had in alternative 1 and will give a reading on the scale proportional to the amount of fuel filled in the tank When the dial shows Empty the float of the tank fitting should be about 1 5 cm 5 s from the bottom of the tank SPEEDOMETER The speedometer is of the eddy current type It is driven through the speedometer cable by worm gear on the output shaft of the gearbox When the speedometer driving cable begins to rotate it carries with it a ring shaped permanent magnet which is placed on the right side of the speedo meter roller The rotational speed of the magnet will thus be the same as that of the driving cable On the left side of the speedometer roller there is a torsion spring the purpose of which is to brake the roller at the same time tending to move the roller to the O p
13. er Checking the speedometer TEMPERATURE GAUGE Testing the temperature gauge and removing the sensor unit If any fault is suspected in the temperature gauge carry out the following check before removing it 1 Drain sufficient coolant from the system so that the sensor unit comes above the coolant level 2 Remove the sensor unit from the cylinder head If it is stubborn carefully prise it backwards and forwards Be careful with the gauge pine 3 Immerse the sensor unit in a container filled with hot water An ordinary and previously checked mercury thermometer is used for ma king comparative readings In order to obtain good measuring results both the sensor unit and thermometer should be prevented from coming into contact with the bottom of the container t is not usually worthwhile to repair the temperature gauge Removing the temperature gauge dial 1 Disconnect the pleated earth lead from the battery 2 Remove the screws which hold the instrument dial and lift it out 3 Remove the rubber grommet from the cowl and pull through the sensor unit Be careful not to make sharp bends in the delicate meas uring pipe Fitting 1 Push the sensor unit through the cowl wall 2 Place the instrument dial in position in the com bined instrument Avoid sharp bends in the measuring pipe Tighten the retaining screws 3 Fit the sensor unit in the cylinder head Fit the rubber grommet in the cowl wall 4 Fill up w
14. ith coolant Check the level after starting the engine and top up if necessary 9 6 Fig 15 Guiding values in C for temperature gauge scale WINDSCREEN WIPER The ability of the windscreen wiper blades to keep the windscreen free from asphalt gravel and insect splashes becomes successively reduced Addi tional factors are the severe operating conditions during winter and the natural ageing of the mate rial The wiper blades must therefore be regarded as replacement items When replacing the wiper blades the spring pressure of the scrapers should also be checked In order to obtain good results any silicon deposits or traffic film on the wind screen glass should be removed with a suitable window cleaning agent Be careful when doing this as most such agents can damage the paint work Replacing the wiper blades 1 Release the scraper by lightly moving the re taining spring 2 out one of the retaining pieces and remove the rubber blade and its retainer from the scraper fitting 3 Fit the new wiper blades Use new retaining pieces 4 Moisten the windscreen when testing the wiper blades Check the contact of the blades with the glass Also make sure that the blades are adjusted so that they do not strike against the windscreen frame Check this with the wiper motor running at full speed LL dE i 1 1 aA riam pe FFEIT Fe r di i 1 L agti Ci NT
15. l tank fitting or in the connecting lead to the instrument dial Instrument shows Full 8 2 Disconnect the lead terminal on the tank fitting Switch on the ignition Earth the lead connected to the tank fitting with the help of a test lead If the pointer goes over to Empty the lead and dial are unda maged The fault is to be found in the tank If when carrying out these tests the pointer does not go over to Empty also disconnect the lead at the terminal on the instrument Earth the contact screw be means of a test lead If the instrument is undamaged the point er should then go over to Empty Otherwise F the fault is due either to poor contact on the terminals between the instrument and lead to the tank fitting or a breakage in the lead A faulty instrument or tank fitting should be re placed with new parts VOLVO 101378 Fig 10 Guiding values for the instrument dial scale Replacing the fuel gauge 1 Disconnect the pleated earth lead from the battery 2 In order to facilitate removing the dial first unscrew both the attaching screws of the igni tion switch Then bend the ignition switch out of the way 3 Mark and disconnect the leads from the instru ment Remove the attaching screws and care fully lift out the instrument Fitting 1 Place the instrument dial in position and tighten the attaching screws 2 Connect up the leads in accordance with the marking previously made Do not conf
16. n and the valve opens again The continuous repetition of this process causes the temperature of the air flowing into the vehicle to be maintained constant at the desired level P 120 REPAIR INSTRUCTIONS HEATER early production The air intake and fan motor are removed as follows 1 Disconnect the lead to the fan motor 2 Remove the rail between the body and air intake 3 Unscrew the three screws under the rubber gasket on the engine casing and lift off the air intake with fan motor The fan motor is removed from the air intake by loosening the remaining two screws on the side after which the motor can be pulled out The fan motor has self lubricating bushings Lubri cation need only be done in connection with re conditioning When fitting make sure that the fan motor is centred accurately and that the earth lead makes good contact The cell system can be removed after the distribu tion housing has been taken off This is bolted on from inside the vehicle The coolant must first be drained before removing The hoses on the cell system can then betaken out When doing this distribution housing can be removed The cell system can then be taken out When doing this hold the pipe ends high up to prevent water from running out inside the vehicle For checking the cell system see under the heading Heater late production Fitting is done in the reverse order Make sure that all hoses and hose
17. osition A magnetic field exists between the permanent magnet and the right hand end of the speedometer roller There are also lines Torsion spring Stop arm for speedometer roller Dial scale Speedometer roller Ring for magnetic lines of force and induced eddy currents Permanent magnet Worm gear for driving mileo meter SUO ucc om Fig 4 Fuel gauge of magnetic force between the magnet and the ring which surrounds the permanent magnet at a certain distance This space is intended for the ring shaped and projecting part of the speedometer roller see Fig 5 When driving varying magnetic fields will arise which when passing over the projecting part of the speedometer roller will give rise to eddy currents The torsional efect which both the mag netic field and the induced eddy currents will have on the speedometer roller depend partly on the speed and partly on the opposing force of the torsion spring Fig 5 Construction of the speedometer The mileometer and trip meter are driven from the speedometer shaft Fig 6 shows how the numeral rollers of these meters are driven The drive ratios from the speedometer to the mileometer and trip meter are worked out by the manufacturer so that the speedometer cable makes 0 63 of a revolution per metre driven This value is also stamped on the reverse of the instrument Concerning percentage error with different tyre sizes see the Specifications on page 12 T
18. oving the combined instrument the bulb holders for the warning lamps and instrument light ing are removed first Then disconnect the speedo meter cable and leads to the fuel gauge The tem perature gauge should be removed from the instru ment if it is not necessary to remove the combined instrument complete It is simpler to do this than to drain the coolant and remove the sensor unit from the cylinder head see under Removing the temperature gauge Remove the nuts which hold the combined instrument to the instrument panel Lift out the instrument When replacing the individual instruments see under the headings concerned FUEL GAUGE Before removing any component belonging to the fuel gauge the fault should first be localized as described below Check that the lead terminals for the dial are pro perly tight Switch on the ignition With a voltmeter or test lamp check to see that there is voltage on the feed side of the instrument When this has been done continue testing as follows Instrument shows Empty 1 Disconnect the lead terminal on the tank fitting and hold the lead away from the vehicle frame Switch on the ignition The fuel gauge should then show Full 2 f the instrument shows Empty disconnect the lead on the instrument the lead wich con nects the dial to the tank fitting If the dial 9 4 now shows Full there is nothing wrong with the instrument and the fault will either be in the actua
19. tact by means of which the breaking pressure can be varied is accessible by removing the pipe on the oil pres sure contact Any adjustment of the breaking pressure must not however be done unless the engine oil pressure is measured at the same time with a separate pressure gauge P 120 f E us 7A pepe 1 f lg F Fig 6 Drive arrangement of mileometer and trip meter Fig 7 Temperature gauge 1 Sensor unit 2 Dial unit VOLVO 101 376 Fig 8 Function of oil pressure contact Engine Breaking pressure B 18 0 6 1 0 kg cm 8 5 14 Ib sq in B 16 0 6 1 0 kg cm 8 5 14 Ib sq in 2 120 WINDSCREEN WIPER The windscreen wiper is driven by an electric motor The motor is connected to the wiper blades through a drive gear housing and link arms The motor has two speeds which can be selected by means of the pull switch on the instrument panel The windscreen is self parking Concerning remov ing lubricating and adjusting the wiper motor drive gears and linkage see Part 3 36 es amus 5 995 Fig 9 Wiper arm and blade assembly 1 2 Retaining spring 3 Scraper fitting 4 Rubber blade and retainer 5 Retaining piece REPAIR INSTRUCTIONS REPLACING THE COMBINED INSTRUMENT Before removing or fitting the combined instru ment one of the battery connections must always be removed from the battery preferably the pleat ed earth lead When rem
20. use the leads 3 Place the ignition switch in position and tighten the attaching screws Replacing the tank fitting 1 Make sure that the ignition key is in the swit ched off position 2 Turn back the mat in the luggage compartment and lift off the tank fitting cover plate 3 Blow well clean round the tank fitting with compressed air 4 Disconnect the lead and remove the screws which hold the tank fitting and then lift it out Fitting Always use a new gasket in order to prevent leakage and petrol fumes inside the vehicle 1 The gasket should be coated on both sides with a sealing adhesive which does not affect rubber and which is not dissolved by petrol 2 Place the gasket in position on the tank Place the tank fitting in position and tighten the screws well Connect the lead SPEEDOMETER In order to correct any faults the special tools and instructions used by a VDO authorized work shop should be availabe If such special tools and instructions are not available any adjustment and checking of the speedometer should be carried out by an authorized instrument workshop Checking the speedometer cable It is most important that the speedometer cable should be fitted correctly in order for the speedo meter to function without trouble The following should therefore be observed At no point must the bending radius of the speedometer cable be less than 100 mm 4 In order to facilitate check ing this it is advisa
21. ve table is calculated for a rolling radius of 318 mm 121 27 which is a standard value established by AB Volvo for this size of tyre at a vehicle speed of about 80 km p h 50 m p h 6 00 15 Tyres Speedometer gears Theoretical percentage pou Number of teeth Ratio error of mileometer Large gear Small gear 4 10 1 10 41 5 16 9 2 1 2 81 4 56 1 9 41 5 18 8 6 1 1 67 The percentage error in the above table is calculated for a rolling radius of 315 mm 1213 32 which is a standard value established by AB Volvo for this size of tyre at a vehicle speed of about 80 km p h 50 m p h 165 S 15 Tyres opeedometer gears Theoretical percentage Rear axle ratio Number of teeth Ratio error of mileometer Large gear Small gear 4 10 1 10 41 5 16 3 2 1 3 8 4 56 1 9 41 5 18 3 6 1 3 7 The percentage error in the above table is calculated for a rolling radius of 308 mm 121 s which is a standard value established by AB Volvo for this size of tyre at a vehicle speed of about 80 km p h 50 m p h 6 40 15 Tyres Speedometer gears Rear axle ratio Number of teeth Large gear Small gear Theoretical percentage rror of mileometer Ratio 2 ES 4 55 1 11 50 5 17 3 4 1 eet The percentage error in the above table is calculated for a rolling radius of 330 mm 13 which is a standard value established by AB Volvo for this size of tyre at a vehicle speed of a
22. y After sealing has been completed check the cell system again for leakage in accordance with the above instructions Assembling 1 Check the rubber support buttons of the cell system and the protective cardboard and make sure that they come properly in position Fig 23 Placing in the cell system of the heater 2 f necessary replace any missing rubber sealing strip with new This is placed in the joint be tween the two halves before the heater is screwed together Fitting Make sure that all damaged hoses and gaskets are replaced with new ones Check that they come properly in position Handle the heater control valve and its copper pipe with great care After fitting check the shutters control and fan motor Make sure that the drain hose from the fresh air intake is open Fill up with the coolant which was previously drained off Start the engine and increase the speed sharply a sufficient number of times to expel the air in the system and then top up with the remaining coolant Repeat this proce dure until the cooling system is completely free from air Replacing the heater controls 1 Remove the bulb holder 2 Unscrew the three star screws and lift out the control unit 3 Remove the control cable retainers and unhook the cables 4 Fit the cables in the new control unit The outer covering should come edge to edge with the retainers 5 Lift up the control unit and check that the cel luloi
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