engine VOLVO 940 1982 Service Repair Manual

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)
Contents
General
Lubrication B 19, B 23 Engines
B200, B230, B204, B234 Engines
B28 Engine
B280 Engine
B
6304 Engine
024, 024 T , 024 TIC Engines
Electrical System
Power Transmission
Brakes
Suspension and steering
Springs , dampers and
wheels
Body and interior
Revisions and changes to the previous edition are indicated by
a
line in the margin.
Order No. TP 30518/10
Supersedes TP 30518/9
70019401960 Specifications
'., ..
SAN DIEGO ~OLVO
tI5384
2
12
15
35
69 86
98
108
118
138
153 155
159
160
We reserve the right to make alterations without prior notification.
11111 1 1111 1111 IIII! 1111
11111 1111 1111 ·1111 1111 11111 1111 11111 1111 11111 1111 1111 1111
;::::::: 1111 1,1 ..... 1111 II,' ....
~:,:,:,: 1111 , ...... 1
1,' .... 1
1 ...... 1 1111 ·11" 1111 ,II', 1111 III'
I:':':':
'"' '"' ~ .... ,'. 1111 , .... " 1 III' 1111
:I:':',~ ·11 11,1
,"' 1111 III'
'" 1111 ...... 1 ,11' "'1 ,II'
"" I .... I~ III
"' "' ·111 1111 ,III
"' I II I
'" 1111
"' 1111
·11' 1111 I II 1 III III 11 .... 1 III 111/ ,II til. '"I III 1111 .'.'111 ,III 111/ ,II
11.'.'1
Itt'.'1
' llt
lit 'II It.'I'1 It.'.'1 III IItl 'II~ III III til "'1 " " , .... 11
'~I~'~

I
70019401960 Specifications
Section 0 General
General data
740
Section 0 General
Modell Designation
Chassis number Engine type Gearbox
year 744 745
1984 E 33720-819E,819ET, AW70, AW71,
81679" 823E,024 M46, M47,
ZF4HP22
1985 F
81680-1-6969 8200K,8200E, AW70, AW71,
215754 " 8200 ET, 8230 A, M46, M47,
8230E,8230F, ZF4H22
8230 K, 8230 ET,
8230 FT, 024, 024 T
1986 G
1-90199 6970-8200K,8200E, AW70, AW71,
62099 8200 ET, 8230 A, M46, M47,
8230E,8230F, ZF4HP22
8230 K, 8230 ET,
8230FT, 024, 024 T
-1987 H 90200-62100-8200K,8200E,
AW70, AW71,
190699 116099 8200 ET, 8230 E, M46, M47
8230 ET, 8230 F, ZF4HP22
8230 FT, 8230 K,
024,024 T, 024 TIC
1988 J 190700-116100-8200K,8200E, AW70, AW71,
294099 176799 8200 ET, 8230 E, M46, M47,
8230 ET, 8230 F, ZF4HP22
8230 FT, 8230 K,
024,024 T, 024 TIC
1989 K"" 294100-176800-8200 K, 8200 E, AW 70, AW 71, AW 72,
France: 396999 242699
8200ET, 8204 E, 8230E, M46, M47,
o (zero) 8230 ET, 8230 F
ZF4HP22
8230 FT, 8234 F, 8230 K
024, 024T, 024TIC
1990 L 397000- 242700-8200E, 8200F, 8204E, AW 70, AW 71, AW 72,
France: 499199
316299 8204GT, 8230E, 8230F, M46, M47,
o (zero) 8230 FT, 8230 GT, ZF4HP22
8234 F, 8230 K
024,024 T, 024 TIC
1991 M 499200- 316300-8200E,8200F, AW70, AW71,
France:
8200 FT, 8230 E, 8230 F ,
M46, M47,
o (zero) 8230 F8, 8230 FT, ZF4HP22
024,024 T, 024 TIC
* 744 and 764 models from 1984 and 1985 were grouped in same chassis number series. ** Sweden : K from chassis number 3422551208548.
2
Final drive
ratio
3.54:1, 3.73:1
3.91 :1
3.31 :1, 3.54:1
3.73 :
1, 3.91:1
3.31:1, 3.54:1
3.73:1,3.91 :1
4.10:1
3.31:1, 3.54:1
3.73:1, 3.91:1
4.10:1
3.31 :1, 3.54:1,
3.73:1, 3.91:1,
4.10:1
3.31:1, 3.54:1,
3 .73:1,
3.91:1,
4.10: 1
3.31 :1, 3.54:1 ,
3 .
73:1, 3 .91:1,
4 .10:1 (
3.31 :1, 3.54:1,
3 .73:1, 3.91:1,
4.10:1

70019401960 Specifications
760
Model Designation Chassis
number Engine type Gearbox
year 764 765
1982 C 1-3799 B28E AW71, M46
1983 D 3800-B28A, B28E, B28F, AW71, BW55
33719 D24T, B23ET M46
1984 E 33720-B28A, B28E, B28F, AW71, BW55,
81679" D24T, B23ET M 46 , ZF4HP22
1985 F
81680-1-999 B
28 A, B 28 E, B 28 F, AW71, M46,
215754" B 230 K, B 230 ET, M 47, ZF4HP22
B
230 FT, D 24 T
1986 G
1-16999 1000-B28A, B28E, B28F, AW71, M46,
8499 B
230 K, B 230 ET, M 47, ZF4HP22
B
230 FT, D 24 T
1987 H
17000-8500-B 230 K, B 230 ET, AW71, M46,
37399 16299 B
230 FT, B 280 E, M47,
ZF4HP22
B280F, D24T, D24TIC
1988 J 37400-16300-B 230 ET, B 230 FT, AW71, M46,
58499 23499
B280E, B280F, D24TIC M47,
ZF4HP22
1989
K"" 58500-23500-B 230 ET, B 230 FT, AW71, M46,
France: 76899
31119
B280E, B280F, D24TIC ZF4HP22
o (zero)
1990 L 76900-31200-B 230 FT, B 230 GT AW71, M46,
France:
B280E, B280F, D24TIC ZF4HP22
o (zero)
• 744 and 746 models from 1984 and 1985 were grouped in the same chassis number series . .. Sweden: K from chassis number 67303/27155.
780
Model Designation Chassis number Engine type Gearbox
year
1986
G 1-1199 D24TIC M46
1987 H 1200-3299 B 200 ET, B 280 E
M46, AW71
B280 F, D24 TIC
1988 J 3300-6499 B 200 ET, B 280 E, M46, AW71
B280F, D24TIC
1989 K" 6500-8999 B 230 FT, B 280 F, M46, AW71
France :
D24TIC
o (zero)
1990 L 9000-11299 B 230 FT, B 280 F, M46, AW71
France:
D24TIC
o (zero)
1991 M 11300-B 230 FT, B 280 F AW71
• Sweden: K from chassis number 7509.
Section 0 General
Final drive ratio
3.31 :1, 3.54:1
3.31 :1, 3.54 :1
3.31 :1, 3.54:1
3.73:1, 3.91:1
3.54:1 , 3.73:1
3 .
91 :1
3.54 :1, 3.73:1
3 .
91 :1
3.54 :1, 3.73:1
3.91 :1
3.54:1, 3.73:1,
3 .
91 :1
3.54:1, 3.73:1,
3.91 :1
3.54:1, 3.73:
1,
3.91 :1
Final drive
ratio
3.54:1
3.54 :
1, 3.73:1
3.91 :1
3.54:1, 3.73:1,
3.91 :1
3 .54:1, 3.73:1
3.54:1, 3.73:1
3.73 :1
3
I
III 'III III III III 'III III 'III III

70019401960 Specifications
Section 0 General
940
Model Desig natio n C
hass is num ber Engine ty pe
Gearbox Fina l driv e
y ea r 944 945 r
a tio
1991 M 1- 1-B200E, B200F, M46, M47, AW70, 3.54 :1, 3.73 :1
France: B200FT, B204
E, B230E, AW 71, ZF4HP22
3.91:1,4.10 :1
o ( z ero) B
230 FB, B 230 FT,
B230GT, B234F, B234 G ,
D24, D24 T, D24 TIC
960
Mode l Designat io n Chass
is nu mbe r Engine type
Gearbox Final d riv e
y ear 964 965 ra tio
1991 M 1-1-
B 204 FT, B 230 GT, M46, AW71,
3.54:1, 3.73:1
France : B
230 FT, B 280 E, B 280 F, AW30-- 43 3.91 :1
o ( z ero) B
6304 F, D 24 TIC
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Carburettor
Fuel pump
Clutch
Alternator ,­
Steering box
SU
Pierburg
Solex Pierburg
Bosch
AC- oelco
Sofabex
Fichtel & Sachs
Verto/Valeo
Bosch
Cam Gear
Zahnrad Fabrik (ZF)
~
'?' .'" ... .
.
---
" .. u.·.. ,
2
3
5
2
3
4
5
2
3
1
2
3
6 . Fina l drive ratio , part and seria l numbers
Located on rear axle .
7. Gearbox type des ig nation, part numbe r and
serial num ber
A. Manual : On bottom of gearbox .
B. Automatic:
BW 55,
AW 55/70171 /72: On LH side of gearbox.
AW3Q-43:
On RH side of gearbox.
8 . Body number pla te
Located above left head lamp.
780
70019401960 Specifications
Section
0 General
3
6
8
7 B 143980
9. Engine type des ig nation, serial number an d
part number
A. 024, o24T, o24TIC
Stamped on cylinder block, beneath vacuum pump.
B. B28
Located on plate in front of oil filter . On B 28 ElF en­
gines: a
decal on the right rear side of cylinder head
shows
last three digits of part number.
B280
Stamped on cylinder block. (Some models: decal)
Early
type : between cylinder banks, to rear.
Late type: front right side, between
inlet manifold and
water pump.
__ -G.-819, B 23
I
Stamped on left side of engine, behind distributor. Last
three digits of part number are shown
on transmission
gearcase.
O. B 200, B 230
Located on timing gearcase . Also stamped in left side of
cylinder block.
E. B6403
Decal
on timing gearcase. Also stamped in right side of
cylinder block, above water pump housing , between
timing gearcase and
manifold.
7
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J

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
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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.
(

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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
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III
:1:1:1
I
11.'.1
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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