Volvo P1800 Workshop Service Repair Manual

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The Volvo P1800 is an iconic Swedish sports car produced between 1961 and 1973, available in Coupe and Shooting Brake (ES variant) body styles. Chassis codes include P1800, P1800S, P1800E,...

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Tipo: Car

Proveedor:

SKU: 80516

Etiquetas: Car EBOOK P1800 Volvo

Variantes de producto

Descripción

The Volvo P1800 is an iconic Swedish sports car produced between 1961 and 1973, available in Coupe and Shooting Brake (ES variant) body styles. Chassis codes include P1800, P1800S, P1800E, and P1800ES. Powered by robust B18 and B20 inline 4-cylinder OHC engines, ranging from 1.8 to 2.0 liters and offering various carburetor and fuel injection configurations, the P1800 is renowned for its exceptional engineering quality, durability, and reliability, embodying Volvo's strong reputation for safety and longevity. Notable features include its distinctive styling, a testament to timeless design, and the availability of manual transmissions with or without overdrive, as well as automatic options. This comprehensive workshop and factory service repair manual in English provides in-depth guidance for maintaining and repairing the Volvo P1800. It covers a wide array of systems, including detailed procedures for engine mechanical and electrical systems, fuel and emission control systems, suspension, steering, brakes, clutch, manual and automatic transmissions, driveshaft, and axles. The manual also addresses bodywork, interior, exterior, and electrical components, offering step-by-step repair and overhaul instructions, troubleshooting guidance, and factory specifications. This resource is invaluable for do-it-yourself enthusiasts and professional mechanics alike, ensuring the continued performance and preservation of this classic vehicle.

🏷️ Basic Information

Identification

Make:

Volvo

Model:

P1800

Body Styles Covered:

Coupe, Shooting Brake (ES variant)

Codes

Chassis Code:

P1800 / P1800S / P1800E / P1800ES

👋 Introduction

Market Position

Target Audience:

Do-it-yourselfer and experienced mechanics seeking factory-level repair information for the Volvo P1800.

Competitive Analysis

Value Proposition:

An inexpensive and authoritative source for maintaining and repairing the iconic Volvo P1800, saving costs compared to dealership services.

Key Features

Manual Content Highlight:

Detailed illustrations, diagrams, wiring schematics, specifications, and step-by-step instructions for comprehensive repair and maintenance.

📋 Manual Details

Coverage Areas

Covered Production Years:

1961-1973

Engine Variants Covered:

B18, B20 (various carburetor and fuel injection configurations)

Transmission Types Covered:

4-speed manual (with/without overdrive), 3-speed automatic

Page Count

Estimated Page Count:

High (indicative of comprehensive factory documentation)

Manual Type

Manual Type:

Workshop Service Repair Manual / Factory Service Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical System:

Detailed disassembly, inspection, reassembly of B18 and B20 engines (cylinder head, block, crankshaft, pistons, camshaft, timing gears, oil pump, etc.)

Engine Electrical System:

Ignition system (distributor, coil, spark plugs), starting system (starter motor), charging system (generator/alternator), lighting, instrumentation

Emission Control System:

Information on emission control devices and adjustments relevant to the period, including fuel system adjustments for emissions

Fuel System:

Carburetor systems (e.g., SU, Zenith Stromberg) and Bosch D-Jetronic fuel injection (for 'E' models): maintenance, adjustment, overhaul, fuel pump, fuel lines

Suspension System:

Front independent suspension (double wishbone, coil springs, telescopic dampers), rear live axle with trailing arms and Panhard rod: maintenance, alignment, component replacement

Clutch System:

Single dry plate clutch, hydraulic actuation: adjustment, inspection, replacement

Manual Transaxle System:

M40, M41 (with overdrive) transmissions: disassembly, assembly, gear oil specifications, troubleshooting

Automatic Transaxle System:

BW35 automatic transmission: operation, maintenance, fluid specifications, basic troubleshooting

Driveshaft And Axle:

Driveshaft, universal joints, rear axle housing and differential: inspection, lubrication, overhaul

Steering System:

Worm and roller steering gear: lubrication, adjustment, component wear checks

Brake System:

Front disc brakes, rear drum brakes: hydraulic system (master cylinder, wheel cylinders, brake lines, calipers, drums), parking brake, fluid specifications, bleeding procedures, component replacement

Body Interior And Exterior:

Body panel repair, doors, hood, trunk, seats, interior trim, glass, weatherstripping, body dimensions, painting preparation

Body Electrical System:

Comprehensive wiring diagrams, lighting circuits, horn, wipers, heater, instrument cluster, power windows (if applicable), fuse box layout

Restraint:

Seat belts (3-point inertia reel introduced later in production), general safety features

Procedures Included

Maintenance Procedures:

Lubrication schedules, fluid changes (engine oil, coolant, transmission fluid, differential oil, brake fluid), filter replacement (oil, fuel, air), spark plug replacement, tune-ups, brake adjustments, clutch adjustments

Troubleshooting Guidance:

Systematic diagnostic procedures for common and uncommon problems across all major vehicle systems, including electrical fault finding using wiring diagrams

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for nearly every part of the vehicle

Overhaul Procedures:

Detailed overhaul instructions for engines, transmissions, carburetors, fuel injection systems, brake calipers, and other major mechanical components

Technical Depth

Technical Depth:

Comprehensive, covering everything from basic maintenance checks to full engine and transmission rebuilds. Includes factory specifications, tolerances, and torque values.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Fully Printable

Zoom Functionality:

YES (Zoom IN/OUT)

Binding Type

Binding Type:

Digital Download (printable)

Paper Type

Paper Type:

N/A (Digital File)

Software Requirements

PDF Reader:

Adobe PDF Reader

Unzipping Utility:

WinZip (or similar)

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Codes:

B18, B20

Engine Type:

Inline 4-cylinder, OHC (Overhead Camshaft)

Performance

Displacement B18:

1780 cc (1.8 Liters)

Horsepower B18 Dual Carb:

90-95 hp (approx.)

Displacement B20:

1986 cc (2.0 Liters)

Horsepower B20 Dual Carb:

100-115 hp (approx.)

Horsepower B20 Fuel Injection:

120-130 hp (approx.)

Fuel System

Carburetor Options:

Single or Twin SU Carburetors, Zenith Stromberg

Fuel Injection System:

Bosch D-Jetronic (on P1800E models)

Lubrication

Oil Capacity Approx:

4.5 Liters (with filter)

Cooling System

Coolant Capacity Approx:

7.5 Liters

🔧 Transmission

Standard

Standard Transmission:

4-Speed Manual (M40)

Optional

Optional Transmission:

4-Speed Manual with Overdrive (M41), 3-Speed Automatic (BW35)

Features

Overdrive System:

Laycock de Normanville overdrive unit on M41 transmission, controlled by a switch on the gear lever or dashboard.

Fluid Specifications

Manual Transmission Fluid:

GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90)

Automatic Transmission Fluid:

Dexron II (or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 4400-4520 mm (depending on model year and variant)

Width:

Approx. 1700 mm

Height:

Approx. 1270-1300 mm

Weights

Curb Weight Approx:

1100-1300 kg (depending on variant and equipment)

🛡️ Safety Features

Ratings

Crash Test Data:

No formal crash test data available from modern standards for this era, but designed with Volvo's reputation for safety. Features like reinforced safety cage and side impact protection were characteristic of Volvo.

Active Features

Braking System:

Dual-circuit hydraulic system with front discs and rear drums, ensuring fail-safe operation in case of a leak.

Passive Features

Seat Belts:

Standard front lap belts, later models and some markets featured three-point retractable front belts.

💡 Technology Features

Infotainment

Original Audio System:

AM/FM radio, often with a single speaker. Later models may have been updated with aftermarket units.

Driver Assistance

Early Safety Features:

Despite its age, the P1800 incorporated Volvo's forward-thinking approach to safety, with a robust chassis and excellent build quality for its time.

Connectivity

Original Connectivity:

N/A (Pre-digital era)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 miles or 6 months, whichever comes first (depending on driving conditions).

Tune Up Interval:

Every 10,000-15,000 miles (ignition timing, carburetor/FI adjustment, spark plugs, points inspection).

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 20W-50 or 10W-30 (depending on climate/year).

Coolant Specification:

50/50 mix of ethylene glycol antifreeze and distilled water.

Brake Fluid Specification:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Carburetor leaks/tuning issues, ignition system components (points, condenser, coil), front suspension bushings, clutch wear, rust (especially in common areas like wheel arches, sills, and A-pillars).

Engine Specific Notes:

B20 engine with D-Jetronic can be sensitive to component age; ensure fuel pressure regulator and injectors are functioning correctly. Overheating can be an issue if cooling system is not meticulously maintained.

📚 Vehicle History

Brand Heritage

Volvo Reputation:

Volvo built its reputation on safety, durability, and reliability, which were key selling points of the P1800.

Model Evolution

Major Updates:

Introduction of the P1800S (with the B18 engine and improved features), P1800E (with electronic fuel injection and disc brakes all around), and P1800ES (the distinctive 'shooting brake' version).

Production

Production Period:

1961-1973

Production Location:

Gothenburg, Sweden; Jensen Motors, West Bromwich, UK (early models); Santa Maria de Melgaco, Portugal (some later models).

Total Production Numbers:

Approximately 47,493 units

🏆 Awards & Recognition

Recognitions

Cult Status:

Iconic status as one of the most beautiful Volvo designs and a highly sought-after classic car. Famous for its long-term reliability, exemplified by Irv Gordon's P1800 which surpassed 3 million miles.