oil type VOLVO 700 1982 Service Repair Manual

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Carburettor
Fuel pump
Clutch
Alternator ,­
Steering box
SU
Pierburg
Solex Pierburg
Bosch
AC- oelco
Sofabex
Fichtel & Sachs
Verto/Valeo
Bosch
Cam Gear
Zahnrad Fabrik (ZF)
~
'?' .'" ... .
.
---
" .. u.·.. ,
2
3
5
2
3
4
5
2
3
1
2
3
6 . Fina l drive ratio , part and seria l numbers
Located on rear axle .
7. Gearbox type des ig nation, part numbe r and
serial num ber
A. Manual : On bottom of gearbox .
B. Automatic:
BW 55,
AW 55/70171 /72: On LH side of gearbox.
AW3Q-43:
On RH side of gearbox.
8 . Body number pla te
Located above left head lamp.
780
70019401960 Specifications
Section
0 General
3
6
8
7 B 143980
9. Engine type des ig nation, serial number an d
part number
A. 024, o24T, o24TIC
Stamped on cylinder block, beneath vacuum pump.
B. B28
Located on plate in front of oil filter . On B 28 ElF en­
gines: a
decal on the right rear side of cylinder head
shows
last three digits of part number.
B280
Stamped on cylinder block. (Some models: decal)
Early
type : between cylinder banks, to rear.
Late type: front right side, between
inlet manifold and
water pump.
__ -G.-819, B 23
I
Stamped on left side of engine, behind distributor. Last
three digits of part number are shown
on transmission
gearcase.
O. B 200, B 230
Located on timing gearcase . Also stamped in left side of
cylinder block.
E. B6403
Decal
on timing gearcase. Also stamped in right side of
cylinder block, above water pump housing , between
timing gearcase and
manifold.
7
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70019401960 Specifications
Section 1 Service and maintenance
Engine oil, capacity, litres (US qts )
Difference
Excl. oil Incl. oil in volum e filter
filter max.-min.
819,823,8200,8230· .................. ................... .
3.35 (3.6)
3.85 (4.1) 1.0(1.1)
8204,8234 ............................ .................... . 3.5 (3.7) 4.0 (4.2) 1.0 (1.1) 86304 ............................................. ........ . 5.0 (5.2) 5.75 (6.1) 1.0 (1.1)
828 ....................................................... . 6 .0 (6 .3) 6.5 (6.9) 1.0 (1.1)
8280 .......................... ............................ . 5.5 (5.8) 6.0 (6.3) 1,0(1.1)
024,024 T, 024 TiC·· ....................... ............... . 5 .0 (5.2) 6 .0 (6.3) 1.0(1.1)
• Turbo: Add extra 0.6 litres if oil cooler is drained . .. Turbo Intercooler : Add extra 0.7 litres (air oil cooler) .
Carburettor
Oil for damper cylinder , 828 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-40 (or SAE 10W-50) Engine oil
8230A................................ ATF
Manual gearbox
Lubricating oil ............................ .................. .
Oil change quantity, M 46, early type -1990 .................... .
late type 1991-..................... .
M
47, early type ...................... . ... .
late type ........................... .
Tightening torque, oil drain
plugs ............................. .
• Volvo Thermo Oil (PIN 1 161 243-9) is recommended for vehicles driven in areas where ambient temperature seldom drops below -10°C (+14°F) , or
high mileage vehicles such as taxis . NOTE! Do not mix oil types .
Automat ic transmission
132414
Lubricating oil AW/8W55, AW70/AW71 -1983 ................. .
AW70/AW 71/AW721AW
30-43/ZF4HP22 ......... .
Oil change quantity (drained only) AW 70, AW 71 lAW 72 ......... .
AW30-43 ................... .
8W55 ............ .......... .
ZF4HP22 ................... . ATF
type F or G
2.3
litres (2.4 US qts)
2.6
litres (2.8 US qts)
1 .3
litres (1.4 US qts)
1.6
litres (1.7 US qts)
27-40 Nm (10-29 ft Ib)
Do not use ATF Oexron as
vibration damper and overdrive
may
slip.
ATF -type G (or F)
ATF type Oexron II 0
3.9 litres (4.1 US qts)
3 .0 litres (3.3 US qts)
3.5
litres (3.7 US qts)
2.0 litres (2.2 US qts)
13
Itt liN
I
III
:1:1:1
I
11.'.1
I
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I

70019401960 Specifications
Section 1 Service and maintenance
Rear axle
134142
Lubricating oil ............................................... .
grade , without limited-slip differential or with
automatic differential lock (Eaton)
............ .
I with limited-slip differential (Dana) .................. .
viscosity , above
- 10 °C (+14°F) ............ ........ .
below
- 10 °C (+14°F) ............ ........ ..
Oil change quantity, 1030 .................................... .
1031, -1990 ............................. .
1031, 1991-.... ......................... .
1035 .................................... .
1041, -1990 .... ......... " .............. .
I
1041, 1991-............................. .
1045 .................................... .
Steering gear
134143
.Lubricant. .................................................. .
quantity
..................... ........ .. ............ .
Power steering fluid .
....................... ................. .
quantity,
828 ................................. .
819,823 ...................... ...... .
8200,8230 .... ...................... .
8280 ................................ .
I 86304 .......... ....... .............. .
D 24, D 24 T
-1986 .................... .
D24,
D24 T, D24 TIC 1987-. .......... .
* Volvo power steering fluid (PIN 1161 317-1 is recommended if temperature
is below -20°C (-4°F).
14 Final
drive oil
API-GL-5(6) or MIL-L-21 05 8(C)
Low -friction oil Volvo
PIN 1161 329-6 0 .5 litrelUS qt
API-GL-5(6) or MIL-L-2105 8(C)
with additive Volvo
PIN 1161129-00.5 litre/US qt
SAE
90
SAE 80
1.3 litres (1.4 US qts)
1.6 litres (1.7 US qts)
1 .75
litres (1.85 US qts)
1.4 litres (1.5 US qts)
1.45 litres (1.55
US qts)
1.6 litres (1.7 US qts)
1 .3 litres (1.4
US qts)
Grease, Volvo
PIN 1161 001-1
approx 100 grams (3.5 ozs)
ATF type
A, F or G*
litres
1.0
0 .8
0.8
0.8
0.8
0.8
0.5
(US qts)
(1.1 )
(0.9)
(0.9)
(0.9)
(0.9)
(0.9)
(0.5)

70019401960 Specifications
Section 2 B 19, 823 Engines
Group 21 Engine block
Cylinder head
Height, new ................................... mm (in) 146.1 (5.756)
min (after machining)
.................... mm (in) 145.6 (5.737)
Max warp ..
.. ..................................... . .
NOTE: If warp is greater than 1 .0 mm (0.094 in) lengthwise
or 0 .5 mm (0.097 in) crosswise, cylinder head must be re­
placed.
Cylinder block
Bore 819 823
Standard C ............................................ .. mm
(in)
D .............................................. mm (in)
E .............................................. mm
(in)
G ........................................... . .. mm
(in)
Oversize 1
...................................... .... .... mm
(in)
2 ..... . -:-......................... ....... ....... mm
(in) 88.9D-88
.
91
(3.5027-3 .5031 )
88 .
91-88.92
(3.5031-3.5034)
88.92 -88.93
(3.5034-3.5038)
88.94-88.95
(3.5042-3.5047)
89 .29-89.30
(3.518D-3 .5184)
89.67-89.68
(3. 533D-3 .5334)
96 .0D-96.01
(3.7824-3. 7828)
96 .01-96.02
(3.7828-3.7832)
96 .02-96.03
(3.7832-3.7836)
96 .04-96.05
(3.7 84D-3 .7844)
96.3
(3.7 942)
96 .6
(3.8060)
Rebore if wear exceeds 0.1 mm (0.004 in) and oil consumption is very high.
Pistons
A = Overall height
8
= From gudgeon (piston) pin to crown
C = Diameter to be measured at right angles to gudgeon pin at
distance
C from bottom of piston.
Engine Weight in gms1 (oz) Dimension mm (in)
type A 8
8 19 E
515±6 (18.4±0.2)
73.9 (2.912) 46.7 (1.840)
8 19
ET 510±6 (18.2±0.2) 71.0 (2.797) 46.0 (1.812)
823E 570±7 (20.4±0.3) 76.4 (3.010) 46.4 (1.828)
823ET 562±7 (19.8 ±0.3) 8.4 (2.657)
46.4 (1.828)
823FT 562±7 (19.8±0.3) 8.7 (2.657)
46.7 (1.840)
1) Max weight difference in same engine = 12 gms (0.43 oz)
Piston running clearance
819 E, 823 E ........................................ mm (in)
819ET .............................................. mm (in)
823 ET, 823 FT ...................................... mm (in)
16
C
7 (0.276)
7 (0.276)
8 (0.315)
12 (0.423)
12 (0.423)
0.01- 0 .04 (0.0004-0.0016)
0 .03- 0.06 (0.0012-0 .0024)
0 .05-0.07 (0.002D-0 .0028)
J
ma x o 25mm
129826
137551

(
70019401960 Specifications
Section
2 B 19, B 23 Engines
Group 28 Ignition system
~
fif!}jJ~
~ 1348~
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8reakerless
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 -4-2
Ig nition sett ing (8.TD.C.)
E ngin e type 12.5 rls 41.7 rls
750 r/min 2500 r/min
819 E* 10 ? 28-33
819 ET* 15° 23-26°
823E* 10° 28-33°
823ET 10°1) -
823FT 12°2) -
• Vacuum unit disconnected. 1) At idle = 14.1 rls (850 r/min) . 2) At 15 rls (900 r/min).
Ignition coil
131753
Resistance of primary coil (terminals 1 and 15) ................ .
B 19 E, B 19 El,
B23E, B23FT
0.6-0.90
6.5-8.5 kO Reistance of secondary coil (terminal 1 to HT terminal) ......... .
Spark plugs, glow plugs
Engine type Designation
PIN Kit numb er
819E, 819ET, 823E W6DC 1 306604-8 273596-7
823ET W7DC 1 306605-5 273597-5
823FT WR7DC 1 346541-4 271 409-5
B23ET
0.50
6.0 kO
Electrode
gap .............................................. .
Tightening torque,
(unoiled plugs) ............................. . 0
.
7-0.8 mm (0.0276-0.0315 in)
25 Nm (18
ft lb.)
Knock sensor
II 146804
Tightening torque, type I ............................ ......... . 11 Nm (8 ft lb.) type 11. ................•..•.....•........... 20 Nm (14.5 ft lb.)
33
III '111 III III III ·111 III ,11' III

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70019401960 Specifications
Section
2 B 200, B 230 Engines
Bea rings
Main bearings
Two types of main bearings are in use. Upper and lower
shells
on same journal must be same type.
Connect
ing rod bearings
Matched
shells are used in production:
Shells are colour -coded (red, blue, yellow) as follows:
136753
Assembly 1 Two yellow shells.
Assembly
2 One blue and one red.
Blue shell in con-rod and red in cap.
Colour code Note that only yellow-coded shells are kept in stock .
• Late type: also main bearing shells .
Connect ing rods
Axial clearance at piston ............................... mm (in) 0.15-0.45 (0.0059-0.0177)
Max weight deviation between connecting
rods
in same engine ................................. gms (oz.) 20 (0.7)
Flywheel
Axial throw, max ...................................... mm (in) 0.021100 diameter (0.0008/3.9400)
Tightening torque data
The tightening torques apply to oiled nuts and bolts.
Oegreased
(washed) parts must be oiled prior to use.
Main bearing
............................................... .
Connecting
rod bearings', step 1 ............................. .
step 2
............................. .
Flywheel/carrier plate (use new bolts) ...................... ... .
Spark plug (do not oil) ....................................... .
Camshaft gear
.............................................. .
Intermediate shaft gear, B 200/230 ............................ .
Camshaft cap
.............................................. .
Crankshaft, centre
bolt pulley, step 1 .......................... .
step 2 .
.. ....................... .
8204/234
Reinforcing strut ............................................ .
Camshaft -
idler pulley ...................................... .
Camshaft -tension
roller .................................... .
Balance shaft housing, assembly on bench .................... .
Balance shaft housing, installation, stage 1 .................... .
stage 2
.................... .
stage 3
.................... .
stage 4
.................... .
Balance shaft pulley ......................................... .
Balance shaft -tension roller .. ............................... .
Crankshaft
pulley, stage 1 .................................... .
stage 2
.................................... .
• Bolts can be reused provided length does not exceed 55.5 mm (2.187 in)
Nm
110
20
angle-tighten 90°
70
25
50
50
20
60
angle-tighten 60°
25
25
50
5
20
Slacken
10
Angle-tighten
90°
20
50
60
Angle-tighten 60°
ftlb
80
14
51
18
37
37
15
43
18
18
37
35
18
7
15
48
44
41
III :11' III II, III 'III III ,11' III

700/940/960 Specifications
Section 2' 8200,8230 Engines
Group 25 Intake and exhaust systems
Turbo engines
'-198~
Engine type .... ; ......... . , ............ .. .............
Charg~ pressure, at full load and ................... r/min
checking
.. ................... kPa (psi)
setting. . . . . . . . . . . . . . . . . . . . .
.. kPa (psi)
Charge air overpressure, switch opens at ....... kPa
(psi)
Charge air pressure, switch closes at ........... kPa (psi)
Tightening torques
4) 18 Nm (13 ft IW)
/
1) Apply sealer PIN 1 161 053-2. 2) Use new nuts
3) Use sealer PIN 1161 035-9.
8200/230 ET
3500
45-53 (6.4-7.5)
50 (7.1)
65-75 (9.2-10.7)
15-25 (2. 1-3.6)
3)
4) Use new boils. If absolutely necessary, old boils can be reused if they
are smeared with sealer PIN 1161053-2.
Mounting bolts, turbocharger -exhaust manifold
• Measure length of bolt. Bolts can be reused if shorter
than
89 mm (3.5 in)
• Apply assembly paste PIN 1 161 078-9 to mating sur-<=;==;=""-~
faces and threads
• Fit new locking plates
•
Tighten bolts in three stages according to below
64
Stage I = 1 Nm (0.7 ft Ib)
II = 45 Nm (33 ft Ib)
III = 45° in one motion without stopping
89mm
135780
~Nm
s::L).Nm
8230FT
3000
46-54 (6.5-7.7)
48-54 (6.8-7.7)
85-95 (12 .1-13.5)
-
136772

70019401960 Specifications
Section
2 B 200, B 230 Engines
Group 28 Ignition system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breakerless
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
E
ngine Ignition
type timing
b.t.d.c.
B200K 15°
B200F .12°
B200E 12 °
B200ET 14°
B204E 15°
B204FT/GT 10°
B230A* 7°
B230K 15°
, Vacuum regulator disconnected . '* Japan -1988: 15 rls (900 rpm).
Speed rls
(rpm)
12.5
(750)
12.1- 13.8 (725-825)
14.2 -15.8
(850-950)
14.7-15.3 (880-920)
14.2-15.8 (850-950)
13.0-13.7 (780-820)
11.7-13.3 (700-800)
13.3 (800)
''* Ignition system Rex, USNCanada : 10°.
Ignition coil
Engine Ignition
type timing
b.t.d.c.
B230E 12°
B230ET 10°
B230F -1988 12 °
1989-12°***
B230FB 12 °
B230fT/GT 12°
B234F/G 15°
B200E,B200K,B230E
B 230 F, B 230 FB, B 230 K,
Speed rls
(rpm)
14.2-15.8
(850-950)
14.7 -15.3 (880-920)
12.2 -12.8 (730-770)* '
12.1-13.8 (725-825)
12.9 (775)
12.2 -12.8
(730-770)* *
13.3-15.0 (800-900)
B200ET,
B230ET B230F
131 7~1 B230A B 230 FT, B 204 E, B 204 FT/GT, Rex
B234 FIG
Resistance of primary coil (terminals
1 and 15) .................................... . 0.6-0.90 0.6-0.80 0.50 0.50
Resistance of secondary coil
(terminal
1 to HT terminal ...................... . 6.5-8. 5 kO 6 .9-8.5 kO 6 .0 kO 5 .0 kO
Knock sensor
II 146804
Tightening torque, type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (8 ft Ib)
type 11......... ............................. 20 Nm (14.5 It Ib)
67
I
I
I
til' ·ut til, til lit ·
t''''' '111 lit

I
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I
70019401960 Specifications
Section 2 B 200, B 230 Engines
Spark plugs, g low plugs
I~~n
~ 143983
E ngin e type Designation Type I Type II
P
IN Se t number PIN Set number
B 200 K, B 200 ET, B 200 F,
B 230 A, B 230 K -1986, B 230 ET WR7DC " 1 306605-5 273597-5
1 367528-5 270 746-1
B 200 E, B 204 ElFT/GT, B 230 K
1987-, B
230 E, B 234 FIG WR6DC** 1 306604-8 273596-7 1 367529-3 270 747-9
B
230 F, B 230 FB, B 230 FT/GT WR7DC 1 346 541-4 271 409-5
1 367528-5 270 746-1
B 230 FT Europe WR6DC 1
367015-3 271 415-2
1 367529-3 270 747-9
• Type II spark plugs are standard on B 200/230 -1988-but can also be used on earlier engines (provided HT leads and ground lead are replaced at same time) . .. Up to 1987 W7DC (W6DC, type I).
Electrode gap .............................................. . 0.7-0.8 mm (0.0276-0.315 in)
25 Nm (18 ft Ib) Tightening torque, (unoiled plugs) ............................. .
Distributor
E ngine type Ignition system
B200E, B230K EZ-K
B
230 E, B 230 F -1988, B 230 FT
-1989
EZ- K
B200K Renix
B200F EZ 116 K
B
230 F 1989-, B 230 FB,
B 230 FT/GT 1990 EZ 116 K (Rex ')
B 200 ET , B 230 ET Motronic
B230A TZ-28 H
B
204 E/FT/GT, B 234 FIG EZ 116 K
'USA only
Centr ifugal governor
Advance, total degrees (distributor) . . . . . . . . . . .. 12,5± 1
Advance begins at distrib. rev/sees ............ 7.5-10.5
distrib . rev/min. . . . . . . . . . . .. (450-630) Data : 5° at distrib . rev/sees . . . . . . . . . . . . . . . . .. 16 .5-20.5 (distrib. rev/min) . . . . . . . . . . . . . . . . .. (1000-1250) 10° at distrib . rev/sees . . . . . . . . . . . . . . . . .. 25-29 (distrib . rev/min) .................. (1500-1750)
Advance max at distrib. rev/sees .............. 31.7
(distrib. rev/min) . . . . . . . . . . . . .. (1900)
Vacuum governor
Control direction ............... .. ........... . Control, total degrees (distributor) .......... .. . Control commences at mm Hg ............... .
Data : 5° at mm Hg . .. ....................... .
max control at mm Hg ........ .... ..... .
68
Positive
7.5±1 105-145
165-210
240
Distributor
Volvo PIN Bosch No
1
336087 0237502001
1 336087 0237502001
1 336 132 0237502002
1 336132 0237502002
1 336 132 0237502002
1 336 132 0237502002
1 336690 0237024013
1 367197 0237502003
Ignition advance, B 230 A
~.
rrr~,o , 2p , 3,0 , 4 ,0 , 5,0 , 6,0~;;. + l ' 0 500 1000 1500 2000 2500 3000 3500 4000 rl min
40.20"~mm Wmfmm ~mmfffi=mmm
o· Ii'
-10' -ft '0237 0 24 013
10 20 30 iii 100 200 40 50 60 kpa 3bo i 460 j mm iHg
13 6780
i

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