VOLVO 940 1982 Service Repair Manual

(
Cylinder block
Bore
Standard (marked C)
........................... ....... mm (in)
(marked
D) ........... ....................... mm (in)
(marked
E) .................................. mm (in)
(marked
G) ................... . .............. mm (in)
Rebore if wear exceeds 0.1 mm and oil consumption is abnormally high.
Pistons
Piston diameter
Diameter to be measured at right
angles to gudgeon pin and
16 mm from bottom of piston.
Standard (marked C)
.................................. mm (in)
(marked
D): ................................ . mm (in)
(marked
E) .. , ........................ ....... mm (in)
(marked
G) ............ ...................... mm (in)
Piston weight
.......................................... g (oz)
Max weight difference between pistons in same engine
......... g
Piston rings
Axial clearance in piston groove ............................ mm
in
Ring gap (measured in cylinder, bore 83.00 mm) ............. mm ? in
Gudgeon (P iston ) pins
Fit in connecting rod ......................................... .
in piston
................................................ .
Valve system
Hydraulic
Valves
Length inlet ...... .................................... mm (in)
exhaust
.............. ......................... mm (in)
Matching surface
angle .................................. .... 0
Edge height, new valve ................................ mm (in)
min after machining .
...................... mm (in)
Max machining of
valve stem ................ ........... mm (in)
Valve Seats
Diameter standard .................................... mm (in)
oversize
.... ................................ mm (in)
Matching surface
angle .......................... ............ 0
Reduction angle, upper ...................................... 0
lower ................. ....... .............. 0
Width ...................................... ... ...... mm (in)
70019401960 Specifications
Section 2 B 6304 Engine
83.00-83.01
83.01-83 .02
83.02-83.03
83.04-83.05
82.98--82.99
82.99--83.00
83.00-83.01
83.02 -83.03
350
± 5
10
(3.2677-3 .2681 )
(3.2681-3.2685)
(3.2685-3 .2689)
(3.2693-3.2697)
(3.2669--3.26 7
3)
(3.2673-3.2677)
(3.2677-3.
2681 )
(3.2685-3.2689)
(12.5 ±
0.2)
(0.4)
Upper
camp. rings
0.05-0.085
0.0020-0.0033
0.2-0.4
0.008--0.016
Lower
camp. rings
0.03-0.065
0.0012-0.0026
0.2-0.4
0.008--0.016
Oil scraper
ring s
0.02-0.055
0.0008 -0.0022
0.25-0.5
0.009--0 .020
Light thumb pressure (close running fit)
Thumb pressure (push fit)
104.05±0.18
103.30±0.18
45.5
1.5
1.2
0 .4 (4
.
096±0.007)
(4.067±0. 007)
(0.059)
(0.047)
(0.016)
inl et exhaust
32.61 (1.284) 28.61 (1.126)
33.11
(1.304) 29 .11 (1.146)
45.25 45.25
20.25 15.25
60.25 60.25
1.4-1.8 (0.055-0.071) 1.8--2.2 (0.071-0.087)
99
Itl
It
Itl
.... 1 '11 Itl ... Itl

70019401960 Specifications
Section 2 B 6304 Engine
Valve Guides
Diameter standard .................................... mm (in)
oversize 1
................................... mm (in)
oversize 2
...................... ............. mm (in)
Clearance, valve stem-guide (measured with new valve) ... mm (in)
Min .
................................................ mm (in)
Valve Springs
External diameter ..................................... mm (in)
Internal diameter ...................................... mm (in)
Length at
270 ± 15 N ................................. mm (in)
Length at
670 ± 32 N ................................. mm (in)
Timing gear
Cams haft
Marking
Inlet ..................................................... .
Exhaust
.................................................. .
Max
lift height ................... ..................... mm (in)
Axial clearance ....................................... mm (in)
Crankshaft assembly
Crankshaft
Max out-ol-true ...................................... . mm (in)
Axial clearance ....................................... mm (in)
Radial clearance (main bearings) ....................... mm (in)
Main bearing journals
Diameter ............................................ mm (in)
Out-ol-round, max
.................................... mm (in)
Connecting rod bearing journ als
Diameter ................................... ......... mm (in)
Out-aI-round, max
.................................... mm (in)
Connecting rods
Axial clearance at crankshaft ........................... mm (in)
Tightening torques
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must
be oiled prior to assembly.
Cylinder
head (stage 1) .............................. Nm (ft Ib)
(stage 2) .............................. Nm (ft Ib)
(stage 3) angle -tightening ....................... 0
Bolts should be tightened in sequence Irom center towards ends .. .
Middle section M 10 (stage 1) ........................ Nm (ft Ib)
M 10 (stage 2) ........................ Nm (ft Ib)
M 8 (stage 3) ........................ Nm (It Ib)
M 7 (stage 4) ........................ Nm (It Ib)
M 10 (stage 5) angle -tightening ................. 0
Bolts should be tightened in sequence Irom center towards ends.
100
inlet
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
27.90±0.20
20.10±0.20
34.00
24.50
PC I
PC E
9.00 0.05-0.20
0.004
0.08-0.19
0.024-0.047
65.00 0.004
50.00 0.004
0.15-0.45
20
60 150
20±2
45±4
24±4
17±3
90
exhaust
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
(1.098±0.008)
(0.791 ±0.008)
(1.339)
(0.965)
(0.354)
(0.002-0.008)
(0. 00016)
(0.003-0.0075)
(0.00094-0.0019)
(2.559)
(0.00016)
(1.969)
(0.00016)
(0.0059-0 .0177)
(15)
(44)
(15±1.5)
(33±3)
(18±3)
(12±2)

(
Connecting rod bearing caps (stage 1) ................ Nm (ft Ib)
(stage 2) angle-tightening ......... 0
Crankshaft pulley (vibration damper), center bolt ........ Nm (ft Ib)
Flange bolts, vibration damper (stage 1) ............... Nm (ft Ib)
(stage 2) angle-tightening ........ 0
Driver plate (stage 1) ......................... ....... Nm (ft Ib)
(stage 2) angle-tightening ......................... 0
Camshaft wheel. .................................... Nm (ft Ib)
Tensi oning pulley, camshaft timing belt ................ Nm (ft Ib)
Damper unit, camshaft timing belt ..................... Nm (ft Ib)
Angle pulley, camshaft timing belt ..................... Nm (ft Ib)
Water pump ........................................ Nm (ft Ib)
Pin bolts, exhaust manifold (in cylinder head) ........... Nm (ft Ib)
(to front pipe) .............. Nm (ft Ib)
Oil sump pan ....................................... Nm (ft Ib)
Plug, oil sump ...................................... Nm (ft Ib)
Oil suction line ...................................... Nm (ft Ib)
Oil cooler, connector block ........................... Nm (ft Ib)
Oil trap ............................................ Nm (ft Ib)
Nipple, oil·filter ...................................... Nm (ft Ib)
Oil pressure switch .................................. Nrn (ft Ib)
Impulse sensor ..................................... ~~m (ft Ib)
Knock sensor ....................................... Nm (ft Ib)
Temperature sensor, rear edge of top cover ............ Nm (ft Ib)
Temperature sensor, thermostat ............... ....... Nm (ft Ib)
Plug, O-adjustment tool .............................. Nm (ft Ib)
Spark plugs ... ..................................... Nm (ft Ib)
20
90
300±30
35
60 45
50
20±2
39±5
24±4
24±6
17±3
20±3
35±5
17±3
38±5
17±3
17±3
15±2.5
40±2
40±5
8±2
20±2
20±2
10±2.5
38±6
25
Group 22 Lubricating System
Genera l
Oil fill volume and type, see p. 12.
Oil pressure with warm engine and new oil filter :
at 12,5 rls (750 rim), at least ....... ................ Mpa (psi) 0.1
at
50 rls (3 000 rim), at least ....................... Mpa (psi) 0.3
max
...................... ....................... Mpa (psi) 0.5
Lubricat ing oil pump
Relief valve spring, length under various loads
unloaded
.................... ....... mm (in)
loaded to 52±4 N (5.2 kp) ....... .... mm (in)
loaded to 85±8 N (8.5 kp) ........... mm (in)
82.13
56.1
39.9
70019401960 Specifications
Section 2 B 6304 Engine
(15)
(221 ±22)
(26)
(33)
(15±1.5)
(29±4)
(18±3)
(18±4)
(13±2)
(15±2)
(26±4)
(13±2)
(28±4)
(13±2)
(13±2)
(11 ±2)
(29±1.5)
(29±4)
(6±1.5)
(15±1.5)
(15±1.5)
(7±2)
(28±4)
(18)
(14)
(43)
(71 )
(3.233) (2.21)
(1.57)
101
I ..... ' '.','
"' ,III III ill u,1

70019401960 Specifications ./ " ' "."--Section 2 B 6304 Engine
Group 23 Fuel System
CO content , idle speed
Check values for CO content. ............................... % 0.4-0.8
12.5 (750) Idling speed ............................ ......... .... rls (rim)
CO content and idling speed can not be adjusted , only checked. Shift
selector
to be in position P when checking.
150362
o 280 160 ... 145 789
t o 280 150 ...
145677
102
Motronic 1.8
Control unit
Bosch number ....................... . 0261 200362
Volvo part number. . . . . . . . . . . . . . . . . . . . . . . 3 517 623-9
Air mass meter
Bosch number ...................... " 0 280 213 012
Volvo part number ....................... 3517569-4
Resistance:
between
terminals 2 and 3. . . . . . . . . . . . . . . .. 2.5-4 0
Pressure regulator
Early type
Bosch number . . . . . . . . . . . . . . . . . . . . . .
.. 0 280 160 294
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 3 517 064-6
Line pressure ..................... " 300 kPa (4 3 psi)
Late type
Bosch number . . . . . . . . . . . . . . . . . . . . . . ..
0 280 160 731
Volvo part number ..................... .. . 3547653
Injector
Bosch number . . . . . . . . . . . . . . . . . . . . . . .. 0 280 150 762
Volvo part number ....................... 3517572-8
Injected quantity . . . . . . . . . . . . . . . . . . . . . .. 185 cm3/min
at line pressure .................. ... 300 kPa (43 psi)

150426
(
1456BB
70019401960 Specifications
Section 2 B 6304 Engine
Idling valve
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . 0 280 140 527
Volvo part number ....................... 3517886-2
Resistance:
between
terminals 1 and 3. . . . . . . . . . . . . . . . . . .. 25 D
Throttle position sensor
Bosch number . . . . . . . . . . . . . . . . . . . . . . .. 0 280 122 001
Volvo part number ............... ......... 1 336385-8
Speed and position sensor
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 389 254-2 .... ,1
,'.'.I ,',', ·111
Camshaft sensor
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 232 101 009
Volvo part number ....................... 1 383966-7
Knock sensor
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . 0 261 231 006
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367 644 -0
103
' .... 1

70019401960 Specifications
Section
2 B 6304 Engine
I
150425
o 580 464 ...
145791
145792
Sil
104
Temperature sensor, coolant
SWF number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 601.605
Volvo part number ....................... 1 362643-7
Resistance
at:
O°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 300 0
+ 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 800 0
+ 40°C (104°F) . . . .. . . .. . .. . .. . . . . . . . . . .. 1 200 0
+ 80°C (176°F) . . . . . . . . . . . . . . . . . . . .. . . . . . .. 300 0
+100°C (212°F)
............................ 1500
See diagram for other values
Lambda-sond
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 280 003 119
Volvo part number ....................... 3531 251-1
Resistance
in preheating resistor:
cold sand, 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . .. 3 0
hot sand, above 350°C (660°F). . . . . . . . . . . . . . . . .. 13 0
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55 Nm
(40 ft Ib) Apply 'Never-Seez', Volvo part number 1 161 035-9, to
entire thread
length.
Fuel pump
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 580 464 039
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 389449-8
Pump capacity at 300 kPa
(43 psi) and +20°C (68°F):
-12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 130 lit res/hour
(1.1 litres/30 secs)
-11 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 108 litres/hour
(0.9 Iitres/30
secs)
-10 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 86 litres/hour
(0.7 litres/30
secs)
Current consumption
at line pressure
300 kPa (43 psi), +20°C (68°F) and 12 V:
max ................................ ....... 6.5 amp
Tank pump
VDO number. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 92151034
Volvo
part number ....................... 3501 928-0
Current consumption . . . . . . . . . . . . . . . . . . . . . .. 3-4 amp
Fuel filter
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. a 450 905 601
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 389 450-6
Filters particles
down to . . . . . . .. 0.002 mm (0.00008 in)
Tightening torque . . . . . . . . . . . . . . . . . . . . . .
.. 20-35 Nm
(15-26 ft Ib)

148680
( 150599
150432
70019401960 Specifications
Section 2 B
6304 Engine
Main relay
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 323592-4
Relay , fuel pump
Volvo part number . . . . . . . . . . . . . . . . . . . . . .. 1 362 914-2
Relay , e lectric cooling fan
Volvo part number. . . . . . . . . . . . . . . . . . . . . . . 1 523872-4
105
III II III
iii ,II lit ,II lit

70019401960 Specifications
Section 2 B
6304 Engine
General
Group 26 Cooling System
128187
General
Coolant-com position-warranty
Since aluminum 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 and is the only
coolant
warrantied by Volvo,
•
Never top-up with water alone, Use genuine Volvo
coolant diluted
with clean water in proportions of 50/50,
• Under normal conditions the coolant will not need to be
replaced, However, after larger repairs requiring draining
of coolant, refill with new coolants, as the old will have
been exposed
to oxidation and contamination ,
• Clean cooling system with solvent (PIN 1161328-8)
prior to
filling new coolant.
Capacity, , , , , , , , . , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , , , . , , . , , approx 10,7 litres (11,3 US qt)
Expansion tank
Pressure valve in cap opens at:
overpressure , , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , . , , . , , , , , , , ,
underpressure , , , . , , , , ,
.. , , . , , . , , . , , , . , , . , , . , , . , , , , , . , , , , , , , ,
Thermostat
Marking , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,
starts opening
at, , , , , , , , , , , , , . , , , . , , , , , , , , . , , , , , , , , , , , , , , , , , ,
fully open at, , , , , , , , . , , , , , . , , . , , , . , , . , , . , , . , , , , , , , , , , , . , , . , , ,
106 150
kPa
7 kPa
(21 psi)
(1 psi)

(
70019401960 Specifications
Section
2 B 6304 Engine
Group 28 Ignition System
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motronic 1.8
Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Ignition timing at 12.5 rls (750 rim). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 °
Made in Germany @
150365
150431
148680
COMPONENTS
Power stage
Bosch number. . . . . . . . . . . . . . . . . . . . . . . .. 0 227 100 203
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367 776-0
Ign ition coil
Nippon Denso number . . . . . . . . . . . . . . . .. 029 700-7260
Volvo
part number . . . . . . . . . . . . . . . . . . . . . .. 1 531 300-6
Resistance of primary coil
(between terminals 1 and 15). . . . . . . . . . . . . . . . . .. 0 .5 [2
Spark plugs
Designation, Bosch ......................... FR 6 DC
Champion. . . . . . . . . . . . . . . . . . .
.. RC 7 YC
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 517629-6
kit number .......................... 271 427-7
Electrode gap. . . . . . . . . . . . . . . . . . . . . . . . . . 0.7-0.8 mm
(0.0276-0.0315 in)
Tightening torque,
unoiled threads . . . . . . . . . . . . . 25 Nm
(18 ft Ib)
Relay, ignition
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 3 323 592-4
Knock senso r
Bosch number ........................ 0261 231 006
Volvo part number . . . . . . . . . . . . . . . . . . . . . .. 1 367644-0
107
III 'IIt III II' III 'III III ,III III

70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Section 2 D 24, D 24 T, D 24 TIC Engines
Group 20 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 108
Group 21 Engine..... ...................... .... 109
Group 22 Lubricating system . . . . . . . . . . . . . . . . . . . . 114
Group 23
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Group 25
Intake and exhaust systems. . . . . . . . . . .. 116
Group 26
Cooling system .. . . . . . . . . . . . . . . . . . . . .. 117
Group 20 Genera l
Performance , co mpress io n r atios
Engine Market Compre
s-Output, DIN
type sion
ra tio
kWat hp at
r/s r/min
024 23:1 60/78 8214700
024T USA+Canada, Austria 1987-23:1 79/80 108/4800
106'/4800
Other
markets 23:1 80/80 109/4800
024TIC 740/760 23:1 90/80 12214800
780
23:1 95/78 129/4650
1) Horsepower 2) Ft Ib
Ge ne ra l da ta
Number of cylinders .. ............... ........................ .
Cylinder bore .................... ...................... ..... .
Stroke ..
............................ ............. ... ....... .
Displacement ........ ....................................... .
Firing order ..
............................................... .
Compression: new
..................................................... .
min
....................... ............................... .
max. difference between
cylinders ........................... .
Weight, approx.,
complete engine including engine mounts
alternator and starter motor
D 24 ....
.............. ... ............ ... ........... approx .
D 24 T
............................................. approx.
108
6
76.5 mm
86.4 mm
2.383 dm
3 (Iitres)
1-5-3-6-2 -4
3.2
MPa (455 psi)
2.4
MPa (341 psi)
0.8 MPa (114 psi)
200 kg (440 lb.)
210
kg (463 lb .)
,/1-'"
It
t1 '
'29750
Max torque, DIN
Nm at
r/s
145/33
190/40
205/42
235/40
250/40
3.0118
in
3.4015 in
kpm at
r/min
14.8/2000
19.4/2400
140
2/2400
20.9/2500
24 .0/2400
25 .5/2400