VOLVO 940 1982 Service Repair Manual

(
70019401960 Specifications
Sect ion
2 024, 024 T, 024 TIC Engines
Cylinder head
Max. warp .......................... , ... .
Cylinder head may not be machined.
It must be replaced if warp exceeds
maximum .
Cylinder head gasket
Group 21
129146
Three different gaskets are used depending on height of piston above cylinder block.
Notches
Height of piston above
cylinder block
mm
0.67-0.80
0.81-0.90
0.91-1.02
in
0.026-0.031
0.032-0.35
0.036-0.040
@.2 mrp = 0.008 in
!:, :' 1 ' . , • t ~I
129147
Gasket
number of thickness
notches mm
in
1 * 1.4 0.055
2 1.5 0.059
3 1.6 0.063
Piston height in same engine must not extend over more than
two classes .
Piston height is measured at the front and back of piston
(along the gudgeon (piston) pin) .
• Not D 24 TID 24 TIC
Cy lind er block
Bore Marking
(honing group)
Standard .
....... , . .. , ...... , .. .... , .. , ................. 651
652
653
Oversi ze 1 ............. , ... , .. , ... , .. , ... , . . , .. , ....... 676
(0.25 mm = 0.010 in) .... " .. , . . " .. , . . , ... , .. , . . , .. , .... 677
678
Oversize 2 ....... ......... , . ........................... 701
(0.50 mm = 0.020 in) .... , ...... , ...... , . ..... , .......... 702
703
Oversize 3 ................ , ... , .... .. , ... , ..... , ... .... 751
(1.00 mm = 0.040 in) ...................... , .. , .. , . , ..... 752
753
Max wear (compared with specified diameter) .... , ............. .
Pistons
Max . weight deviation between pistons in
same engine .............................. , .. .
Piston float, new .......... , ...... , .. , ........ . .
max
.................. ....... , .. , .. .
Piston diameter, see cylinder bore table
Max wear (compared with specified diameter) .....
Piston diameter is measured at right-angles to gudgeon
piston
lower edge .
12 grams
0.03-0.05 mm
0.13 mm
0.04 mm
Piston diameter
mm in
76.48 3.0110
76.49 3.0114
76.50 3.0118
76.73 3.0209
76.74 3.0213
76.75 3.0216
76.98 3.0307
76.99 3 .0311
77.00 3.0315
77.48 3.0504
77.49 3.0508
77.50 3.0512
0.04
mm (0.0016 in)
0.0012 -0.0019 in
0.0051 in
0.0016 in
Cylinder bore
mm in
76.51 3.0122
76.52 3.0125
76.53 3.0130
76 .76 3.0220
76.77 3.0224
76.78 3.0228
77.01 3.0318
77. 02 3.0322
77.03 3.0326
77.51 3.0515
77.52 3.0519
77
.53 3.0523
~ 0 • + .... I
t 129835
109
,III
.' .... 1
"' ·111
'" ·111
'" ·111

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engine
Pistons rings
~~ ~L---,-C--., -L-J
• ""~,
129521
Side cleara n ce
P iston rings R in g gap
Side clearanc e
(measured with ring
Uppe r comp ress ion
mm in Lo
wer comp ress io n O il sc rape r
mm in
mm
in
on piston) new ........ .
max
....... .
0.11-0 .14
0 .2 0
.0043 -0.0055 0.07-0.10
0.008 0.2 0.0028-0
.0039 0.03-0.0 7
0.008 0.
15
0.0012-0 .0028
0 .006
Ring gap (measured
in cylinder, see
illustration) new. . . . . . . . 0 .3-0.5
max........ 1.0 0.012
-0.020
0 .040 0.3-0.5
1.0 0.012
-0.020
0.040 0.25-0
.50
1.0 0
.010-0.0197
0.040
Gudgeon (piston ) pins
Fit, in connecting rod ........................................ .
Ligh t thumb pressure (close running fit)
T humb pressure (push
fit) in piston .............................. ............. ..... .
Valv e system
Valve clea ra nces
128157
Cold engine = engine at room temperature
= intake valves
A = exhaust valves
Check/adjust valves in this order : 1-5 -3 -6-2- 4
Va lv e cleara n ces
C heck ing
Settin g
m m in
mm
Intake valve, warm engine ..... ............................... . 0 .20-0.30 0.008 -0.012
0.25
cold
engine ................ ..................... . 0.15-0 .25 0.006-0 .010 0.2 0
E xhaust valve, warm engine ............. ..................... . 0.40-0 .50 0.016-0.020 0.45
cold
engine ................ . " ................. . 0 .35-0.45 0.014-0.018
0.40
Shims, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.00 to 4.25 at intervals of 0.05 mm
(0.012 to 0.16 7 at intervals of 0.002 in)
Valves (dimensions in mm)
7,97
~r-i4--Min. 0 ,5
Int ake va lv e
130061
44 ,5 °
7,95
Exh au st valve
in
0 .010
0 .008
0 .018
0.016
129836
Note : Exhaust valves are stellite plated. Only the valve face may be ground.
110

(
70019401960 Specifications
Section 2
024, 024 T, 024 TIC Engines
Valve seats (measured in mm)
I!+ (O'O~rIOS)
I max 1,5
129843
Intak e valve sea t
Exhaust valv e seat
When
replacing valve seats: the interference between the valve seat and its bore in the cylinder head shall be 0.074-
0.105 mm (0.0029-0 .0041 in) i.e. valve seat diameter must be 0.074-0.105 mm greater than the diameter of the bore in the cylinder head .
Valve guides
Inner diameter ............... ................. .
Height above cylinder head
lower sur1ace ........ .
8.000-8.015 mm 0 .3149-0.3155 in
40.1-40.5 mm 1 .5787-1.5944 in Clearance valve stem -guide (see illustration),
new........................................ 0.3 mm
max.. ...................................... 1.3 mm
Clearance is measured with new valve and with valve
stem flush with valve guide.
/
Valve springs
Inner va lv e spring s
Length Load
33.9 mm 0 0.0118
in
0.0511 in
Outer
valve springs
Length Load
40.2 mm 0
1,3mm '-.~
115083
28.6 mm 67-77 N (15-17 .5 Ib)
18.3 mm 209-231 N (47-52.2 Ib)
32.6 mm 167-185 N (38-42 Ib)
22.3 mm 433-479N (98-108.3 Ib)
S him s (for valve clearance)
Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.00-4.25 at intervals of 0.05 mm
(0.012-0 .167 at intervals of 0 .002 in)
Timing gears
Toothed belts
Belt tension (measured with tool 5197)
Check
value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Setting
... . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Camshaft
Max. lift height , intake ....................................... .
exhaust
...................................... .
Bearing clearance, new .
..................................... .
End clearance , max. . ....................................... .
Camshaft setting
is checked by using gauge 5190
8.5 mm
9.0 mm
0.05-0.10 mm
0 .15 mm
133536
0.334 in
0.354 in
0.0019-0.0039 in
0.006 in
111
·111 1111 ·111 1111 ·111 1111 11 .... 1 III

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Crankshaft
Max1
) runout, two centre bearings ............................. .
others
........................................ . .
Crankshaft, end
clearance, new ............................... .
max .
.............................. .
main bearing
clearance, new ....... ............... .
max
....................... .
Connecting
rod bearings, side clearance, max .................. .
bearing
clearance, max ............... .
new
............... .
l)Measured with two outer main bearings in V·blocks.
Main bearing journal s
Out of round, max ........................................... .
Taper, max
................................................. .
Diameter, standard .
.................................... ..... .
undersize 1 .
...................................... .
2 ....................................... .
3 ......................... .............. .
Con necting rod bearing journ als
Out of round, max ........................................... .
Taper, max
................................................. .
Diameter, standard
.......................................... .
undersize 1
....................................... .
2
....................................... .
Con necting rods
Only to be replaced in sets.
0.06 mm 0.0023 in
0.04 mm
0.07-0.18 mm
0.25 mm
0.016-0.075 mm
0.16 mm
0.0015 in
0.0027-0.0071 in
0 .0098 in
0.0006-0.0029 in
0.0062 in
0.4 mm 0.0157 in
0.12 mm
0.015-0.062 mm
0.0047 in
0 .0005-0.0024 in
0.03 mm 0.0012 in If ~ 0.05 mm 0.0020 in
58.00 (57.955-57.975) mm
2.2834 (2.2816-2.2824) in -+ +-) 57.75 (57.705-57.725) mm
2.2736 (2.2718-2.2726) in
57.50 (57.455-57.475) mm t
2.2637 (2.2620-2.2627) in 57.25 (57.205-57.225) mm Out of round 115089
2.2539 (2.2521-2.2529) in
0.03 mm 0.0012 in
0.05 mm 0.0002 in
47.80 (47.758-47.778) mm
1.8818 (1.8802-1.8810) in
47.55 (47.508-47.528) mm
1.8720 (1.8703-1.8711) in
47.30 (47.258-47 .278) mm
1.8622 (1.8605-1.8613) in Taper
Side clearance on crankshaft, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm 0.0157 in Max. weight deviation between connecting rods in same engine. . . 6 grams
Flywheel
Warp, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm at 150 mm diameter
0.0019 in at 5.90 in. diameter
112

(
70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Tig ht enin g to rqu es
Tightening torques apply to oiled bolts and nuts. Oegreased (washed) parts should be oiled prior to assembly .
I' ~ ~ 0 8 CD 0 (IJ
#' ~ G e Q e Q GJ
128149
Tighten
sequence for cylinder head bolts
Note: Loosen the bolts in the reverse order when removing the cylinder head.
R etorquing of cylinder head bolts
Retorque after 1 000-2000 km (600-1200 miles). The en­
gine
should be cold or almost cold.
Tighten each bolt separately in correct sequence (see
above
illustration).
Tighten bolt 90°. Note: This should be done in one move ­
ment without stopping.
Bolts should not be slacken ed
first.
Crankshaft
pulley (vibration damper) Ti
g
hten cylinde r h ea d bolts in stages
Remove oil and dirt from bolt holes. Oil left in holes will
reduce the pressure on the cylinder head gasket.
Bolt threads and washers must however be oiled, other-
wise
frictional forces will be too large.
Use new bolts .
Tighten in six stages in sequence shown above
Stage 1 = 40 Nm (30 ft Ib)
2 = 60 Nm (44 ft. Ib)
3 = 75 Nm (55 ft. Ib)
4 = tighten 180°. Note: This should be done in
one movement without stopping .
5
= run engine until oil temperature is at least
+50°C (112°F).
6 = tighten 90°. Note: This should be done in one
movement without stopping
Nm
ft lb.
center bolt1) ............................... ............... . 350 258
Allen bolts ..... :: ......................................... . 20 15
Flywheel (use new bolts and locking fluid,
Volvo PIN
277 961-9) ............................... .
75
55
Camshaft gear, front
......................................... .
45
33
rear
....................................... .. . 100 74
Camshaft bearing caps .................................... .. . 20 15
Main bearing caps .......................................... .
65 48
Connecting rod bearing caps (use new nuts)
................... .
45
33
1) Tightening torque 350 Nm (258 ft. lb.) applies when using special tool 5188.
5187
G lo w plugs
Threads and bolt head contact surface to be smeared with lock­ing compound (Volvo PIN 277961-9).
If a torque wrench is used directly on the centre bolt (without 5188), the bolt must be tightened to 450 Nm (332 ft. lb.) .
PIN.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 257889-4
Tightening
torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft Ib)
113
'il IN 11 '11 11
·11 III

70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Group 22 Lubricating system
General
Oil capacity and quality, see page 12.
Oil pressure with an oil temperature of +80°C = 176°F and
engine speed of 33.3 rls (2000 r/min) , at least. . . . . . . . . . . . . . . . . . . 200 kPa 28 psi
Oil pressure sensor
Cut-out point, indicator lamp goes out at. ...................... . 15-45 kPa (2.1-6.4 psi)
Lubricating oil pump ,
Relief valve opens at ........................................ . 600-700 kPa (85-99 psi)
Relief valve spring, length at different loads 024 o 24TfTlC
Length, Load,
Length, Load,
mm (in) N (Ib) mm (in) N (Ib)
49 (1.93) 0 53.5 (2.11) 0 22 (0.87)
175-195
36 (1.42) 152-162
(39-44) (34-36)
19.8 * ca 200 (45)
28(1.10) 229 (37)
115 083 (0.78) 25.9 * -
(1.02)
* Fully compressed
Group 23 Fuel system
Injection timing, idle
Engin e Market
type
024 -1986
1987-
024T USA+Can ada
1982-1983
1984
Federal + Canada
California
1985-
Austr ia 1987 -
Other markets
024TIC
*Injection timing = pump piston stroke at t.d .c . ** - 1985 = 87 (5200).
114
Injecting timing, * mm
Engine speed rls (r/min)
Adjusting (check ing)
Idle Max
0.70 (0.65-0 .73)
12.5 (750) 90 (5400)* *
0.80 (0.77-0.85) 12.5 (750) 90 (5400)
0.80
(0.77-0 .85) 12.5 (750) 90 (5400)
0.85 (0.82-0 .90) 12.5 (750) 90 (5400)
0.75 (0.72- 0 .80) 12.5 (750) 90 (5400)
0.75 (0.72-0 .80) 13.8 (830) 90 (5400)
0.75 (0.72-0.80) 13.8 (830) 90 (5400)
0 .90
(0.87-0 .95) 13.8 (830) 90 (5400)
0.90
(0.87-0.95) 13. 8 (830) 90 (5400)

(
l
70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Fuel inject ion pump
Type ....................................................... . Distributor pump
Model and designation ....................................... .
Bosch VE6/10 F 2400 + designation below
VE 6/10 F 2400 ••. -. 136777
Injectors
I
Eng ine
type
024
o24T
o24TIC
Market
U
SA+Canada 1982-83 Federal+Canada
California
U
SA+Canada 1984 Federal+Canada
California
USA+Canada 1985-, Austria 1987-
Other markets
7401760
780 -86
78087-
Man
L32-2
L
116~3
L144
L144
L135
L194
L116
i 1'IC 2 : ' TIC 1
TIC 3
Model
and designation: (complete) 024 . . . . . . . . . . . . . . . . . . . . . . . . Bosch KCA 30 SO 27/4 (44)
024 TITIC Engines . . . . . . . . . . . Bosch KCA 30 S 36/4
Aut
L32-3
L 116-2
L 144 -1
L144-1
L
135-1
L194- 1
L116-1
TIC 2-1
-
-
Eng ine typ e Injector -.complete Distributor (Bosc h)
Designation
024 068130201 E
068130201 E
068130201 F
024 T (USA+Can . 068130201 H
136778 Austria 1987-)
024 T (Others) 068130201 B
o24TIC 068130201 B
Injector opening pressure,
checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. MPa (psi)
adjusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. MPa (psi)
Tightening torques
Volvo PIN
1 257144
1 328336
1 328073
1 328209
1 328208
1 328 108
024
12.0-14.0
(1707-1991)
13.0-13.8
(1849-1963)
Nm
Injectors, in cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
upper-lower sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fuel injection pump, pump gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Designation
oNO SO 193
oNO SO 293
oNO SO 1930
oNO
SO 1930
oNO
SO 1930
oNO SO 293
024 T, 024 TIC
14.5-16 .3
(2062-2318)
15.5-16.3
(2205-2318)
ftlb
52
52
33
Volvo PIN
1 ,257146
1
328298
1 328096
1 328096
1 328298
1
328298
115

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Group 25 Intake and exhaust systems
Turbocharger
Charge pressure
D 24 T, at 3000 rlmin (full load) ............................... .
Pressure sensor
Cut-out point, approx
.................................... .. .
D 24
TIC, at 2400 rlmin (full load) ............................. .
Overpressure safety valve, opens ........................... .
Tightening torques
Use sealing paste (PIN 1 161 035-9) on bolts below.
Mount ing nuts, front exhaust manifold-turbo D 24 T .............. . D24TIC ............ .
Mounting
bolts, turbine housing ............................... .
compressor housing
..................... ..... .
rear housing (with waste gate)
024 T ........... .
D24 TiC ......... .
024 TIC Lock nut, pull rod -pressure actuator ................. .
024 TIC Pressure actuator nuts ............................... .
Mounting
bolts, turbocharger -exhaust manifold ................ .
116
70-77 kPa
80-85 kPa
90-100
kPa
110-130 kPa
Nm
25
20
20
18
20
25
6
6
60
10-11 psi
11-12 psi
13-14 psi
13-18 psi
ftlb
18
15
15
13
15
18
4
4 45

(
General
024
Capacity: with manual
gearbox ......... litres (US qts) 9.5
(9.9)
with
aut.
gearbox ......... litres (US qts) 9.2
(9.7)
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Group 26 Cooling system
128187
024T 024TIC
11.0 11.5
(11.6) (12
.
2)
10.0 11.5
(10.6) (12.2)
Coolant
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 1 161 328-8)
prior to
filling new coolant.
• If tropic type radiator is filled add 0.6 (0.6) to above.
Important: do not operate engine if cooling system is not topped-up. Failure to observe this may cause high local tem­peratures which could cause cylinder head to fracture .
Expansion tank /
Pressure valve in cap opens at:
overpressure, early type ............................ kPa (psi)
late type ............................. kPa (psi)
underpressure
............... ...................... kPa (psi)
Thermostat
Marking ..................................................... .
Starts to open
at ............................................ .
Fully open
at ............................................... .
Opening dimension, min ..................................... .
Drive belts Profile x length:
100 (14.2)
150 (21)
10(1.4)
87°C
87 °C
102°C
8 mm
A HC 38 x 1238
B HC 38 x 750
C HC
50 x 913
A HC 47 cog x 1 150
B HC 38 cog x 1 013
C
HC 50 cog x 913
--, / , I 5 I 1 I
--~_/
7401760 -1986 142814
Tightening torque
1 Crankshaft pulley 2 Alternator 3 Fan 4 Power pump
5 AC compressor
Nm
Fan.......................... ............................... 9
189°F
216 °F
0 .
31 in
780 1986 + 7401760 1987
ftlb
6.6
117
lit til' lit ,", ·111 11,1 ·111 1111 ,11'
--'

70019401960 Specifications
Section 3 Electrical system
Section 3 Electrical system
Group 31 Battery............................... 118
Group 32 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 118
Group 33 Starter motor . . . . . . . . . . . . . . . . . . . . . . .
.. 123
Group 35 Lighting......... . . . . . . . . . . . . . . . . . . . .. 127
Group
37 Fuses.... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 128
Group 38 Instrumentation . . . . . . . . . . . . . . . . . . . . . .. 137
Group 31 Battery
System voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Earth connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative terminal
Battery capacity
Model Co
ld start current*
Reserve capacity* Recommended
CCA SAE
RC SAE (DIN) charging current
B23ET, B28A1E, B280E (66 Ah) 7A
024, 0 24 T -1986 (88 Ah) 9A
024,024 T, 024 TIC 1987-600 A 125 min 9A
B 19/23, B 200, B 230, France 330
A 70 min 5A
B 19/23, B 200/230, not France, B 28 F, B 280 F 450 A 90 min (55 Ah) 6A
1991-type and market adaption
Volvo PIN Cold start current*
Reserve capacity*
Recommended
CCA SAE
RC SAE (DIN) ·charging current
3515893
440 AMP 85 min (50 Ah) 6A
3515895 520 AMP 100 min (60 Ah) 7A
3515897 600 AMP 125 min (70 Ah) 9A
• Cold start current (CCA, SAE) is the discharge current that a battery can deliver for 30 sec at a temperature of -18°C (O°F) without drop­
ping below 7 .2 V.
Reserve capacity (RC, SAE) is the time required at + 2rC (80°F) for a steady discharge current of 25 A to reduce the potential of a fully charged battery to 10.5 V .
118