Volvo P1800 1961–1973 Service Manual Collection (P/N TP 10138/2)
604 Pages • ZIP Download: 19 Printable PDFs • 574.74 MB
Volvo Models Covered & Key Technical Specifications
Models: P1800, 1800, 1800 S
Sub-models / Variants: P1800-334 (VA, HA), P1800-335 (VA, HA), 1800 S-334 (VB, HB, VD, HD), 1800 S-335 (VB, HB, VD, HD, VE, HE, VF, HF, M, P, S)
Trade Names: P1800, 1800, 1800 S
Model Years: 1961–1973 (1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973)
Serial Numbers: P1800 VA/HA: 1–6000; 1800 S VB/HB: 6001–8000; VD/HD: 8001–12499; VE/HE: 12500–16499; VF/HF: 16500–20999; M: 21000–25499; P: 25500–28299; S: 28300–30000
Wiring diagram chassis ranges: Illustration I: 1–7000; Illustration II: 7001–10000; Illustration III: 10001–12500; Illustration IV: from 12501
Shock absorber chassis break: 1800 up to chassis No. 2443: Gabriel Type I or Type II; from chassis No. 2444: Delco
Brake system chassis break: P1800 up to chassis No. 6999: vacuum tank and early hydraulic connections; from chassis No. 7000: revised servo-brake layout
Body-floor drawings: 1800 up to chassis No. 16499; from chassis No. 16500
Overdrive serial break: 1800 overdrive unit, late-production pressure specification from manufacturing serial No. 32-3340-5643
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Engine types: B 18 B (Types 1–4; Type 1: 496800; Type 2: 496812–496817), B 20 B (1800 S model S)
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Transmission types: M 40 (manual, -334 variants), M 41 (manual with overdrive, -335 variants); separate earlier-overdrive and Type J service documentation
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Final drive ratios: 4.10:1, 4.30:1, 4.56:1
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Cylinder count: 4 cylinders
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Cylinder head height (B 18 B, Types 2 and 3): 86.2 mm (3.39")
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Valve stem diameter (B 18 B, Inlet): 8.685–8.700 mm (0.3419–0.3425")
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Engine oil capacity (incl. filter): 3.75 liters (7.91 US pints)
Volvo Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| 1800 / 1800 S specifications — P/N TP 10138/2, 1970 printing | 31 |
| 10,000 km (6,000-mile) service — P/N TP 10639/1 | 44 |
| Lubrication, P 120 / P 1800 — P/N TP 10416/1 | 20 |
| B18A base engine manual — P/N TP 10402/1A | 67 |
| B18B / B18D engine supplement — P/N TP 10115/2A | 34 |
| B20A / B20B engine manual — P/N TP 10516 1 | 78 |
| S.E.V. Motorola alternator equipment — P/N TP 10453/1 | 13 |
| P 1800 electrical system — P/N TP 10334/1A | 58 |
| Clutch, 120 / 140 / 1800 — P/N TP 10055/3 | 26 |
| M40 / M41 gearbox, P 1800 — P/N TP 10133/1A | 18 |
| Overdrive, 120 / 140 / 1800 — P/N TP 10125/2A | 22 |
| Type J overdrive — P/N TP 10487/1 | 21 |
| Propeller shaft, P 120 / 140-series / P 1800 — P/N TP 10373/1 | 11 |
| Rear axles: Salisbury, Spicer 23/27/30 and Volvo 1030 — P/N TP 10307/1 | 28 |
| Spicer Model 27 rear axle — P/N TP 10075/1 | 24 |
| Disc brakes, P 120 / P 1800 — P/N TP 10053/2A | 31 |
| Front end and steering, P 120 / P 1800 — P/N TP 10094/1A | 32 |
| Springs, shock absorbers and wheels, 120 / 1800 — P/N TP 10099/2A | 22 |
| 1800 body — P/N TP 10268/1A | 24 |
For B18B repair, use the B18A volume for common engine procedures and the B18B/B18D supplement for the components that differ.
Engine coverage addresses carbureted configurations. The identification chart traces the 1961 P1800 through the 1968 1800 S build series; shared component books also contain instructions for other Volvo models.
PDF Access, Diagrams and Included Files
Search and diagram detail: Manual text is not searchable, and none of the PDFs has embedded bookmarks. Small wiring labels require zooming. The vehicle wiring diagrams use Swedish labels with English component legends.
The ZIP contains 19 printable PDFs totaling 604 pages, including 38 original cover pages and 17 notes or bulletin-reference pages. It also contains 19 DOC files and a JPG thumbnail.
Engine Overhaul, Overdrive Diagnosis and Chassis Repair
The following are selected areas of coverage; other topics include heater operation and windshield-wiper service.
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Engine repair: Step-by-step engine removal, disassembly, internal inspection and reassembly, plus cylinder-head, valve, piston, crankshaft and timing-gear work.
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Fuel and cooling: SU and Zenith-Stromberg carburetor adjustment, synchronization and fault tracing, fuel-pump repair, thermostat checks and water-pump service.
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Electrical diagnosis: Generator and starter overhaul, distributor testing, alternator and regulator checks, fault charts and chassis-specific wiring diagrams.
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Clutch and overdrive: Clutch inspection and adjustment, gearbox overhaul, overdrive pressure testing, valve service and engagement-fault diagnosis.
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Rear axle and driveshaft: Differential setup, pinion-bearing adjustment, shaft-seal replacement, universal joints and center-support bearing service.
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Brakes and suspension: Caliper and master-cylinder service, brake-servo diagnosis, bleeding, steering-box overhaul, wheel alignment and suspension-bushing replacement.
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Body repair: Door and lock adjustment, window removal and installation, weatherstripping, interior trim and body-floor dimension drawings.
Suited to mechanics and experienced owners equipped for precision measurement, press work and the specified Volvo service tools.
Engine, Carburetors and Cooling
The engine books document bore, stroke and compression ratios, cylinder-block materials, piston clearances and valve-spring loads. Crankshaft journal dimensions and bearing-shell thicknesses distinguish standard and undersize parts, with wear limits and cylinder-head tightening sequences.
The B18B supplement adds early-production oil-cooler service and twin SU-HS6 procedures. The B20 volume separates SU and Zenith-Stromberg work, including temperature-compensator and throttle-bypass checks and mixture adjustment with or without a CO meter.
Cooling coverage includes radiator replacement and leak testing. B20 illustrations show coolant flow with the thermostat open and closed.
Gearbox, Overdrive and Rear-Axle Setup
Gearbox fault charts relate difficult shifting, gear disengagement, noise and oil leakage to likely causes. Separate overdrive pressure tests help distinguish electrical-control faults from hydraulic or internal clutch problems before choosing the relevant repair section.
The earlier overdrive book explains lubrication changes and mainshaft compatibility. Type J has its own valve, filter and pressure-test procedures, including use of pressure gauge SVO 2834. Both books warn that reversing with an overdrive stuck engaged can damage the unit.
Rear-axle instructions include shim selection, bearing preload and tooth-contact patterns. The shared axle book distinguishes different axle constructions rather than applying one setup procedure to every unit.
Charging Tests, Brakes and Body Work
Alternator test diagrams show the instrument connections for charging and regulator checks. The instructions warn that loose test leads can damage the alternator and regulator.
The brake book includes a servo fault-tracing scheme and hydraulic leakage tests. Its caliper instructions prohibit splitting the caliper body, citing the pressure-testing equipment and special bolt-locking compound required for reassembly.
Suspension work involves loaded coil springs and vehicle support; brake work requires the specified bleeding and leakage checks. Body-floor control drawings distinguish earlier and later chassis layouts for dimensional assessment.
Selected B18B and Alternator Reference Data
The B18B Type 3 specification lists an SAE output rating of 115 hp at 6,000 rpm. B18B fuel-pump pressure is specified at 0.11–0.25 kg/cm², measured at the same height as the pump.
For the S.E.V. Motorola alternator, rotor resistance measured between the slip rings is 5.2 ± 0.2 ohms at 25°C (77°F).
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