weight VOLVO 940 1982 Service User Guide

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
Crank mechanism
Cranks haft
Max run-out (measured on two centre main bearing journals) ..... .
Crankshaft, end
float ........................................ .
Crank
journals, side clearance ................................ .
Main bearing journal s
Out of round, max. ; ..................... .
Taper, max
............................. .
Diameter
............................... .
Connecting rod bearing journal s
Out of round, max ....................... .
Taper,
max " ............................. .
Diameter
............................ ... .
Connecting rods
0.007 mm
0.01 mm
70.043-70.062 mm
0.007 mm
0.01 mm
59.971-59.990 mm
End float on crankshaft ...................................... .
Max weight difference between can rods
in same engine ........ .
Tightening torque
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must
be oiled prior to assembly.
Crankshaft pulley ........................ ................... .
Camshaft gear
.............................................. .
Carrier
plate (use new bolts) ................................. .
Spark
plugs (do not oil) .. .................................... .
Valve cover ........................................... ...... .
Connecting
rod bearings ..................................... .
90 0.02
mm
0.070-0.270 mm
0.20-0.38 mm
(0.0002 in)
(0.0003
in)
(2.7575-2.7583
in)
(0.0007 in)
(0. 0027-0.0106 in)
(0.0078--0.0149
in)
115089
Out of round
(0.0002 in)
(0.0003 in)
(2.3629--2.3636 in)
0.18--0.32
mm
2.5 grams
Nm
240-280
70-90
45-50
12±2
15
1 Oil threads
Taper
(0.0071-0.0126 in)
ft. lb.
177-206
52-66
33-37
9±1.5
11
2 Tighten No.1 bolt to 25 Nm (18 ft.lb)
3 Tighten
No.2 bolt to 25 Nm (18 ft.lb) + angle­
tighten 75°
4 Angle -tighten No. 1 bolt 75°
5 Check/tighten both bolts to 50 Nm (37 ft.lb)

70019401960 Specifications
Section 2 B 6304 Engine
Section 2 B 6304 Engine
Group 20 General.... . . . . . . . . . . . . . . . . . . . . . . . . .. 98
Group 21 Engine............................... 98
Group
22 Lubricating System. . . . . . . . . . . . . . . . . . .. 101
Group 23 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . .. 102
Group 26 Cooling system . . . . . . . . . . . . . . . . . . . . . .. 106
Group 28 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . 107
Group 20 General
Performance , compression ratios, octane requirements
Engine Notes Compres-Octane
Output
type sion
requirement
Ratio
RON· kWat hp at Nm at
rls rim
rls
B6304F 10,71
) 95 150/100 204/6000 267172
Notes:
1) Unleaded fuel only. Can be run on 91 octane unleaded . • RON stands for Research Octane Number, and is a measure of the ability of the fuel to withstand knocking. MON stands for Motor Octane Number, another way of measuring the same property .
(R+M)/2, also called AKI (Anti Knock Index) is a combination of these two measurements . 95 RON is equivalent to 91 (R+M)/2. 91 RON is equivalent to 87 (R+M)/2 .
Other general data
Number of cylinders ......................................... .
Bore .
.................................................... .. .
Stroke .......................................... .......... . .
Displacement ......................... ................ ...... .
Firing order
............................................... .. .
Compression
(normal rating) 1) • ••••• ••••••••••••••••• •.••••••.•
Weight, approx ............................................. .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 rIm)
6
83.00 mm (3.268 in)
90 .00 mm (3.543 in)
2.922 dm3 (Iitres)
1-5 -3-6-2 -4
1 .3-1 .5 MPa (184-213 psi)
180 kg (397 Ib)
Group 21 Engine Block
Cylinder head
Max torque
kpm at
rim
27.214300
Height, new ............................... ........... mm (in) 129 .00±0.05
Max machining .............. ......................... mm (in) 0.3
(5.0787±0.0020)
(0.0012)
Max warp:
along ......... .... ................................. mm (in) 0.020
across .................................. ...... ..... mm (in) 0 .008
98

(
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 2 024, 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

(
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 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
4 Power Transmission
Tightening torqu es
Pinion drive flange, pinion with spacer .......... ........ ....... .
pinion with compression
sleeve ' ............ .
Differential bearing caps .............................. ...... . .
Crown
wheel " .. ............................ .......... ...... .
Wheel nuts ...... ............................... .. .......... .
Lock nut -speedometer sensor .
............................. .
• Do not exceed specified torque .. Use new bolts.
I Final drive 760 /780 4-door 1988-, 960
Reduction ratio ................................... .......... .
Axial throw , crown wheel ..................................... .
Backlash ............... .................................... .
Pinion bearing
preload , new .................................. .
old ........ .. ..... .................... .
Differential bearing, preload .................................. .
Clearance , speedometer' -impulse wheel ....... ............... .
Radial throw , outer diameter, impulse wheel ....... ............. .
Lubricant.
..... ............................................. .
T ightening torque s
='.. Coupling flange -pinion (nut) ................................ .
Crown
wheel -differential housing bolt + 60 deg . angle-tightening.
Wheel nuts .. ............................. .................. .
Impulse sender -rear casing (bolt) ............................ .
Rear casing -
final drive (bolt) ................................ .
Side bracket -final drive (bolt) ............................... .
Lock washer -adjustment nut
(bolt) ........................... .
Balance weight -final drive (bolt) ............................. .
Oil drain plug ............................................... .
Oil filler plug ................................................ .
Drive shaft
bolts (+900 angle tightening) ....................... .
Drive shaft nuts,
(+600 angle tightening) ............... ........ .
152
Nm ttlb
200-250 147-185
180-280 130-207
45-60 33-44
90-110 66-81
85 63
25-40 18-29
3.54:1, 3.73:1, 3.91:1
Max 0.08 mm (0.0032 in)
0.1-0. 16 mm (0.04--0 .006 in)
1.2-2.8 Nm (0.87 -2.0 ft Ib)
1.0-2.5 Nm (0.72-1 .8 ft Ib)
1 + 1 notches on each side
0.35-0.75 mm (0.014--0.030 in)
Max.
0.2 mm (0. 008 in)
See page 9
Nm
180-280
35
85
8-12
20-28
40-56
40-56
20-28
27-40
27-40
30
140
ftlb
(133-207)
(26)
(63)
(6-9)
(14--20)
(29-40)
(29-40)
(14--20)
(20-29)
(20-29)
(22)
(103)