VOLVO 940 1982 Service Owner's Guide

Injector ballast resistor pack
Coolant temperature sensor
0280130 ... 135791
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 026
Volvo PIN ....................... ........ 1 332 396-9
Resistance
at:
-10°C ( - 14°F) .................... . 8260-10560 n
+20°C (68°F) ....................... 2280-2720 n
+80°C (175 °F) ......................... 290-364 n
A ir control valve
Lambda-sond
0258~3 ... '
70019401960 Specifications
Section
2 B 19, B 23 Engines
Bosch number ...................... " 0 280 159 001
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 336 810-5
Four resistors
(1 per injector)
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 5.5-6.5 n
40000
20000
10000 8000 6000
4000
2000
1000 800 600 400
200
100
--
il
-30 -20 0 20 40 60 80 100 120°C
-22 -4 32 68 104 140 176 212 248°F
135792
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . . . .• 501
Volvo PIN ................. " ..... ....... 1 317957-7
Resistance between terminals 3 and 4
and between 4 and 5 . . . . . . . . . . . . . . . . .
.. approx. 20 n
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 006
Volvo PIN ............................... 1 346 738-6
Resistance of
ballast resistor at:
Cold sond (20°C = 68°F) . . . . . . . . . . . . . . . . . . . . .. 3 n
Warm sond (above 350°C = 660°F) ............ 13 n
Tightening torque. . . . . . . . . . . . . . . . . .. 55 Nm (40 ft Ib)*
• Apply "Never Seez" (PIN 1161 035-9) to entire length of thread .
29
III
IN III ·11 III
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III III

70019401960 Specifications
Section 2 B 19, B 23 Engines
Fuel pump
~
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 025
Volvo PIN ....... ................. ..... .. 1 336 679-4
0580464 ... 135793
Pump capacity at a line pressure of 300 kPa (42 psi),
+20°C and 12V .......................................... .
11 V ......................... ................. .
10V .......................................... .
Current consumption at a
line pressure of 300 kPa (42 psi),
+20°C and 12V .... .... ...... .......................... .. .
Tank pump
130 litres/hr (1.08 litres/30 secs)
108 litres/hr (0.9 litres/30 secs)
86
litres/hr (0.7 litres/30 secs)
max 6.5 A
Current consumption . . . . . . . . . . . . . . . . . . . . . . . .
.. 1-2 A
,'."
30

70019401960 Specifications
Section 2 B 19, B 23 Engines
Group 25 Intake and Exhaust systems
Turbocharged engines
En gin e type ................................... B 19ET B23ET
C harge pressure, at full load .............. rlmin 3500
3500
checking ............ kPa (psi) 60-70 (8.5-10.0) 45-53 (6.4-7.5)
adjusting ............ kPa (psi) 64-70 (9. 1-10.0)
50 (7.1)
Charge air overpressure,
switch, opens at ...................... kPa (psi) 85-95 (12.1-13.5) 65-75 (9.2-10.7)
Charge air pressure, switch, closes at .. kPa (psi) -15-25 (2.1-3.6)
Tighten ing torque data
4)
1) Apply sealer (PIN 1161053-2). 2) Use new nuts.
3) Use sealer (PIN 1 161 035-9).
4) Use new bolts . (Old bolts can if absolutely necessary be reused if they
are smeared with sealer PIN 1161053·2).
Mounting bolts, turbocharg er - ex hau st m anifold
•
Measure length of bolt. Bolts can be reused if shorter
than
89 mm.
• 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
Stage I = 1 Nm (0.7 ft Ib)
II = 45 Nm (32.5 ft Ib)
III = 45 ° in one movement without stopping
89mm
135780
sfJ
Nm
45Nm 45·
B23FT
3000
46-54 (615-717)
48-54 (6.8-7.7)
85-95 (12.1-13.5)
-
31

70019401960 Specifications
Section 2 B 19, B 23 Engines
General
Group 26 Cooling system
128187
Coolant - composit ion -guarantee
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 (blu e-green), diluted
with clea n water in proportions of SO/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 40,000 km
(25,000 miles) since the corrosion-protective additives in
the coolant lose their effect in time.
• The cooling system should be cleaned using solvent
PIN 1 161 328-8 prior to filling new coolant.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx 9.5 litres (10.05 US qts)
Expans ion tank
Pressure valve in filler cap opens at:
overpressure
........ ' ..................................... .
underpressure .
.............................. --: ............ .
Thermostat
Marking .................................................... .
Starts to open
at ............................................ .
Fully open at ...................................... ......... .
Fan belts
Designation (Volvo PIN), early type ..... : ...................... .
late type ............................. .
32
65-85 kPa (9.2-12 psi)
7.0 kPa (1.0 psi)
Type 1
87
86-88°C
(187-190°F)
9rC (207°F)
1983
HC 38x925
HC 38 cogX925
Type 2
92
91-93°C
( 196-199°F)
102°C (216°F)
1984
HC 38x913
HC 38 cogX913

(
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

70019401960 Specifications
Section
2 B 19, B 23 Engines
Distributor
Engine type
Ignition system Distributor
Volvo
PIN Bosch No
819E,823E TZ-28 H 1 336689"" 0237020075
819ET TZ-28 H 1 336694 0237020031
823ET Motronic" 1 317298 0237501 003
823FT EZ-K" 1 332587 0237506001
* Computerized ignition system (Le. distributor does not have a mechanical advance or vacuum unit). ** Modified distributor: same values as 1 336690 (8230 A).
Bosch number .............................................. .
Volvo P/N .................................................. .
Direction of rotation ......... ................................ .
Centrifugal governor
Advance, total, degress (distributor) ........................... .
Advance begins
at distrib. rev/sees ............................ .
distrib. rev/min)
............................ .
Data :
5° at distrib. rev/secs ......................... ......... .
(distrib. rev/min)
...... ........................... .
10° at distrib. rev/secs .................................. .
(distrib. rev/min) .
................................ .
Advance
max at distrib. rev/sees .............................. .
(distrib. rev/min)
............................. .
Vacuum governor
Control direction ............................................ .
Control, total degrees (distributor) ........ ', ' ................... .
Control commences at mm Hg ............................... .
Data:
5 ° at mm Hg .......................................... .
max
control at mm Hg .................................. .
Direction
of rotation ......................................... .
Max control, distr. degrees ................................... .
Control begins at mm Hg ........ ............................ .
Data:
1 ° at mm Hg ............... ........................... .
Max control mm Hg ........................ ... ............. . .
Ignition advance
B19E, B23E
0237020075
1 336689
Clockwise
12.5±1.5
6.7-9.2
(400-550)
20-26
(1200-1560)
33.3--39
(2000-2340)
26.7
(1600)
Positive
7.5±1
105-140
175-215
235
B19ET
0237020031
1 336694
Clockwise
12. 5±1.5
6,7-11,7
(400-700)
12,8-16
(770-960)
17.5-22.3
(1050-1340)
40
(2400)
Positive
7.5±1
105-145
175-220
250
Negative
2.5±1
105-180
135-210
225
B19ET cce:;p B19E, B23E ""~~ c I:~.
l r ~ IO~O, ! ,
'I)''ll~C 3000 4000 5000 r/min 2000 lr~Ii' . l~?O 2000 3000 4000 SOOO r /min I,!! I .. I ,,,I,,,! .. i,,, ,I 1" , I, ,I" I ,,1 I I ,. I ",I
10 20 30 40 50 60 70 80 90 r
l s 10 20 30 40 SO 60 70 80 90 ,I , 20" 40~ 20' 40' ++~ ,
1+ WiTI:l: - ij Is<' JO~ IS O
30' -I
I
,=' ; , ,
10' 2
0 ' li : ,
R s' 10'
0 ' O
· + I I
-5' -10'
9lhiO~23±7~0±20~O~31~±§~~~~ij±~~~ -10" -20' J: 40 30 20 10 10 20 30 40 kpa it) 300 200 100 iii I 100 200 300 mm Hg
o 237 020 075 -10 -20' 40 30 20 10 10 20 30 40 kp' 1 I I I I i I I 300 200 100 a 100 200 300 mmHg
PRESSURE VACUUM 138223 PRESSURE VACUUM 138222
34

(
70019401960 Specifications
Section 2 B 200, B 230 Engines
Section 2 B 200, B 230 Engines
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Group 21 Engine block ........................... 32
Group
22 Lubricating system ....................... 38
Group
23 Fuel system ......... ................ .. 39
Group
25 Intake and exhaust systems. . . . . . . . . . . .. 60
Group 26 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .. 62
Group
28 Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 63
..... 1/
j. Group 20 General
Performance , compression ratio, octane requirements
Engine Remarks Compres-
type slon ratio
B200K Europe, manual 10.0 automatic 10.0 Overseas
8.5
B200 E 10
.0
B200 F 1990 10.0 1991 10.0
B200ET 8.5
B204
E 9.7
B204FT / 8.2
B204GT 8.2
B230A Scandinavia 10 .3
B230K -1986 Europe 10.3 Overseas 9.0 1987-10.5
B230 E 10.3
B230ET 9
.0
B230 F USA, Canada 9
.8 Other markets 9.8
B230FB 9.3
B230 FT USA , Canada, Japan -1989 8.7 Other markets -1989 8 .7
USA, Canada 1990-8.7 Other markets 1990-8.7
B230GT 8.7
B234F USA, Canada 10.0
B234 F IG Other markets 10.0
LH-drive, man gearbox -1989 10.0
11 Unleaded fuel can also be used . 21 Unleaded fuel only. 91 octane unleaded fuel can be used. 31 Horse power. 41 Ft lb.
•
RON stands for Resea rch Octane Number, and is a measure of
the ability of a fuel to withstand knocking. MON stands for Motor Octane Number and is another way of
measuring the same property.
(R+M)/2,
also called AKI (Anti Knock Index) combines these two
m eas urem ents .
95
RON is equivalent to 91 (R+M)/2. 91 RON i s equivalent to 87 (R+M) /2.
Octane Output Max torque require-ment kWat hp at Nm at RON" rls
r/min rls
98 76/90
103/5400 165/45 98 78/90 106/5400 170/45 93 74/90 100/5400 165/45
95 1
.
71 89/95 121/5700 158/80
9521 80/98 110/5900 155/48 9521 82/95 11115700 158/57
98
118/92 160/5500 245/58
9511 102/100 139/6000 181/80
952
) 140/88 190/5300 280/49
9511 147188 200/5300 290/49
98 82/83 112/5000 192/42
98 84/87
114/5200 192/42 9311 80/87 109/5200 185/42 9511 86/87 117/5200 194/42
95 1
.
71 96/92 131/5500 190/55
98 134/97 182/5800 260/57
9521 85/90 11431/5400 183/4251
9521 85/90 116/5400 183/4251
9521 96/92 130/5500 185/49
9521 119/88 16031/5300 253/48 9521 115/80 156/4800 242/55 9521 121180 16231/4800 264/57 9521 121/80 165/4800 264/57
9511 125/80 170/4800 265/57
9521 114/95 15331/57 00
203/75
952
.81 114/95 155 /5700 203/75
9521 117/97 159/5800 210/74
51 With Regina-Re x I: 182/42 .
61 With Regina-Rex I: 134/2500 and 18.6/ 2500 . 71_1986: 98 octane .
81 B 234 G: Leaded fuel can be used .
~ ""
129750
kpm at r/min
16.8/2700
17.3/2700
16 .8/2700
16 .1/4800
15 .8/2900
16.1/2800
25 .0/3500
18.4/4800
28 .5/2950
29 .6/2950
19 .6 /2500
19.6/2500 18 .9 /2500 19 .8/2500
19.4/3300
26.5/3400 135
41/250061
18.7/250061
18 .9/2950
18rl/2900
24.7/3300
19541/3450 26 .9 /34 50
27.0/3450
150
41/ 4450
20 .7/4450 21.4/4450
35
I
I
I
I
I
I
I
""
III
III· III
III· ·111 III '111 III

70019401960 Specifications
Section 2 B 200, B 230 Engines
Other General Data
Number of cylinders ......................................... .
80re .................................................... mm
Stroke .................................................. mm
Displacement. ..................................... dm3 (litres)
Firing order ................................................. .
Compression pressure
.............................. MPa (psi)
Max deviation between
cylinders ................... MPa (psi)
Weight
.................... ..................... .......... kg
(Ib)
B200
B204
4 88.9
80
B230
B234
4
96
80
2.32 1-3-4-2
0.9 (128)
0.2 (28)
140-150
(308-330)
with turbocharger .................................... kg
1.99
1-3-4-2
0.9 (128)
0.2 (28)
140-150
(308-330)
165 (363) 160-165 (352-363)
1) With hot engine throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
Cylinder block
Bore
Group 21 Engine block
Standard, C ............................................. mm
(in)
o .... ............ ..................... ........ mm
(in)
E
.... ......................................... mm
(in)
G .
............................................ mm
(in)
Oversize
1 .......... . ........... ........................ mm
(in)
2 ............ -.................................. mm
(in)
B200
88.90-88.91
(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
(3.5180-3.5184)
89 .
67-89.68
(3.5303)
Rebore if wear exceeds 0.1 mm (0.004 in) and oil consumption is very high.
Pistons
Piston diamete r (A)
Standard (C) ............................................. mm
(D) ............................................. mm
(E)
....................................... ...... mm
(G) ........ .................................... mm
Oversize 1 .............................................. mm
2 ................................ ······· ·······mm
Diameter measured at right angles to pin at distance 'B' from bottom
of piston
B200
88.88-88.89
88.89-88.90
88.90-88.91
88.92-88.93
89.27-89.28
89.65--89 .66
B
8200/204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4 mm
B230K 1987-..... ...... ................. ................... 13 .5 mm
8230 others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm
8234....................................................... 11 mm
Max weight difference in same engine 8200/230 . . . . . . . . . . . . . . . . 16 g 8204/234 ................ 14 g
P iston running clearance
B230
96.00-96.01
(3.7824-3.7828)
96.01-96.02
(3.7828-3.7832)
96.02-96.03
(3.7832-3.7836)
96.04-96.05
(3.7840-3.7844)
96.30-96.31 (3.7942-3.7946)
96.60-96.61
(3.8060-3.8064)
B230
95.98-95.99
95.99-96.00
96.00-96.01 96.02-96.03
96.28-96.29
96.58-96.59
(fJ .... .,
8200 1985 .......................................... mm (in)
8200 1986--, B 204/230/234 ..... ...................... mm (in)
0.003-0.027 (0.0001-0.0011)
0.010-0.030 (0.0004-0.0012)
36
... -,.
B
~r
~~
143981

Piston rings
129521
Axial clearance
Side clearance measured with ring on piston 8200 ........... mm
(in)
8204 ........... mm
(in)
8230/234 ....... mm (in)
Ring gap (checked
in 88.9, 96.0 mm bore) 8200/204 ........ mm (in) 8230/234 ........ mm
Gudgeon (Piston) pins
Fit, in connecting rod. . . . . .. Light thumb pressure
(close running fit) (in)
in piston.
. . . . . . . . . . . . .. Thumb pressure (push fit)
Cylinder head-
Height, new ............................... mm
(in)
after machining
..................... mm
(in)
• Max machining 0.3 mm
B204/234
103.5
(4.078)
102.7*
(4.078)
Max warp .......................................... .
NOTE: If warp is greater than 1.0 mm (0.0394 in) length­
wise or 0.5 mm (0.0197 in) crosswise, cylinder head must
be replaced.
Valve clearance
B200/230
Inlet and exhaust valves
cold
engine ............................................ mm
(in)
warm engine
........................................... mm
(in)
70019401960 Specifications
Section 2 B 200, B 230 Engines
Upp er Compo rings 0.060-0.092
(0.0024-0.0036)
0.040-0.072 (0.0016-0.0028)
0.060-0.092 (0.0024-0.0036)
0.30-0.50
(0.0118--0.0236)
0.30-0.55
(0.0118--0.0217)
B200/230
146.1
(5.756)
145.6
(5.737)
Checking
0.30-0.40 (0.012-0.Q16)
0.35--0.45 (0.014-0.018)
Lower Compo rings 0.030-0.062 (0.0012-0.0024)
0.030-0.062 (0.012-0.0024)
0.040-0.072 (0.0016-0.0028)
0 .30-0.55
(0.0118--0.0217)
0.30-0.55
(0.0118--0.0217)
Adjusting
0.35--0.40
(0.014-0.016)
0.40-0.45 (0.016-0.018)
Ring gap 129520 Oil scraper rings 0.020-0.055
(0.0008--0.0022)
0.020-0.050 (0.008--0.0019)
0.030-0.065 (0.0012-0.0026)
0.20-0.50 (0.0098--0.0197)
0.30-0.65 (0.0118--0.0256)
max o 25mm
129 826
Adjusting shim, thickness .............................. mm (in) 3.30-4.50 (0.1300-0.1773)
in increments of 0.05 (0.002)
Valve stem, B 204/234
Valve stem height . . . . . . . . . . . . . . . . . . .. 49.4±0.04 mm
(measured with gauge 5222) . . . . . . . . .. 1.946±0.002 in
Note: Valve stem height must be as specified. Otherwise
tappets will not function properly.
37
III III
ill III ill
IN liN
t·

70019401960 Specifications
Section 2 B 200, B 230 Engines
Valves
IMPORTANT: Exhaust valves are stellite-flashed and must not
be machined . They may only be ground in against seat.
Min:
8200/ 230 = 7,935 8204/234 = 6 ,95
IMPORTANT : Scrapping exhaust valves. The exhaust valves on turbo engines are sodium filled and must not be mixed with
ordinary scrap iron before first removing the sodium.
Min: 7,945
144 027
Inlet valve Exhaust valve (Not Turbo)
Exhaust valve turbo engines
Valv e sea ts
Inlet Exhaust
Valve guides
D+O,17mm
~F-~
133 646 113945
Note: When replacing valve seats the interference between
the seat and its bore should be 0.17 mm (0.0067 in) ie valve seat diameter should be 0.17 mm greater than
diameter of bore in cylinder head . 8204/234: 0.10-0.14 mm (0.0039-0 .0055 in).
Inner diameter ........................................... mm
Inlet valve
8.000-8.022
(0.3152-0.3161 )
15.4--15.6
(0.6068-0.6146)
E xhaust 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 8200/8230 ....................................... mm 0.03-0.06
(0.0012-0.0024)
0.03-0.06
(0.0012-0.0024)
0.15 0
.
06-0.09
(0.0024--0.0036)
0 .04--0 .07
(0.0016-0 .0028)
0.15
(in)
8204/234 ....... ........................................ mm
(in)
max
.............. .................................... mm
Valve guides are available in three oversizes , marked
with grooves.
Adju sting sh im
(in) (0.0059)
Standard
Oversize 1
Oversize 2
Oversize 3
*8204/234: 5373
(0.0059)
Marking
No groove
1 groove
2 grooves
3 grooves Reamer
5161 *
5162
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.
Thickness ............................................ mm (in) 3.3-4.5 (0.13-0. 18)
at increments of 0.05 (0.002)
38