VOLVO 940 1982 Service Manual PDF

70019401960 Specifications
Section
2 B 28 Engine
Section 2 B 28 Engine
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69
Group 21 Engine................................ 70
Group 22 Lubricating system ...................... 74
Group 23 Fuel system ............ . . . . . . . . . . . . . .. 75
Group 25
Intake and exhaust systems ............. 82
Group 26 Cooling system ......................... 83
Group 28
Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 84
129756
Group 20 General
Performance, compression ratios, octane requirements
E ngine Compression Octane
type ratio r
eq
uirement
B28A 8.8:1 91-93
B28E 9 .5 :1 981
)
B28F 8.8 :1 912
)
1) Australia 97-98 octane 2) According to research method (RON). Unleaded gasoline
According to formula (R+M/2) = 87 octane 3) ft. lb. 4) Horse power
Other general data
kWat
rl s
96/88
115/95
100/92
Number of cylinders ......................................... .
Bore
.............. ......................................... .
Stroke ................ " ................................... .
Displacement ............................................... .
Firing order
................................................. .
Compression
(normal rating)l) ........................... ..... .
Weight, approx
................ ............................. .
I) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
Output
hp at
r/min
130/5250
156/5700
136/5500
134
4)/5500
6
91 mm (3.582 in)
73 mm (2.874 in)
2 .849 dm3 (Iitres)
1-6-3-5 -2-4
Nm at
rl s
212150
235/50
215/46
0.8-1 .1 MPa (114-156 psi)
150 kg (330 Ib)
/ ......
l.t
~ '
129750
Max torque
kpm at
r/min
21.6/3000
24.0/3000
21. 9/2750
1593)/2. 700
69
"' '" ill
,' ....
N,'
'" III

70019401960 Specifications
Section'-2" B 28 Engine
Group 21 Engine block
Cylinder head
Max warp:
Maxium warp is
0.05 mm (0.002 in) per
100 mm (4 in) length.
Note: Do not level a warped cylinder head,
replace it!
Cylinder liners
[
Bore, liners marked 1 (A-marked piston) ....................... .
2 (B-marked piston) ....................... .
3 (C-marked piston) ...................... .
Liner height above
block face:
checking (runing engine,
old shims) ....................... .. .
adjusting (new shims)
..................................... .
Pistons
Max weight difference between pistons in same engine .......... .
Piston
float ................................................. .
Piston diameter A-marked pistons
......... .
B-marked pistons
......... .
C-marked pistons
........ .
]
91.00-91.01 mm
91.01-91.02 mm
91.02-91.03 mm
0.14--0.23 mm
0.16-0.23 mm
6 grams
0.020-0.040 mm
90.970-90.980 mm
90.980-90.990 mm
90.990-91.000 mm
3.5826-3.5830 in
3.5830-3.5835 in
5.5835-5.5838 in
0.0055-0.0091 in
0.0063-0.0091 in
0.0007-0. 0015 in
3.5814-:3.5818 in
3.5818-3.5822 in
3.5822-3.5826 in
((0)) t
'" ~L-f
Piston diameter is measured at right-angles to gudgeon pin bore, S mm from bottom edge.
135676
Piston rings
/,
I 111111111 ~III
'--J 115085
Side clearance (measured with ring on piston) ............... mm
in
Ring gap when checked in 91 mm (3.5826 in) cylinder,
Ring gap measured 15 mm
(0.6 in) from lower edge of
cylinder
U 129520 pper
compression
ring
0.045-0.074
0.0017-0.0029
Lower Oil ring
compression
ring
0.025-0.054 0.009--0.233
0.0009--0.0212 0.0003-0.0091
(see fig) ................................................. mm 0.40-0.60 0.40-0.60 0.40-1.45
in 0.0157-0.0236 0.0157-0.0236 0.0157-0.0570 Gudgeon (piston) pins
Clearance in connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.041 mm
piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.010-0.016 mm
70 0.0007-0.0016
in
0.0003-0.0006 in

(
70019401960 Specifications
Section
2 B 28 Engine
V alve s yste m
Valve clearance
Inlet valves, cold engine ................................. .... .
warm engine ...
................................. :
Exhaust valves, cold engine ..... ................ ............. .
warm engine
................................. .
V alves (sizes in mm)
0.10-0.15 mm
0.15-0.20 mm
0 .25-0.30 mm
0.30-0.35 mm
0 .004-0.006 in
0.006-0.008 in
0.010-0.012 in
0.012-0.014 in
7,975-7,990 7,965-7,980
44
Valve seats
Seat for inlet
valve Inlet
valve
Venturi seat: 15° and 60° angles can be
used to reduce seat width.
Exhaust valve
,
I:i~~' 13 0021
Seat for exhaust valve
When replacing valve seats: the interference between the valve seat and its bore in' the cylinder head shall be 0 .070-0.134 mm (0.0028-0.0053 in), i.e. valve seat diameter must be 0.070-0.134 mm greater than the diameter of the bore in the cylinder head.
Valve seats are available in three oversizes .
Valve guide s
Inner diameter ................. ............................. .
Press -in measurement to cylinder head contact surface against
block:
inlet
............................................... ...... .
exhaust ..
............... ................................. .
Clearance in cylinder head ............. ...................... .
8 .000-8.022 mm
39.5-40.5 mm
36.9-37.9 mm
0.052-0.095 mm
0 .3149-0.3158 in
1.5551-1 .5944 in
1.4527-1.4921 in
0.0020-0. 0037 in
129851
71

70019401960 Specifications
Section
2 B 28 Engine
.. Valve guides are available in three oversizes and are
marked with grooves.
Standard
Oversize 1
Oversize 2
Oversize 3
129865
Valve springs
115083
Rocker arm mechanism
Marking Reamer
No groove
1 groove 5166
2 grooves 5167
3 grooves 5168
Springs marked green
Length
mm
in
47.1 1.85
40.0 1.57
30.0 1 .18
Load
N
o
230-266
613-689
The rocker arm tips are surface hardened and must not
be
ground.
lb.
o
52-60
137-154
Clearance. shaft-rocker arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012-0 .054 mm (0.0005-0.0021 in)
Timing gears
Camshaft
Engine type ............................. B28A, E B28F
Left
Right
Marking ................................. F
F
Part number
(last three digits).
early type ............................... .. .615 . . .616
late type ................................ . .. 977 .. .978
740~
Letter
B28A, E B28F
Max lobe lifting height. left and right. inlet ...................... .
exhaust. .
................ "
5.96 mm (0.2348 in) 5.44 mm
5.96 mm (0.2348 in) 5.94 mm
Checking camshaft settings (cold engine):
adjust
valve clearance on 1 st and 6th inlet valves to .......... . 0.7 mm (0.0275 in) 0.7 mm
The inlet valves should then open at:
Left
G
... 486
. . .979
1 st .................................................... . 8±3° B.T.D.C. 1 ±3° B.T.D.C.
6th .. ,
................................................. . 8±3° B.T.D.C. 1 ±3° B.T.D.C.
Journal clearance ........................................... . 0.035-0.085 mm
(0.0013-0.0033 in)
End play, new .............................................. . 0.070-0.144 mm
(0.0027-0.0056 in)
max .............................................. . 0.5 mm
(0.0196 in)
72
Right
G
... 487
... 980
(0.2142
in)
(0.2339 in)
(0. 0275 in)

{
Crank mec ha ni sm
Cr ank sh aft
Max run-out (measured on two centre main bearing journals) ..... .
Crankshaft, end float
........................................ .
clearance (main bearings) ......................... .
Crank
journals, side clearance ...........•.................... .
clearance .................................... .
M ain bea rin g journ als
Out of round, max ....................... .
Taper, max
...... ....................... .
Diameter, standard ...
................... .
undersized
.................... .
Conne cting rod b ea ring journ als
Out of round, max ....................... .
Taper, max
............................. .
Diameter, standard
...................... .
undersized
.................... .
C onnec tin g rods
0 .007 mm
0.01 mm
70.043-70.062 mm
69 .743-69.762 mm
0.007 mm
0.01 mm
52.267-52 .286 mm
51.967-51.986 mm
End
float on crankshaft (both can rods fitted) ................... .
Max weight difference between can rods
in same engine ........ .
Flywh eel
0.02 mm
0 .070-0.270 mm
0.038-0.088 mm
0.20-0.38 mm
0 .030-0.080 mm
0.0002 in
0.0003 in
2.7575-2.7583 in
2 .7457-2.7465 in
0.0002 in
0.0003 in
2.0577-2.0585 in
2.0456-2.0466 in
0.20-0.38 mm
2.5 grams
Axial throw, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 .05 mm
T ig hte nin g torq ue
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must be
oiled prior to assembly.
Connecting rod bearings ................. .......... ..... ..... .
Crankshaft
pulley . ........ .......... ........................ .
Camshaft gear
................................. ............. .
Flywheel (use new bolts) ... -................................. .
Spark plugs (do not oil) ...................................... .
Valve cover ......... .................................... .... .
Nm
45-50
240-280
70-90
45-50
12±2
15
70019401960 Specifications
Section 2 B 28 Engine
0 .0007 in
0.0027 -0.0106 in
0.0014-0.0034 in
0.0078-0 .0149 in
0 .0011-0.0031 in
Out-of-round
Taper
0 .0078-0.0149 in
0.0019 in
ttlb
33-37
177 -206
52-66
33-37
9±1.5
11
115089
73
t't'. -II II· II II' ,II II'
,II II'

70019401960 Specifications
Section
2 B 28 Engine
Cylinder head
Tighten all bolts in stages:
1 Tighten
bolts to 60 Nm (43 ft Ibs) 2 a Loosen bolt 1, tighten it to 20 Nm (15 ft Ibs) b Angle-tighten to 106 degrees using special tool 5098. Repeat this for remaining bolts in sequence shown.
118650
Tightening sequence for cylinder head bolts
L~~::~:~' ~I ~: I I I I
i61I~-
c Loosen and tighten each bolt in turn.
3 Adjust valves.
4
Warm-up engine.
5 Allow engine to cool for 2 hours.
6 Angle-tighten each bolt a further 45 degrees
Main bearings
Tighten all nuts in stages:
1
30 Nm (22 ft Ibs) 2 Slacken nut 1 3 Tighten nut 1 30-35 Nm (22-26 ft Ibs) 4 Angle-tighten nut 1 73°_77 °
1111-
i@1lf11 -
5 Slacken and retighten the other nuts in the order specified in stages 2-4.
---,---,---,---,-115091
Tightening sequence for main bearings (via lower crankcase)
Group 22 Lubricating system
General
Oil capacity and quality, see page 12.
Oil pressure, warm engine new oil cleaner:
at 15 rls (900 r/min), minimum .............................. .
50 rls (3000 r/min) .......... ....... ......... ............ .
Lubricating oil pump
End float ................................................... .
Clearance between tooth tip and pump housing wall (excl.
bearing clearance) .......................................... .
Backlash (excl bearing clearance) ................ ............. .
Bearing
clearance, driveshaft ................................. .
idler shaft. ................................ .
Relief valve spring, length under various loads:
unloaded
................................................. .
loaded to 88.3 N (8.83 kp) ............ ... .... .............. .
74
0.1 MPa
0.4 MPa
0 .
025-0.084 mm
0.110-0.185 mm
0 .17-0.27 mm
0.015-0.053 mm
0.015-0.051 mm
89.5 mm
56.5-60.5 mm
(14.2 psi)
(57 psi)
0.0009-0.0033 in
0.0043-0.0072 in
0.0066-0.0106 in
0 .0006-0.0021 in
0.0006-0.0020 in
3 .52 in
2.22-2.38 in

(
70019401960 Specifications
Group 23 Fuel system
CO content , idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or
idle speed
• CO should be checked/adjusted when engine is warm and idling
•
CO content outside check values shown below = adjust to specified setting value
• CO
content within check values need not be adjusted provided engine is operating satisfactorily
Eng
ine Market CO%
type
Adjusting Volvo
(checking) Mono-Tester
B28A 2.5 (2.0-3.5) -
B28E 2.0 (1. 0-3.0)1 -
B28F USA, Canada, Australia 1.0 (0.7-1.3)2 42
° (39-45°)3
Japan 1.0 (0.7-1.3) 2 42° (39-45°)3
1) Pulsair system disconnected and plugged. 2) Lambda-sand disconnected . 3) Lambda-sand connected. 4) AC switched off. Idle speed increases to 15.0 rls (900 r/min) when AC is switched on again .
Section 2 B 28 Engine
\\\\Iffll
rpm
1 35 528
Idling speed
r/s (r/min)
15.0 (900)
15.0 (900)
12.5 (750)4
15.0 (900)
75
II' .. III .. II' ... II' ... II'

70019401960 Specifications
Section 2 B 28 Engine
Carburetted engine (828 A)
Throttle valve marking
SU-HIF 6 carburettor
(0.0079-0.0118 in)
0.5-1.5 mm (0.0197-0.0591 in)
---* ~
Carburettor PIN
Meter ing needle
119943
1.1-1.7 mm t (0.0433-0.0670 in)
SAE 10W-40
(SAE 1 OW-50)
~~
. ==tt
25 mm (0.9850 in)
Max engine speed 20.8-22.5 rls (1250-1350 r/min)
Fuel pump
Fuel pressure measured at same level as pump at 50 rls
(3000 r/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27 kPa (2.1-3.8 psi)
76
6 mm (0.2364 in)

70019401960 Specifications
Section 2 B 28 Engine
CI-SYSTE M (8 28 E , 8 28 F)
Pressures
Line pressure .............. ......................... ........ . 470-550 kPa (67-78 psi)
240-320 kPa (34-45 psi)
Rest pressure ....... .............. ..... .................... .
Control pressure , see graphs .
Contr ol press ure reg ulato r
Type of control pressure regulator fitted to vehicle depends on en­
gine type and
model year. Identification number is stamped in top of
regulator (last three numbers).
Volvo PIN
B28E .................... .
Bosch PIN
... 038
... 099
. . . 128
... 099
269 837-1
1 269779-3
1 336678-6
1
269779-3
B28F 1983 ... ..... ....... .
1984-USA ....... .. .
B 28 F 1984-Canada, Japan
0438 140 ... 134734
CONTROL PRESSURE REGULATOR ... 038
Control
pressure, Warm engine
engine off. . . . . . . . . . . . . . . . . . . . . . . . . ..
305-335 kPa
(43-48 psi)
engine
on . . . . . . . . . . . . . . . . . . . . . . . . . .. 345-375 kPa
(49-53 psi)
Control pressure cold engine see diagram.
Note: Diagram shows control pressure with engine
turned
off.
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-24 0
3.5
3 .0
2.5 250
2 .0 200
1.5 150
1 .0 100
0 .5 50
o 10 2 0 30 40 50 60 70 80 oc 3 2 50 68 86 104 122 140 158 176 of 132 943 /5
CONTROL PRESSURE REGULATOR ... 099
Contro l
pressure, warm engine ........... 345-375 kPa
(49-53 psi)
cold engine . . . . . . . . . . .. see diagram
Resistance,
at temp below 12°C (53 °F) . . . . . . . . . . . .. 31.5-38.5 0
at temp above 18°C (64°F) . . . . . . . . . . . .. 12.6-15.4 0
kp/cm2
kPa FFFffi+flFfFm+R=R=FfFmm+!=FfFl+R
3.5 350
3 .0
300
'2.5 250
2.0 200
1.5 1 5 0
1.0 100
0 .5 50
a 10 20 30 40 50 60 70 BO °C 3 2 50 <C' q 86 104 122 104.... 15 P 176 .. F 13294317
77
lilt III lit III .Iltl III
'II' III lilt

70019401960 Sp~cifications
Section 2 B 28 Engine
Control pressure regulator ... 128 (altitude compensated)
Resistance at temperatures
below 12°C (53°F) ................. . 19.5-21 .70
9.8-11.0 0 above 18°C (64 °F) ................. . kP/cm2 kPa
4 400
3,5 350
3 300
2,5 250
200
1.5 150
10 50 20
68
30
86
(Torr) 835 626 855 641 875 656 895 671 915 686 935 701 955 716 975 731 980 735
Control pressure (cold engine) at different altitudes 137 667
Tolerance: ±25 kPa (0.25 kp/cm2 = 3.6 psi)
Injectors
127 182
Identification number
on side of injector.
Bosch number
0437502022 Volvo PIN 1 269713-2
Start injector
0280170 ...
134 264
kp/cm2 kPa
5 500
4.5 450
4 400
3.5 350
3 300
1013
760
950 900 850 800 750 700 mba,
713 675
638 600 563 525 mm Hg (Dry)
Control
pressure (warm engine) at different altitudes 137668
The above graphs apply to air pressure at sea level and up to altitudes of approx . 600 m = 2.000 It (947 mbar or higher). For
higher altitudes it is necessary to know the prevailing air
pressure to be able to calculate the correct control pressure.
Opening pressure ........... kPa (psi) 350-410 (50-58)
No leakage permissible below ....... 290 (41)
Injection time. (Controlled by thermal timer during cold
starting and by impulse relay during hot starting.)
Cold starting, below +35°C (95°F). Max time (at -20°C
(-4°F), 7.5 secs. The hotter the engine, the shorter the
time.
Hot starting : Engaged after about 1.5 seconds after which:
injection
0 .1 sec-pause 0.3 sec -injection 0 .1 sec-pause 0.3
sec etc.
B28E B28F
Bosch No ................................................. . . ... 404
462865-7
115 cm3/min
... 400
269292-9
165 cm3/min
Volvo PiN .................................................. .
Injected quantity ............................................ .
78