VOLVO 940 1982 Service Manual Online

(
Thermal time switch
-20° C 7,5sek
135562
Cut-out temperature and engagement time are
stamped on side
of switch.
Aux iliary air valve, B 28 E
(828 E without constant idle speed system) .
0280140 ... 134740
Air flow sensor
70019401960 Specifications
Section
2 B 28 Engine
Sec
8
6
4
2
- .20 - 4 -10 14. o 32 10 50 20 68 30 86 ° C of . 134739
Engagement time at different temperatures
Tolerance, time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ±2 secs
temperature . . . . . . . . . . . . . . . . . . . . . . .. ±4°C (7.2 °F)
Various types of auxiliary air valves with different
apertures are
used. Make sure that the correct valve is
fitted .
Identification number
on side of valve .
Bosch No
Automatic, early type. . .. 114
late type .. . .. 114
Manual ................ 110'
Volvo PIN
1 266910-7
1 346477-1
1
269319~8
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40--60 0
Fully open at. . . . . . . . . . . . . . . . . . . . . . . . .. -30°C (-22°F)
Fully closed at. ............ '. ' . . . . . . . .. + 70°C (158 °F)
The auxiliary air valve is controlled electrically and should
be fully closed after 5 minutes driving at +20°C (68 °F), am­
bient temperature.
Metering disc rest position. Carry out check at maximum
control pressure (i.e. hot engine, fuel pump running).
79

70019401960 Specifications
Section 2 B 28 Engine
Fuel pump
&
Bosch No
828 E, early type . . .. . .. 963
late type ......... 948
0580254 ... 828 F ................. 948
138069
Capacity at 500 kPa (71 psi), 20°C = 68°F and:
12V ...................................... ............. .
11 V .. .. ............................................... .
10V ........... ................. ....................... .
Current consumption max
......................... ........ .. . .
Tank pump
120 litres/hour (1.0 litres/30 secs)
96 litres/hour
(0.8 litres/30 secs)
75 litres/hour (0.6 litres/30 secs)
max 9.5
A
Volvo PIN
1 306028-0
1 336677-8
1 336677- 8
Current consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 A
80

70019401960 Specifications
Section
2 B 28 Engine
CONSTANT IDLE SPEED SYSTEM (CIS) (828 ElF)
Control unit
0280220 ...
136607
Temperature sensor
0280130 ... 135791
80sch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 028
Volvo PIN ............................... 1 306 024 -9
Resistance at:
-10°C (14°F) .... ................. 32000-530000
+ 20°C (68°F). . . . . . . . . . . .. . .. . . . . .. 8500-11 500 0
+ 80°C (176 "F) . . . . .. . . . . . . . . . . . . . . . .. 770-1 320 0
Air control valve
Type of control unit fitted to engine depends on engine
type. Identification number
is stamped on side of cover.
Bosc h No
828 E, early type . . . . . .. 00 8
late type . . . . .. . .. 020
828 F ................. 00 8
ohms 100000 80000 60000
40000 30000
20000
10000 8000 6000
I\..
"I\..
~
" "-
'" "-
Vo lvo PIN
1 274452-0
1 274711 -9
1
274452- 0
4000 3000
2 000
"
1000 800 600
400 -10 0 14 32 20 40 68 104
I" ........ .........
60 80 100 "c 140 176 212 "F
133374
Type of valve fitted to engine depends on engine type.
Identification number
is stamped on side of valve.
Bosc h No
828 E ... .............. 501
828 F, early type . . . .. . .. 500
late type. . . . .. . .. 501
Resistance between terminals 3 and 4,
Vo lvo PIN
1 317957-7
1 276 871-9
1
317957- 7
5 and 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. approx 20 0
81
Itl It III It III ·It III · It III

70019401960 Specifications
Section
2 B 28 Engine
Group 25 Intake and exhaust systems
LAMBDA-SOND SYSTEM (B28F ONLY)
Control unit
135 202
Lambda-sond
82
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 050
Volvo PIN ............................... 1 274368-8
Duty cycle
disconnected sand. . . . . . . . . . . . . . . . . . . . . . . . .
42-48°
grounded thermal switch . . . . . . . . . . . . . . . . . . .. 51-57°
grounded microswitch* ..................... 51-57"
grounded pressure differential switch .......... 82°~
* B 28 F USA 1983 models designed for high altitude use:
microswitch must be disconnected at all times.
Bosch No . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 037
Volvo PIN ..................... .......... 1 274367-0
Tightening torque. . . . . . . . . . . . . . . . . .. 55 Nm (40 ft Ib)*
* Apply 'Never-Seez' PIN 1 161 035-9 to entire thread length.

(
General
70019401960 Specifications
Section
2 B 28 Engine
Group 26 Cooling system
128187
Coolant -composition -guarantee
Since aluminium is used in the engines, active corrosion
protection is necessary
in the coolant to help prevent corro­
sion damage .
Use genuine
Volvo coolant, type C (blue-green ) diluted
with clean water in proportions of 50/50. This mixture helps
to prevent corrosion and frost damage.
• Never top-up the cooling system with water alone. Use
genuine
Volvo coolant diluted with clean water in propor­
tions of
50/50.
•
The coolant should be changed every 25,000 miles
(40,000
km) since the corrosion-protective additives in
the coolant lose their effect in time.
• Clean cooling system with solvent (P/N 1161328-8)
prior to
filling new coolant.
litres
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0
US qts
10.5
Expansion tank
Pressure valve in cap opens at:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kPa
overpressure, early type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
late type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0
Thermostat
Marking .................................................... .
Starts opening
at. ........................................... .
Fully open at ............................................... .
Fan belts
Designation, type 1 ..... : ................................ .... .
type
11. ..................•......•................
type III (not B 28 F USA) ......................... .
92
91-93°C (196-199°F)
102°C (216°F)
HC 38 x 1100
HC 38 cog x 1100
HC 38 cog x 1075
psi
11
21
1.0
83
til ·tt til II III '11 III ·tt II'

70019401960 Specifications
Section
2 B 28 Engine
Group 28 Igni t ion system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breakerless
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 -3-5-2-4
E ngin e-
Ignition timing Spee d rls
type b.t.d.c .
(rpm)
8 28A*
10° 11.7 -13.3 (70D-800)
8 28 E* 10° 11.7 -13.3 (70D-800)
828F* 23° 41.7 (2500)
* Vacuum regulator disconnected.
Ig niti on coil
/
Resistance of primary coil
(terminals
1 and 15). . . . . . . . . . . . . . . . . . . . . . . . . .. 0.5 0
Resistance of secondary coil
(terminal
1 to HT terminal) . . . . . . . . . . . . . . . . . . .. 9.5 kO
Spark plugs , glo w p lugs
E ngin e type D
es ign ation
B28A, B28E, B28F HR6DC
1317S3
PIN
1269915-2 Kit
number
273599-1
Electrode gap .............................................. .
Tightening torque,
(unoiled plugs) ............................. .
0.6-0.7 mm ((0.0236-0.276 in)
12 Nm (9 ft Ib)
84

70019401960 Specifications
Section
2 B 28 Engine
Distributor
Eng ine type Ignit ion system Distributor
Volvo P IN Bosch No
B28A, B28E TSZ-4 1269191 0237402013
B28F TSZ-4 1269380 0237402017
B28A, E B28F
Bosch number ............... ............................... . 0237402013 0237402017
Volv o PIN ................................................... . 1
269 191 1 269380
Direction of rotat ion ............................ ... .......... . Clockwise
Clockwise
Resistance of impulse sender coil, [2 .........•................. 540-660
540-660
Air gap, rotor -stator , min ............. ...................... . 0.3 mm 0.3 mm
Centrifugal governor
Advance, total, degrees (distributor) ........ ................... .
Advance
begi ns at distrib. rev/sees ............................ .
distrib. rev/min
............................. .
Data:
5 ° at distr ib. rev/sees .............................. _ ... .
'III 13±1
11±1 '" III 7.fr-9.6 8.fr-10 ttl
(450-575)
(500-600) :':':': 12.fr-15.4 12.4-15.3 I'NI
(distrib. rev/min) ................................. . (750-925)
(740-920)
10° at distrib. rev/sees .................................. . 23.3-32.5 30-50
(distrib. rev/min)
................................. . (1400-1950)
(1800-3000)
Advance max at distrib . rev/sees ... .......................... . 40 33 .3
(distrib. rev/min)
............ ................. . (2400)
(2000)
Vacuum governor
Control direction ............................................ . Positive
Positive
Contro l, total
degrees (distributor) ............................. . 7,5±1 10±1
Control
commences at mm Hg ............................... . 160-210 10fr-135
Data: 2° at mm Hg ......................................... . . 200-240 11 fr-145
max control at mm Hg .................................. . 300 210
Ignition advance
60-~O , I
I I
I I I I ,. I
I I
I , .tls 0 500 1000 1500 2000 2500 3000 3500 4000 r min
~ !=ttl-It ~~ 30' 15'
.,r~'
1 G~ 2,0. 3.0 , 4,0 , 5,0 I 6,0~~, 40~ 2Cf~ 50~ l~OO 1500 2000 2500 3000 3500 4000 rjmin
20' 10 + ~ IT , 1{,llrD ,I=±' -~ --+;r -IT ~I -' I=l=l-~ I 1-
f:=:t 17/ 1-,+-1 ~ -+
ffi rtt~ . -I-t--
Mo237 402 013 +r
0 ' cf'
- 10 ' -s
0' if
-10' -s 0237402017 -20' -10
0 10 20 30 40 50 60 kpa I I
I I I I I I I I I 0 100 200 300 400 mmHg o 10 20 30 40 50 60 kpa iii i I Iii a 100 200 JOD 400 mm Hg 135969 135356 B28A, B28E B28F
85

70019401960 Specifications
Section 2 B 280' Engine .
Section 2 B 280 Engine
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Group
21 Engine..... ................. .......... 87
Group
22 Lubricating system. . . . . . . . . . . . . . . . . . . . .. 92
Group
23 Fuel system ........................ ... 93
Group
26 Cooling system ......................... 96
Group
28 Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 97
Group 20 General
Performance , compression ratios, octane requirements
Engine Compression Octane
type ratio
requirement
kW'a t
rls
B28 0E
Sca ndinavia 10.0:1 Min 951
) 115/88
B280 E r
Other markets 10 .0:1 Min 951
) 125/90
B280 F 9.5:1 Min 912
) 108/85
1) Unleaded fuel can be used 2) Unleaded fuel only 3) Horse power 4) Ft lb.
Other general data
Number of cylinders ................. ........................ .
Bore
.. ............................ ......................... .
Stroke ............................................... ...... .
Displacement
............................................... .
Firing order .
.................................. .' ............. .
Compression (normal
niting)l) ................................ .
Weight, approx ..
.................. ......................... .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
86
Output
hp at
r/min
156/5250
170/5400
147/5100
145/5100
3
6
91 mm (3. 582 in)
73 mm (2.874 in)
2.849 dm3 (Iitres)
1 -6-3-5-2-4
Nm at
rls
245/53
240175
235/63
0.8-1 .1 MPa (114-156 psi)
150
kg (330 Ib)
IL ~
j.
~ 1'
129 750
Max torque
kpm at
rlmin
25.0/3200
24.5/4500
24.0/3750
173/37504

(
70019401960 Specifications
Section
2 B 280 Engine
Group 21 Engine block
Cylinder head
Max warp:
Maximum warp is 0.05 mm (0.002 in) per
100 mm (4 in) length.
I
[
Note: Do not level a warped cylinder head,
replace it!
n~Ql;J 129860
Cylinder liners
Bore liners marked 1 (A-marked piston) ........................ .
2 (B-marked piston) ....................... .
3 (C-marked piston) ....................... .
Liner height above
block face ................................. .
Shims for adjustment of liner height:
thickness, orange paint marking
............................ .
white paint marking
.............................. .
blue paint marking ............................... .
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
0.14-0.21 mm
0 .098-0.134 mm
0.118-0.154 mm
0.138-0.194 mm
6 grams
0.070-0.090 mm
90.920-90.930 mm
90.930-90.940 mm
90 .940-90.950 mm
(3.5826-3 .5830 in)
(3.5830-3.5835 in)
(3.5835-3.5838 in)
(0.0055-0.0083 in)
(0.0039-0.0053 in)
(0. 0046-0.0061 in)
(0.0054-0.0076 in)
(0.0028-0 .0035 in)
(3.5822-3.5826 in)
(3.5826-3.5830 in)
(3.5830-3.5834 in)
((0)) t
~ ~~ Piston diameter is measured at right-angles to gudgeon pin bore, 13 mm (0.512 in) from bottom edge.
135676
Piston rings
Side clearance (measured with ring on piston) .. ............ . mm
Ring gap measured 13 mm (0.51 in)
from
lower edge of cylinder
Upp er Lower Oil ring
com pres-compres-
sion ring sion ring
0.045-0.
074
0.025-0.054 0.009-0.233
in
Ring gap when checked in 91 mm (3.5826 in)
. 0.0017-0.0029
0.0009-0.0212 0.0003-0.0091
(cylinder,
see fig) ..................................... .... mm
Gudgeon (piston ) pins in
0.40-0.60 0.40-0.60 0.40-1.45
0.0157-0.0236 0.0157-0.0236 0.0157-0.0570
Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007-0.017 mm (0.0003-0.0007 in)
87
"' lit ill lit ·,11 tit ill, til Itil

70019401960 Specifications
Section 2 B 280 Engine
Valve system
Valve clearance
Inlet valves, cold engine ..................................... .
warm engine
................................... . .
Exhaust valves, cold engine
.................................. .
warm engine
................................. .
Valves (sizes in mm)
44,5°
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)
7,973-7,995
7,965-7,980
45,3
129851
Inlet valves Exhaust valves
Valve guides
18-22mm 20-24mm
'·Il'I====JI, '·':1 ~:J' 141 RClfj 130021
Seat for Inlet valve
Seat for exhaust valve
When replacing valve seats: the interference between the valve seat and its bore in the cylinder head shall be 0.136-0.200 mm (0.0054-0.0079 in), i.e. valve seat diameter must be 0.136-0.200 mm greater than the diameter of the bore in the cylinder head .
Valve seats are available in three oversizes .
Valve guides
Inner diameter .............................................. .
Press-in measurement to cylinder head contact surface against
block: inlet .
.................................................... .
exhaust
........................... ....................... .
Clearance
in cylinder head ................................... .
88
8.000-8.022 mm
46-47 mm
36.9-37.9 mm
0.053-0.098 mm
(0.3149-0.3158 in)
(1.8124-1.8518 in)
(1.4527-1.4921 in)
(0.0020-0 .0037 in)