VOLVO 940 1982 Service Service Manual

70019401960 Specifications
Section
2 B 200 , B 230 Engines
Valve springs
Different types of valve springs are in use as follows. Typ
e 1: B 200 K and E Type 2: B 200 ET, B 200 F Type 3: B 204 and B 234
~LF~
:. 032,5'1 1,025,9"1 1.026,2 "I
~~
1 46816
L e ng th
B230A, K, E and ET B230F, K 1989-and FT
Type 1
Type 2
Lo ad
-. L e n gth
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) (160-178) (1.08) (154-163) T
yp e 3
L e ngth
Load
mm (in)
N
(Ib)
43.0 0
(1.69) 37.0 212-252
(1.46) . (48--56) 26.5 600-680
(1.04) (135-153)
Tim ing gears
Cams haft
Profile letter stamped on
end of camshaft
E ng in e
type Ca
msh aft C hecking cam sh aft setting (cold en gine) ;
Pr
ofile Max lift h
eight V alve clea rance for Inl et/exha u st valve
mm (in) numbe r 1 inlet
should open at*
B200 K y 10.35 (0.4078) 0.7 (0.0276) 8° B.T.D.C .
B200E V 11.37 (0.4480) 0.7 (0.0276) 11° B.TD.C.
B200 ET T 9.9 (0.3901)
0.7 (0.0276)
4° B.T.D.C.
B200 F M 9.5 inlet 0.7
(0.0276)
6° A.T.D.C.
10 .5 exhaust 0.7 (0.0276)
44° B.B.D.C.
B204E u, (inlet) 9.38 (0. 3696) 0
.7 (0.0276) 5.1° B.T.D .C
u (exhaust) 9.38
(0.3696)
0.7 (0.0276) 37.1 ° B.BD.C.
B204 FT/G T F I (inlet) 6.81 (0.0268) 0.7 (0.0276)
12.9° A.T.D.C .
F A (exhaust) 7.45 (0.0294)
0.7 (0 .0276) 31. 2 ° B .B.D .C.
B230A A 10.5
(0.4137) 0.7 (0.0276)
13° B.T.D.C.
B
2 30 K - 198 6 X 10.65 (0.4196) 0.7 (0.0276)
10° B.T.D.C.
1987 -T 9.9 (0.3901)
0.7 (0.0276)
4° B.T.D.C.
B230 E V 11.37 (0.4480)
0.7 (0.0276) 11 ° B.T.D .C.
B230ET A 10.5 (0.4137) 0.7 (0.0276)
13° B.T.D .C .
B230 F M 9.5 (0.374) inlet 0.7 (0.0276)
6° A .T.D.C.
10 .5 (0.4137) exhaust 0.7 (0.0276)
44° B.L.D.C.
B230FB VX3 11.37 (0.4480) inlet 0.7 (0.0276) 7.7" B.T .D.C.
10.65 (0.4196) exhaust 0.7 (0.0276) 50.1° B.L.D.C ;
B230FT T
9.9 (0.3901) 0.7 (0.0276) 4° B .T.D.C.
B234F u, -(inlet) 9 .38 (0.3696) 0.7 (0.0276) 5.1 ° B.TD.C .
u - (exhaust)
9.38
(0.3696) 0.7
(0.0276)
37.1 ° B.B .D .C .
• B.TD.C. = before top dead centre, A.T.D.C. = after top dead centre, B.L.D.C. = before lower dead centre
Radial clearance , new ........... .. .................... mm (in)
max ............. .................... mm (in)
Axial clearance, B 200/230 ......... .................... mm (in)
B 204/234 ............... .. ............ mm (in)
Inte rmed iate s h aft B 200 /230
Radial clearance .................. .................... mm (in)
Axial clearance ....................... ................ mm (in)
0.030-0.071 (0.0012-0.0028)
0.15 (0.0059)
0.1-0.4 (0.0344-0.0158)
0 .05-0.40 (0.0019--0 .0158)
0.020-0.075 (0.0008--0.0030)
0 .
20-0.46 mm (0.0079-0.0181)
39
I
I
III II ill II,
II' /I , III
\'.'1

70019401960 Specifications
Section 2 B 200, B 230 Engines
Camshaft belt, sp ring s, B 204/234
144B!Hi
Balanc e shaf ts , B 204 /234
Length
75.6 mm (2.979 in)
65.0 mm (2.561 in)
52.0 mm (2.049 in)
Axial clearance. . . . .. 0.06-0.19 mm (0.0024-0.0075 in)
Belt tension, B 204/ 234
Camshaft belt
Coolant
Checking limits ' Used belt New belt
temp.
20°C < 2 .5 or > 3.5 3.2±0.3 3.8±0.3
40°C < 3.2 or > 4.2 3.9±0.3 4.4±0.3
8rC < 4.6 or > 5.3 5
.1 ±0.2 5 .5±0.2
• Carry out at 10,000 km (6,000 miles) after belt replacement.
< = less than
> = more than
Crankshaft assembly ,/
Cranksh aft
Max out-at -true .................................. ..... mm (in)
Axial clearance, max .................................. mm (in)
Radial clearance (main bearings) early type ............. mm (in)
late type ............... mm (in)
Connecting rod bearings, radial clearance ............... mm (in)
Main bearing journals
Out-at-round , max ................................ .... mm (in)
Taper, max
........................................... mm (in)
Early type
Diameter , standard ............. mm (in) 55 (2.1574)
54.75 (2.1572)
54.50 (2. 1473)
undersize
1
.......... mm (in)
2 .......... mm (in)
Connecting rod bearing journa ls
Out-at-round max ..................................... mm (in)
Taper, max .
.......................................... mm (in)
Diameter, standard .
............ , ...................... mm (in)
mm (in)
40
undersize 1 ................................. mm (in)
mm (in)
2 ................. ................ mm (in)
mm (in)
Load
o
153 N
340 N
Balance shaft belt
Used belt New belt
3.4±0.2 3.8±0.2
4.0±0.2 4.3±0.2
4.7±0.2 4.9±0.2
0 .040 (0.0016)
0.080-0 .270 (0.0032-0.0106)
0 .
024-0.072 (0.0009--0 .0028)
0.024-0.064 (0.0009--0.0025)
0.023-0.067
(0. 0009--0.0026)
0.006 (0.0002)
0.006 (0.0002)
Late type
63 (62.987-63 .000) mm
62.75 (62.737-62.750) mm
62.50 (62.487-62.500) mm
t
Taper
0.025(0.0010) f ~
0.025 (0.0010) ) 49.00 (1.9306)
48.984-49.005
(1.9300-1.9308)
48.75 (1.9207)
8.734-48.755 (1.9208-1.9209)
115 089
48.50 (1.9109) Out-ot-round
48.484-48.505 (1.9103-1.9111)

(
70019401960 Specifications
Section
2 B 200, B 230 Engines
Bea rings
Main bearings
Two types of main bearings are in use. Upper and lower
shells
on same journal must be same type.
Connect
ing rod bearings
Matched
shells are used in production:
Shells are colour -coded (red, blue, yellow) as follows:
136753
Assembly 1 Two yellow shells.
Assembly
2 One blue and one red.
Blue shell in con-rod and red in cap.
Colour code Note that only yellow-coded shells are kept in stock .
• Late type: also main bearing shells .
Connect ing rods
Axial clearance at piston ............................... mm (in) 0.15-0.45 (0.0059-0.0177)
Max weight deviation between connecting
rods
in same engine ................................. gms (oz.) 20 (0.7)
Flywheel
Axial throw, max ...................................... mm (in) 0.021100 diameter (0.0008/3.9400)
Tightening torque data
The tightening torques apply to oiled nuts and bolts.
Oegreased
(washed) parts must be oiled prior to use.
Main bearing
............................................... .
Connecting
rod bearings', step 1 ............................. .
step 2
............................. .
Flywheel/carrier plate (use new bolts) ...................... ... .
Spark plug (do not oil) ....................................... .
Camshaft gear
.............................................. .
Intermediate shaft gear, B 200/230 ............................ .
Camshaft cap
.............................................. .
Crankshaft, centre
bolt pulley, step 1 .......................... .
step 2 .
.. ....................... .
8204/234
Reinforcing strut ............................................ .
Camshaft -
idler pulley ...................................... .
Camshaft -tension
roller .................................... .
Balance shaft housing, assembly on bench .................... .
Balance shaft housing, installation, stage 1 .................... .
stage 2
.................... .
stage 3
.................... .
stage 4
.................... .
Balance shaft pulley ......................................... .
Balance shaft -tension roller .. ............................... .
Crankshaft
pulley, stage 1 .................................... .
stage 2
.................................... .
• Bolts can be reused provided length does not exceed 55.5 mm (2.187 in)
Nm
110
20
angle-tighten 90°
70
25
50
50
20
60
angle-tighten 60°
25
25
50
5
20
Slacken
10
Angle-tighten
90°
20
50
60
Angle-tighten 60°
ftlb
80
14
51
18
37
37
15
43
18
18
37
35
18
7
15
48
44
41
III :11' III II, III 'III III ,11' III

70019401960 Specifications
Section 2 B 200, B 230 Engines
8204/234
Cam carrier (centre fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7
Oil pump, inlet ..... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8
Oil pump -pulley, step 1 ..................................... 20 15
step 2 .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . angle-tighten 60 °
Cylinder head , tighten in stages : 8200/230
1 = 20 Nm (14 ft Ib)
2 = 60 Nm (43 ft Ib)
3 = angle tighten 90° in one movement
8204/234
1 = 20 Nm (15 ft Ib)
2 = 40 Nm (30 ft Ib)
3 = Angle tighten 115°
134 266 ~'--~3---1---5,---w9'~
Bolts should be replaced if centre section shows signs of ex­
tension.
o ~O
o O~ 0
-~8,---..... 4-2 6 1
ns 125 Do not reuse bolts more than 5 times . If in doubt fit new bolls . Tightening sequence for cylinder head bolts
Group 22 Lubricating system
General data
Oil capacity and quality, see page 12.
Oil pressure at 33 rls (2000 rim in), warm engine and
new oil
filter ........ ; ............................... MPa (psi) 0.25-0.60 (35.6-85.3)
Oil pump
8200/230
0.02-0. 12
(0.0008-0.0047)
0 .
02-0.09
0.0008-0.0035)
0 .
15-0.35
(0.0059-0.0138)
0 .
032-0.070
(0.0013-0.028)
0 .
014-0.043
(0.0006-0.0017)
8204/234
Axial clearance ................ ... ....................... mm
(in)
Radial clearance (excluding bearing clearance) . ......... mm (in)
(in)
Backlash (excluding bearing clearance) ..................... mm
(in)
Bearing clearance , drive shaft
............................. mm
(in)
idling shaft .................... ......... mm
Relief valve spring length under different loads:
115083
42
8200/230
Length
39.2 mm (1.5445 in)
26.25 mm (1. 0343 in)
21.0 mm (0.8274 in) (in)
Load
o
46-54 N (10.12 Ib)
62-78 N (14-17 Ib)
0.05-0.
10 (0.0020-0.0040)
8204/ 234
Length
47.6 mm (18.8 in)
32.0 mm (1.3 in)
26 .0 mm (1.0 in)
Load
o
(40-48 N (9-11 Ib)
55-67 N (12-15 Ib)

(
70019401960 SpecHications
Section
2 B 200, B 230 Engines
Group 23 Fuel system
Petrol/gasoline engines . CO content, idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or id-
le.speed
•
CO should be checked/adjusted when engine is warm and idling
•
CO content outside check values shown below = adjust to specified setting value
• CO content within check values need not be adjusted provided engine is operating satisfactorily
Engine Remarks
type Co-meter % Setting
B200K 1
.5
B200E 1.0
B200F not adjustable -
B200ET 1.5
B204E 0 .8
B204FT not adjustable -
B204GT not adjustable (1990) -
B230A 2.0
B230K Switzerland -1986 1 .5 Other markets -1986 1.0 1987-1.0
B230 E 1
.0
B230ET Scandinavia , Switzerland, I Australia 1.54
)
Other markets 1.0
B230F Japan -1988 0.6
Other markets -1988 0 .6 1989-not adjustable -
B230FB not adjustable -
B230FT Japan -1988 0.6
Other markets -1989 0 .6 1990-not adjustable -
B230GT (1990 not
adjustable) 1.0
B234F not adjustable -
B234G 0.8
I) Pulsair system disconnected and plugged, as applicable 2) Connected Lambdasond . Measured in front of catalytic con­verter . 3) Disconnected Lambdasond . Measured in front of catalytic con-
verter 4) 1988-only for 760 with manual gearbox . 5) 1990, connected Lambdasond. 6) AC switched off. Idle speed should rise to 15.0 r ls (900 rpm) when AC is switched on again
CO leveP
Idle speed
Volvo rls (r/min)
Checking Mono Tester
Manual Automatic
1.0-2
.5 15.0 (900)
0 .5-2.0
15.0 (900)
0.4-0.8
2 ) 12.9 (775)
1.0-2.5 15.0 (900)
0.6-1.0 15.0 (900)
0.4-0 .8
2
) 13.3 (800)
0.4-0.8
5 ) 13.3 (800)
1.5-3 .0 15.0 (900)
1 .
0-2.5 13.3 (800) 15. 0 (900)
0 .5-2.0 13.3 (800) 15. 0 (900)
0.5-1 .5 13.3 (800) 15. 0 (900)
0.5-2.0 15.0
(900)
1.0-2.54
) 15.0 (900)
0 .5-2.0 15.0 (900)
0 .4-0.8
3
) 20-7004
) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0 .82
) 12.9 (775)
0.4-0 .82
) 12.9 (775)
0.4-0.83
) 20-7004 ) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0.82
) 12.5 (750)
0 .
5-2.05
) 12.5 (750)
0
.4-0.82 ) 14.2 (850)
0 .5-1.1
14.2 (850)
Page
Carburetted engines
(8200 K, 8230 NK) .. ....... 44
CI-system (8200/230 E) ........................ 48
Motronic (8200/2 30 ET) ...... ... .. .. .......... . 51
Constant idle speed system (8200/230 ET) ....... 54
LH-Jetronic (8200/230 F/FT/GT) ................. 55
Regina (8230 F USA) .......................... 58
LH-Jetronic 2.4
(8204 E, 8204 GT, 8204 FT, B 234 F/G) .. ........ 61
43
I
I
III 'III III III III ,III III ,III III

70019401960 Specifications
Section 2 B 200, B 230 Engines
CARBURETTED ENGINES ( B 200 K , B 230 AlK )
Fuel pump
Fuel pressure measured at same level as pump
at 16.6 rls (1 000 r/min) ............................... kPa (psi) 15-27 (2.1-3.8)
B200K
Solex-C isac carburettor
2,7mm
--n ---~~ : I
'~I
1'1I~1~:·,1
I { I
IJ ......... j I
Adjusting vacuum servo
• Choke fully out • Vacuum servo rod fully in (ie at bottom)
44
~_m_m_ .....
Adjusting max engine s peed
• Choke fully in

ENGINE B 230 A
Pierburg (OVG) 175 COUS Carburettor
0,5--1, 5 mm = 0.020-0.059 in
(
" 2.5 mm = 0.0 98 in
70019401960 Specifications
Section
2 B 200, 230 Engines
Me te rin g need le
des ig natio n
NC
= 0.0 20 in
25 mm = 0.985 in
Max idl e speed
20.8-22 .5 rls
(1250-1350 rpm)
136755
4 5
III III
ill III
III II, ill III III

70019401960 Specifications
Section 2 B 200, B 230 Engines
ENGINE B 230 K 1985-1986
Pierburg 2 B 5 carburettor Max idle speed
Cam No.6
- +
~
Switzerland automatic ............... 4.8 mm (0.189 in) Other markets ..... ...... 4.0 mm (0.158 in)
50/120 Switzerland 140 47.5/120 Other markets
45/145
65
(pres sed in cover)
140
(pre ssed
in cover)
46
85
13 6 78 2
Carburettor Switze rland Other markets
designation .
........... 7 .17952.44 7.17952.40
PIN .................. 1 332364-7 1 317036-0
F
loat le v e l
x 140 S witzerland, x 137. 5 Other mark ets
x
117.5 S witzerland x 112.5 Other 100 markets
143982
• Spring-loaded pin in needle valve must not be de­
p ressed
• Float level is not adjustable. If level not to spec. fit
new float and needle valve pin.

(
ENGINE B 230 K 1987-
Pierburg 2 B 7 carburettor
45/130
140
(pressed
in cover)
47,5/115 140
142,5
70019401960 Specifications
Section 2 B 200, B 230 Eng ines
I ----. -----, Max Idle speed
Cam No.6
- +
~
~~~iiiiI" •• .J Automatic , . ............. 5.6 mm Manual .................. 5.0 mm
65 (pressed in cover)
100
136782
Carburettor
designation
..... ....... 7.17952.51
PIN .................. 1 357 108-8
Float le v e l
143982
• Spring-loaded pin in needle valve must not be de­
pressed .
• Float level is not adjustable. If level not to spec. fit
new float and needle valve pin.
47
III
III
'II III ,II 1',',1 III III

70019401960 Specifications
Section
2 B 200, B 230 Engines
B 200 E , B 230 E: CI System
. Pressures
Line pressure .............. kPa (psi) 450-530
(64-75)
Rest pressure .............. kPa (psi) 150-240
(21-34)
Control pressure
warm engine ............. kPa (psi) 345-375
(49-53)
cold engine, see diagram
Control pressure regulator
0438 140 ...
Injectors
""n
0437502 ... 132945
Start injector
0280170 ...
134264
48
'.
Bosch No ............. ...... " . . .. . .. .. . . .. 004
Volvo PIN ............................. " 463 971-2
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 20-30 (2
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 015
Volvo PIN ............................... 1 276037-7
Opening pressure ........... kPa (psi) 350-410 (50-58)
No leakage permissible
below ................... kPa (psi) 290 (41)
Early type Late type
Bosch No ................ 413 ... 445
Volvo PIN.. .. .. . .. ... 1 276 498-1 3 517 065-3
Injected
quantity. . . . . . . . . . . . . . . . . . . . . . . .. 85 cm3/min
Injection time is controlled by a thermal timer (see
diagram
on next page.)