VOLVO 940 1982 Service Manual PDF

145630
kO
6 3.0
4 0 .0
2 5 .0
( 16. 0
10 .0
6. 3
4.0
2.5
1 .6
"' I'\.
I\. ,
I\.
i'..
'i'.
'" 1 .0
0 .63
0.40 "" ...... ..... 0.25
0 .16
0 .10 .....
~
·40 -20 20 40 60
80 100 120 DC
145720
A ir contro l (idle ) va lve
146338
Lambda-so nd
14 6339
7001940 1960 Specifieations
Section
2 B 200, B 230 Engines
Air press ure sensor
Volvo PIN ... .... ...................... . 1 378 162-0
Signal
strength about 4.4 V at. .......... .
3,2 V at. .
......... .
2,1 Vat ........... .
1,1 V at. .......... .
0,5 V at. ......... . .
145631
A ir intake te m pe ra ture se nso r
100 kPa
80 kPa
60 kPa
40 kPa
20 kPa
Volvo PIN ....................... ....... 1 389 556-0
Approximate resistance values in Os:
- 40 °C
(-40°F) . ........................... .
-20°C (-4°F) ......... .................... .
O °C (32 °F) .............................. .
+
20 °C (68 °F) ........... ......... ......... .
+80°C (176°F) ....... ........ ...... ...... ..
For other resistance values, see chart .
45,000
15 ,000
5,800
2,500 330
Volvo
PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1389557-8
Resistance ..... ......... .. ............... approx 4 0
Volvo
PIN .... . .......................... 3517394-7
Resistance of preheating resistors:
cold Lambda (20°C = 68 °F) .................... 30
warm Lamds sand (above 350°C = 662 °F) ...... 130
Tightening torque. . . . . . . . . . . . . . . . . .. 55 Nm (40 ft Ib)*
• Apply Sealer (PIN 1161 035-9) to threaded section of sond .
59
II. III III III
III
III
III
I' ....

70019401960 Specifications
Section
2 B 200, B 230 E ngin es
Fuel pump
B230 F
~
Early typ e
Bosch
PIN. . . . . . . . . . .. . .. 022
Late typ e
... 039
1389449-8 Volvo PIN ....... ..... 1 306932 -3
0580464 ... 135793
B 230 F ea rly typ e, B 230 FT
Capacity at a
line pressure of 300 kpa (42 psi)
+20°C (68 °F) and 12 V ......... : . ......................... .
11 V ...... ....... ..................... .. .
10V .......... .......................... .
Current consumption
at a line pressure of 300 kPa (4 2 psi)
+20°C (68 °F) and 12 V ........................ ............ .
B
230 F l a te typ e
Capacity
at a line pressure of 250 kPa (36 psi)
+20°C (68 °F) and 12V .................................... .
11 V ............. .. .... ............... .. .
10V ..................... ............... .
Current consumption
at a line pressure of 300 kPa (36 psi),
+20°C (68 °F) and 12V ..................... ............... .
B230F , Regina 1 99 0
(P ump in ta nk)
((
145697
130 litres/hr (34.3 US Galls . per hr)
108 litres/hr (28.5 US Galls. per hr)
85 litres/hr (22.4 US Galls. per hr)
max 6.5 A
140 litres/hr (37.0 US Galls. per hr)
120 litres/hr' (31.7 US Galls. per hr)
95 litres/hr (25.1 US Galls. per hr)
max 5.0 A
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3531 165-3
Pump capacity at a line pressure of 350 kPa (50 psi)
+20°C (68 °F) and 13.5 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 litres/hr (25.1 US Galls . per hr)
Current consumption
at a line pressure of 350 kPa (50 psi)
+20°C (68 °F) and 13.5 V.. . . .. . . .. ... . . . . . . . .. . . .. . . . . . . .. . . 8 .8 A
Tank pump
B230FT/ G T
... 025
1336679-4
Current consumption . . . . . . . . . . . . . . . . . . . . . . . .
.. 1- 4 A
60

70019401960 SpeCifications
Section
2 B 200, B 230 Engines
B 204 E /B 204 GlI B 204 FT/B 234 G /B 234 F: LH-JETRONIC 2.4 .
Air mass meter
Bosch PiN ............
Volvo PIN . ...........
Resistance: [ 0280212 ...
• between terminals 2 and 3 ............
• between terminals
2 and 6 ............
8204E
... 007
1346645-3
3.5-4.00
0--10000
8234F
Type I"
8204GT/FT
. . . 012
3517569-4
2.5-4.00
8234F
Type II" 146044
Line pressure , pressure regulator
146333
Injector
(
~ 0280150 ...
136790
Bosch PiN ............
Volvo PIN ............
Resistance:
• between terminals
2 and 3 ............
... 016
3517020-8
2.5-4.00
. . 010
3501987-6
2.5-4.00
• Type I = 1989: All automatics, right hand drive as well as USAf Canada manual. 1990-: All models and markets . .. Type II = 1989: All other manuals .
8204FT
Bosch PIN. . . . . . . . . . .. . .. 730
Volvo PIN ............ 3547368-5
Others
... 294
3517064-6
Line pressure. . . . . . . . . . . . . . . . . . . . . .. 300 kPa (42 psi)
Shut-down pressure. . . . . . .
.. 200--300 kPa (28-42 psi)
8204 E 8204GT/FT 8234 FIG
Bosch PiN ............ ... 762
... 804 ... 749
Volvo PIN ..... ....... 3517572-9 3517283-2 3501986-8
Injected quantity at a ... 185 cm3/min 300 cm3/min 214 cm3/min
line pressure of ........ 300 kPa 300 kPa 300 kPa
(42 psi) (42 psi) (42 psi)
61
'" II' .11 II'
'II
II, III III
'"

70019401960 SpetJiftdiIttons '
Section
2 ' B 200, ' B230:1Engines
Air con1ro'~(id{e~i.valve
146171
Injector ballast resistor pack
Coolant temperature sensor
0280130 ... 135791
Bosch PIN. . . . . .. .. . .. . .. . .. . . .. . . .. .. . . . .. . .. 032
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 346030-8
Resistance:
1Q° C (14 °F) ........................ 8.10-10.77 kO
20°C (68 °F) ......................... 2.28-2.72 kO
+80° C (176 °F) ......................... 290-3640
Lambda-sond
0258~3 ... ' 138112
62
Bosch PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 516
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 389618-8
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. approx 8
0
Four resistors (1 per injector)
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5.5-6.5 0
4
I\.
rf' r\. 8 "-6 "-4
"
-3
2
" '8 "-6 I"-... 4 3
""" 2
~ 0' 8
6
4 3
2
0' -30 20 0 20 40 60 80 100 120 C 142811
B204GT B204FT B234F
Bosch PIN. . . .. . .. 085 .. . 090 ... 034
Volvo PiN ..... 3517778-1 3531400-4 3501753-2
Resistance of preheating resistors:
cold Lambda (20°C = 68 °F) .................... 30
warm Lambda sand (above 350°C = 662 °F). . .. 130
Tightening torque. . . . . . . . . . . . . . . . . .. 55 Nm (40 ft Ib)*
* Apply Never seez (PIN 1161 035-9) to threaded section of sond.

Fuel pump
~
0580464 ...
135793
Tank pump
70019401960 Specifications
Section
2 B 200, B 230 Engines
Bosch PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 039
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 389449-8
Pump capacity at
300 kPa (42 psi) line pressure.
+20°C
12 V .............................. .
'
11 V ............................. ..
10 V .............................. . 130
litres/hour
108 litres/hour 65 litreslhour
Current consumption at
300 kPa (42 psi) line pressure.
+20°C & 12 V .......................... max 6.5 A
Current consumption. . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 A
63

700/940/960 Specifications
Section 2' 8200,8230 Engines
Group 25 Intake and exhaust systems
Turbo engines
'-198~
Engine type .... ; ......... . , ............ .. .............
Charg~ pressure, at full load and ................... r/min
checking
.. ................... kPa (psi)
setting. . . . . . . . . . . . . . . . . . . . .
.. kPa (psi)
Charge air overpressure, switch opens at ....... kPa
(psi)
Charge air pressure, switch closes at ........... kPa (psi)
Tightening torques
4) 18 Nm (13 ft IW)
/
1) Apply sealer PIN 1 161 053-2. 2) Use new nuts
3) Use sealer PIN 1161 035-9.
8200/230 ET
3500
45-53 (6.4-7.5)
50 (7.1)
65-75 (9.2-10.7)
15-25 (2. 1-3.6)
3)
4) Use new boils. If absolutely necessary, old boils can be reused if they
are smeared with sealer PIN 1161053-2.
Mounting bolts, turbocharger -exhaust manifold
• Measure length of bolt. Bolts can be reused if shorter
than
89 mm (3.5 in)
• 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
64
Stage I = 1 Nm (0.7 ft Ib)
II = 45 Nm (33 ft Ib)
III = 45° in one motion without stopping
89mm
135780
~Nm
s::L).Nm
8230FT
3000
46-54 (6.5-7.7)
48-54 (6.8-7.7)
85-95 (12 .1-13.5)
-
136772

Turbo engines
1990-
700194 01960 Specifications
Section
2 B 200, B 230 E ngines
Engine type ......... ................................ ..... .. .... B23 0FT/GT
Charge p ressure, at full load and ......... ' .................. r/min 3000
checking ............................. kPa (psi)
48-54 (6.8-7.7)
setting ...... .................... ' ...... kPa (psi) 51 (7.3)
Pressure sensor, leak test kPa (psi)
Relief valve , fully open at pressure difference kPa (psi)
Tightening torques
J.
'1:C@1 ,
147 943
T ightening sequ ence (Turbocharger -exhaust manifold)
60-70 (8.5-10.0)
22 (3.1)
Turbocharger -exhaust manifold ' ...... 3 0 N m (22 ft Ib)
Use special tool 5411 (at 90° angle to torque wrench)
T urbocharger
-exhaust pipe ' .......... 30 Nm (22 ft Ib)
• Use sealer PIN 1161035-9 .
65

70019401960 Specifications
Section 2 B 200, B 230 Engines
General
Expansion tank
Group 26 Cooling system
128187
Coolant -composition -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 (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 1161328-8
prior to
filling new coolant.
Capacity, B 200/230. . . . . . . . . . . . . . . . . . approx 8.5 litres
US qts 9.0
B 204/234. . . . . . . . . . . . . . . . .. approx 9.5 litres
US qts 10.0
Pressure valve
in filler cap opens at;· . kPa psi
11
14
21
1.0
overpressure, early type .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
late type without turbo . . . . . . . . . . . . . . . . . . . . . . . . . 100
with turbo and B 204/234. . . . . . . . . . . . . . . 150
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .0
Thermostat
Marking ............................ ........................ .
Starts to open
at ......... .............. ..................... .
Fully open at ............................................... .
66
Type 1
87
86-88 °C
(187-190 °
F)
9rC
(20rF)
Type 2
92
91-93°C
( 196-199 °F)
102°C
(216 °
F)

70019401960 Specifications
Section
2 B 200, B 230 Engines
Group 28 Ignition system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breakerless
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
E
ngine Ignition
type timing
b.t.d.c.
B200K 15°
B200F .12°
B200E 12 °
B200ET 14°
B204E 15°
B204FT/GT 10°
B230A* 7°
B230K 15°
, Vacuum regulator disconnected . '* Japan -1988: 15 rls (900 rpm).
Speed rls
(rpm)
12.5
(750)
12.1- 13.8 (725-825)
14.2 -15.8
(850-950)
14.7-15.3 (880-920)
14.2-15.8 (850-950)
13.0-13.7 (780-820)
11.7-13.3 (700-800)
13.3 (800)
''* Ignition system Rex, USNCanada : 10°.
Ignition coil
Engine Ignition
type timing
b.t.d.c.
B230E 12°
B230ET 10°
B230F -1988 12 °
1989-12°***
B230FB 12 °
B230fT/GT 12°
B234F/G 15°
B200E,B200K,B230E
B 230 F, B 230 FB, B 230 K,
Speed rls
(rpm)
14.2-15.8
(850-950)
14.7 -15.3 (880-920)
12.2 -12.8 (730-770)* '
12.1-13.8 (725-825)
12.9 (775)
12.2 -12.8
(730-770)* *
13.3-15.0 (800-900)
B200ET,
B230ET B230F
131 7~1 B230A B 230 FT, B 204 E, B 204 FT/GT, Rex
B234 FIG
Resistance of primary coil (terminals
1 and 15) .................................... . 0.6-0.90 0.6-0.80 0.50 0.50
Resistance of secondary coil
(terminal
1 to HT terminal ...................... . 6.5-8. 5 kO 6 .9-8.5 kO 6 .0 kO 5 .0 kO
Knock sensor
II 146804
Tightening torque, type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (8 ft Ib)
type 11......... ............................. 20 Nm (14.5 It Ib)
67
I
I
I
til' ·ut til, til lit ·
t''''' '111 lit

I
I
I
70019401960 Specifications
Section 2 B 200, B 230 Engines
Spark plugs, g low plugs
I~~n
~ 143983
E ngin e type Designation Type I Type II
P
IN Se t number PIN Set number
B 200 K, B 200 ET, B 200 F,
B 230 A, B 230 K -1986, B 230 ET WR7DC " 1 306605-5 273597-5
1 367528-5 270 746-1
B 200 E, B 204 ElFT/GT, B 230 K
1987-, B
230 E, B 234 FIG WR6DC** 1 306604-8 273596-7 1 367529-3 270 747-9
B
230 F, B 230 FB, B 230 FT/GT WR7DC 1 346 541-4 271 409-5
1 367528-5 270 746-1
B 230 FT Europe WR6DC 1
367015-3 271 415-2
1 367529-3 270 747-9
• Type II spark plugs are standard on B 200/230 -1988-but can also be used on earlier engines (provided HT leads and ground lead are replaced at same time) . .. Up to 1987 W7DC (W6DC, type I).
Electrode gap .............................................. . 0.7-0.8 mm (0.0276-0.315 in)
25 Nm (18 ft Ib) Tightening torque, (unoiled plugs) ............................. .
Distributor
E ngine type Ignition system
B200E, B230K EZ-K
B
230 E, B 230 F -1988, B 230 FT
-1989
EZ- K
B200K Renix
B200F EZ 116 K
B
230 F 1989-, B 230 FB,
B 230 FT/GT 1990 EZ 116 K (Rex ')
B 200 ET , B 230 ET Motronic
B230A TZ-28 H
B
204 E/FT/GT, B 234 FIG EZ 116 K
'USA only
Centr ifugal governor
Advance, total degrees (distributor) . . . . . . . . . . .. 12,5± 1
Advance begins at distrib. rev/sees ............ 7.5-10.5
distrib . rev/min. . . . . . . . . . . .. (450-630) Data : 5° at distrib . rev/sees . . . . . . . . . . . . . . . . .. 16 .5-20.5 (distrib. rev/min) . . . . . . . . . . . . . . . . .. (1000-1250) 10° at distrib . rev/sees . . . . . . . . . . . . . . . . .. 25-29 (distrib . rev/min) .................. (1500-1750)
Advance max at distrib. rev/sees .............. 31.7
(distrib. rev/min) . . . . . . . . . . . . .. (1900)
Vacuum governor
Control direction ............... .. ........... . Control, total degrees (distributor) .......... .. . Control commences at mm Hg ............... .
Data : 5° at mm Hg . .. ....................... .
max control at mm Hg ........ .... ..... .
68
Positive
7.5±1 105-145
165-210
240
Distributor
Volvo PIN Bosch No
1
336087 0237502001
1 336087 0237502001
1 336 132 0237502002
1 336132 0237502002
1 336 132 0237502002
1 336 132 0237502002
1 336690 0237024013
1 367197 0237502003
Ignition advance, B 230 A
~.
rrr~,o , 2p , 3,0 , 4 ,0 , 5,0 , 6,0~;;. + l ' 0 500 1000 1500 2000 2500 3000 3500 4000 rl min
40.20"~mm Wmfmm ~mmfffi=mmm
o· Ii'
-10' -ft '0237 0 24 013
10 20 30 iii 100 200 40 50 60 kpa 3bo i 460 j mm iHg
13 6780
i