VOLVO 940 1982 Service User Guide

Volvo PIN for each code
Pos Front Shock Brake Brake Pos
1,2 spring absorber,
disc caliper 1,2
front
31 1329822-9 274040-5 1359906-3 1329640-5 EG
1329641-3
42 1329822-9 1329648- 8
1359908-9 1329642-1 EN
1329643-9
44 1329824-5 3530274-
4 1359908-9 1329642-1 ER
1329643-9
54 1329822-9 274040-5
1359906-3 1329866-6
ET
1329867-4
( 5L 1329824-5
271105-9 1359906-3 1329866-6
1329867 -4
5M 1293449-3 271105-9 1359906-3 1329866-6
1329867-4
Pos
5P 1329823-7 271105-9 1359906-3 1329866-6 3
1329867-4
1
5Y
1329822- 9 274040
-5
1359906-3 1329866-6
2
1329867-4
3
9A 1329822-9 274040-5 1359906-3 1359557-4
1359558-2 4
9F
1329823- 7 271105-9
1359906-3 1359557-4 5
1359558-2 6
9X
1329822- 9 274040-5
1359906-3 1359557-4
1359558-2 7
A2 1329822-9
1329648-8 3516567-9 3516565-3 8
3516566-
1 A
A3 1329823-7 3530274-4 3516567-9 3516565-3 B
3516566-1
A4 1329824-5 3530274-4 3516567-9 3516565-3
3516566-1
A5 1387678-4 3530274-4 3516567-9 3516565-3
3516566-1
A9 1387677-6 3530274-4 3516567-9 3516565-3
3516566-1
03 1329824-5 271105-9
1359908-9 3516517-4 Pos
3516518-2 6
07 1329823-7 271105-9
1359908-9 3516517-4 1
3516518-2 2
DC 1329823-7 3530274-4 1359908-9 3516517-
4
3
3516518-2
E2 1329823-7 3530273-6 1359908-9
3516513-2
3516514-1
EE 1329824-5 271105-9 1359908-9
3516513-2
3516514-1
EJ 1293449-3 271105-9 1359908-9 3516513-2
3516514-1
Spring,
front
1329822- 9
1329823-7
1387677-6
1387678-4
Anti-roll
bar, front
1330220-3
1330218- 7
1330221-1
1330219-5
1359808-1
1359807-3
3530276-9
3530277- 7
3516447-4
3516446-6
Anti-roll
bar, rear
3516573-7
3516572-9
3530751-1
70019401960 Specifications
Section
0 General
Shock Brake Brake
absorber, disc
caliper
front
271105-9 1359908-9
3516513-2
3516514
-1
271 105 -9 1359908-9 3516513-2
3516514-1
271 105-9
1359908-9 3516513-2
3516514-1
271105-9 1359908-9 3516513-2
3516514-1
Pos Shock ab-Pos Spring,
4 sorber,
rear 5 rear
1 1329501-9
4 1273759-9
5 1329505-0
7 1273977-7
7 1329507-6 A 1273977-7
9
1329504- 3 C 1359710-9
C 1329500-1 E 3530199-3
F 1330332-6
9 1387836-8
G 1330702-0
H 3516668-5
J 3530200-9
N 3542466-2
M 3530283-5
Pos Bump
7 rubber
4 1330853-1
5 1359653-1
6 1387181-9
9
Itl tit
til til
Itl - til til -til
til

70019401960 Specifications
Section
0 General
Identification number, other markets (not USA/CAN )
l~ L
YV1 74468 2 C 1 001234
TTL----
Vehicle identification number, USA & Canada
YV1DH6923C1001234
11"--------
10
Manufacturer's code
Vehicle type
Engine type
Chassis number
Assembly plant
Model
year
designation
Transmission
Mc; mufacturer's code
-1985: D = 70 with 3 poi nt seat belts
1986-1990: F = 740 G = 760 H = 780
1991-: F = 740 H = 780 J = 940 K = 960
-1985: Vacant
1986-: A = SRS (Air bag) and front 3-point
seat
belts
X = 3 -point seat belts
Engine type
Body version 2
= 2 door
4
= 4 door
5 = 5 door
Chassis number
Assembly plant
Model
year
designation
Check number
(

Engin e typ e Asse mbly plant
21 = B200 FT 77 = 024 o = Sweden (VKAV)
23 = B200K 81 = B230A, B234G 1 = Sweden (VTV)
24 = B19E,
B200E 82 = B230GT 2 = Belgium (VEC)
25 = B204FT 83 = B230K 3 = Canada (VCl)
26 = B 19 ET, B 200 ET 84 = B23E, B230E 4 = Thailand (TSA)
27 = B200F 85 = B230FB 5 = Malaysia (SMA)
28 = B204GT 86 = B 23 ET, B 230 ET 6 = Australia
29 = B204E 87 = B230FT 7 = Indonesia
f 62 = B28A 88 = B230F (ISMAC)
·
68 = B28E, B280· E 89 = B234F A = Sweden
69 = B 28 F, B 280 F 95
= B6304F (Uddevalla)
75 = 024TIC o = Italy, Bertone
76 = D24T

Model year
d es ignation
C = 1982
0= 1983
E = 1984
F = 1985
G = 1986
H = 1987
J = 1988
K = 1989
l =
1990
M = 1991
70019401960 Specifications
Section
0 General
Transmission
2 = M46
3 = M47
5 = ZF4HP22,
AW 71 l -87
6 = AW70l, AW71l,
AW 72l, AW 30-43
7 = AW:70, AW 71
8 = BW55
11
1111 'III 1111 III 1111 'II' 1111 ,III 1111

I
I
70019401960 Specifications
Section 1 Service and maintenance
Section 1 Service and maintenance
Group 16 Lubrication
MAX
M'N
Petrol (gaso line ) eng ines
U
SA,Can ada,Japa n
011 quality According to API. ................. min SG "
• Oils with designations SG/CC and SG/CD fulfill this requirement.
Viscos ity (stable ambient temperatures)
• -3,0 -20 -10 0 10 20 30 40°C -I ! ! ! ! ! ! !
-22 -4 14 32 5 0 6 8 8
1
6 104 of
S A E 5W/30 ~ I
«iprttWn: WSAE 10W/30¥ti'i'iW,iJl>
I < S AE 15W/4 0
141375
Ot he r marke ts
Oil quality According to API .... .............. min SG "
According to CCMC ........... class G4/GS "
• Oils with designations SG/CC and SG/CD fulfill this requirement.
Viscos ity (stable ambient temperatures)
-30 -2 0 -10 0 10 20 30 40°C • I I ! ! ! I ! I -22 -4 14 32 50 68 86 104 of I I I SAE 5W/30 I
1<:::SAE1Q~Jii •
::I:i:1SD:flQWZ401t ::::It:I:,
< SA E 15W /40
SA E 20W/40
k" SAE 30
k SAE40
13 7 642
D iese l eng ines
USA, Can ada,Japa n
MAX
MIN
135901
Oil quality According to API Service .......... min CD"
• Oils with designations SE/CD and SF/CD fulfill this requirement.
Viscosity (stable ambient temperatures)
-22 -4 14 32 50 68 86 10 4 of 1----~SA~E~5~W~V=3~0--~--L-~)
14138 1
Other marke ts
Oil q uality According to API ...... ............ min CD "
According to CCMC .......... class 02lP01"
• Oils with designations SE/CD and SF /CD fulfill this requirement.
Viscos ity (stable ambient temperatures) I
• -3 P -2 p -1,0 Q W 2 p 3 p ~O °C
- 2
12 -4 14 32 50 68 8 6 104 of
S A E 5W/30
···t.:.::':·::ISil\E(1S:WZ4l·::: :ttit
SA E 20W/40
I<-.. SA E 30
I< SAE40
142444
Synthetic or semisynthetic oils may be used if their specifications comply with the oil quality re­
quirements.
12
V olvo does not re comme n d additio nal o il additives, as they ca n ad ve rsely affect the
e n g
ine.
Note ! SA E 1SW/40 and SA E 20 W/40 engine oils are recommended for use in extreme driving
conditions which
involve high oil consumption ego mountain driving with frequent deceleration
or fast motorway driving.
~9te however the lower temperature limits.
(

(

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
I
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, B 23 Engines
Section 2 B 19, B 23 Engines
Group 20 General ................................ 15
Group
21 Engine assembly ........................ 16
Group 22 Lubricating system
....................... 20
Group 23 Fuel system ............................ 21
Group 25 Intake and exhaust systems .............. 31
Group 26 Cooling system .......................... 32
Group 28
Ignition system .......................... 33
j'"
I.t
Group 20 General ~ :,
129750
Performance , compression ratios, octane requirements
Engine Remarks Compres-Octane
Output Max torque
type sion
ratio r
equire-
ment
kWat hp at
r/s r/min
819E 10.0:1 98 86/100
117/6000
819ET 7.5:1 98 110/92
150/5500
823E Scandinavia, Switzerland 10.3:1 96 95/88 129/5250
Other markets 10.0:1 98 96/90 131/5400
823ET 9.0:1 981 127/95 173/5700
823FT 8.7:1 912
• 3 117/88 160/5300
1575/5300
1) Australia 97-98 octane 2) Unleaded
petrol (gasoline) 91 octane RON (Research Octane Number). AKI = 87, according to R+2M where M stands for Motor Octane Number
. "
Nm at
r/s
158/50
230/60 190/50
190/60
250/57
250148
3) Fill with premium unleaded petrol (gasoline) (AKI = 91) to improve performance and driveability at altitudes in excess of 2000 It (600 m) in warm climates 4) Ft Ib 5) Horse power.
Other general data
No. of cylinders ............................................. .
Bore .
............................................. .. mm (in)
Stroke ..
.... ......................................... mm (in)
Displacement. ...................................... dm3 (litre)
Firing order ................................................. .
Compression pressure1) ..
............................ MPa (psi)
Max . deviation between
cylinders ................... MPa (psi)
Approx. weight.
............... ........... ..... ......... kg (Ib)
Turbocharged versions ................................. kg (Ib)
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
819
4
88.9
(3.503)
80 (3.152)
1.99
1-3-4-2
0.9 (128)
0 .2 (28)
165 (363)
170 (375)
823
4
96 (3.782)
80 (3.152)
2.32 1-3-4-2
0 .9 (128)
0 .2 (28)
165 (363)
170 (375)
kpm at
r/min
16.1/3000
23.4/3600
19.4/3000
19.4/3600
25.5/3400
25.5/2900 184
4/2900
15

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
P iston rings
129521
Clearance In piston groove
Clearance in piston groove
819 E, 819 ET, 823 E .................................. mm
(in)
823ET, 823FT .............. .......................... mm
(in)
Ring gap (see above)
819E, 819ET, 823E .................................. mm
(in)
823ET, 823FT ................ .......... .............. mm
Gudgeon (Piston ) pins
Fit, in connecting rod. . . . . .. Light thumb pressure
(close running fit)
in piston. . . . . . . . . . . . . .. Thumb pressure (push fit)
Valves
Valve clearance
Inlet
and exhaust valves
(in)
cold engine ............................................ mm
(in) warm engine ........................................... mm
(in)
Adjusting shim, thickness .................................. mm
(in)
Valves
Upper
Camp.
rings
0.040-0 .072
(0. 0016-0.0028)
0.060-0 .092
(0.0024-0.0036)
0 .35-0.65
(0.0014 -0 .0026)
0.40-0 .
65
(0.0158-0.0256)
Checking
0.30-0.40
(0.012-0.Q16)
0.35-0.45
(0.014-0.018)
3 .
30-4.50
Ring gap 129 520
Lower Oil scraper
Camp.
rings rings
0.040-0.072 0.030-0.062
(0.0016 -0 .0028) (0.0012 -0.0024)
0.040-0.072 0.030-0.065
(0.0016-0.0028) (0.0018-0.0026)
0.35-0.55 0.25-0.60
(0.0014-0.0022) (0.0010-0.0024)
0.40-0.65 0.30-0.60
(0.0016-0.0256) (0.0118-0.0236)
'Adjusting
0.35-0.40
(0. 014-0 .016)
0.40-0.45
(0. 016-0.018)
(0.1300-0 .1773)
in increments of
0.05 (0.002)
IMPORTANT: Valves are stellite-flashed and must not be machined . They may only be ground in against seat. IMPORTANT! Scrapping valves. Exhaust valves in turbo en­gines are sodium filled and must not be mixed with ordinary
scrap iron without first removing the sodium.
Min: 7,935
Inlet valve
44,5°
44,5 °
Min: 7,945
144027
Exhaust valve turbo engines (8 19 ET, 823 ET/FT)
Exhaust valve E-engines (8 19 E, 823 E)
17
III' III III
III
III ,111 III ·111 III

70019401960 Specifications
Section 2 B 19, B 23 Engines
Valve seat
Inlet
Valve guides
Exhaust
D+O,17mm
~\ i~
133646 113945
When replacing valve seats the interference between the seat
and its bore should be 0.17 mm (0.0067 in) i. e . valve seat dia­meter should be 0.17 mm greater than the diameter of bore in cylinder head.
Inner diameter ........... . ..... ...... ....... ............. mm
Inlet valve
8.000-8.022 mm
(0.3152-0.3161 )
15.4-15.6
(0.6068-0.6146)
Exhaust valve
8.000-8. 022
(0.3152-0.3161 )
17 .
9-18.1
(0.7053-0.7131 )
(in)
Height above upper face of cylinder head ................... mm
(in)
Clearance , valve stem-guide (measured with new valve) ,
new .......... . ...................................... . mm
(in)
max .
................. ................ . ~ .. ,,~ ....... "" ....... mm
(in)
Valve guides are available in three oversizes, marked
with grooves .
0.030-0.060
(0.0012-0.0021
)
0 .15
(0.0059)
Marking
0.060-0.090
(0.0024-0.0035)
0.15
(0.0059)
Reamer for seat
Standard
No groove
V alv e springs mm (in)
~
I. 032,5 . 1
rn~
Typ e 1
113946
wu , .. 025,9 1 I •
..g======'lb
Type 2 135065
Adjusting shim s mm (in)
Oversize 1
1 groove 5161
Oversize 2 2 grooves 5162
Oversize 3 3 grooves 5163
NOTE! The force used when pressing in valve guides must be at least 9000 N (1980 Ib). If the pressing force used is lower
then the recess for the guide must be reamed out to the near­est oversize and a guide of the corresponding size pressed in.
B 19 E, B 23 E, B 23 ET
B 19 ET, B 23 FT
Type 1 Type 2
Length Load
Le
ngth Load
mm (in)
N (Ib) mm (in)
N (Ib)
45.0 0 45.5 0
(1.77)
(1.79)
38.0
280-320 38.0 280-320 (1.50) (62-70)
(1.50) (62-70)
27 .0
710-790 27 .5 702-782
(1.06)
(156-174)
(1.08) (154-172)
Thickness.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .30-4.50 (in increments of 0.05) (0. 1300-0.1773) (in increments of 0.0020)
18