oil VOLVO 940 1982 Service Repair Manual

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

70019401960 Specifications
Section 1 Service and maintenance
Rear axle
134142
Lubricating oil ............................................... .
grade , without limited-slip differential or with
automatic differential lock (Eaton)
............ .
I with limited-slip differential (Dana) .................. .
viscosity , above
- 10 °C (+14°F) ............ ........ .
below
- 10 °C (+14°F) ............ ........ ..
Oil change quantity, 1030 .................................... .
1031, -1990 ............................. .
1031, 1991-.... ......................... .
1035 .................................... .
1041, -1990 .... ......... " .............. .
I
1041, 1991-............................. .
1045 .................................... .
Steering gear
134143
.Lubricant. .................................................. .
quantity
..................... ........ .. ............ .
Power steering fluid .
....................... ................. .
quantity,
828 ................................. .
819,823 ...................... ...... .
8200,8230 .... ...................... .
8280 ................................ .
I 86304 .......... ....... .............. .
D 24, D 24 T
-1986 .................... .
D24,
D24 T, D24 TIC 1987-. .......... .
* Volvo power steering fluid (PIN 1161 317-1 is recommended if temperature
is below -20°C (-4°F).
14 Final
drive oil
API-GL-5(6) or MIL-L-21 05 8(C)
Low -friction oil Volvo
PIN 1161 329-6 0 .5 litrelUS qt
API-GL-5(6) or MIL-L-2105 8(C)
with additive Volvo
PIN 1161129-00.5 litre/US qt
SAE
90
SAE 80
1.3 litres (1.4 US qts)
1.6 litres (1.7 US qts)
1 .75
litres (1.85 US qts)
1.4 litres (1.5 US qts)
1.45 litres (1.55
US qts)
1.6 litres (1.7 US qts)
1 .3 litres (1.4
US qts)
Grease, Volvo
PIN 1161 001-1
approx 100 grams (3.5 ozs)
ATF type
A, F or G*
litres
1.0
0 .8
0.8
0.8
0.8
0.8
0.5
(US qts)
(1.1 )
(0.9)
(0.9)
(0.9)
(0.9)
(0.9)
(0.5)

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

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70019401960 Specifications
Section
2 B 19, B 23 Engines
P iston rings
129521
Clearance In piston groove
Clearance in piston groove
819 E, 819 ET, 823 E .................................. mm
(in)
823ET, 823FT .............. .......................... mm
(in)
Ring gap (see above)
819E, 819ET, 823E .................................. mm
(in)
823ET, 823FT ................ .......... .............. mm
Gudgeon (Piston ) pins
Fit, in connecting rod. . . . . .. Light thumb pressure
(close running fit)
in piston. . . . . . . . . . . . . .. Thumb pressure (push fit)
Valves
Valve clearance
Inlet
and exhaust valves
(in)
cold engine ............................................ mm
(in) warm engine ........................................... mm
(in)
Adjusting shim, thickness .................................. mm
(in)
Valves
Upper
Camp.
rings
0.040-0 .072
(0. 0016-0.0028)
0.060-0 .092
(0.0024-0.0036)
0 .35-0.65
(0.0014 -0 .0026)
0.40-0 .
65
(0.0158-0.0256)
Checking
0.30-0.40
(0.012-0.Q16)
0.35-0.45
(0.014-0.018)
3 .
30-4.50
Ring gap 129 520
Lower Oil scraper
Camp.
rings rings
0.040-0.072 0.030-0.062
(0.0016 -0 .0028) (0.0012 -0.0024)
0.040-0.072 0.030-0.065
(0.0016-0.0028) (0.0018-0.0026)
0.35-0.55 0.25-0.60
(0.0014-0.0022) (0.0010-0.0024)
0.40-0.65 0.30-0.60
(0.0016-0.0256) (0.0118-0.0236)
'Adjusting
0.35-0.40
(0. 014-0 .016)
0.40-0.45
(0. 016-0.018)
(0.1300-0 .1773)
in increments of
0.05 (0.002)
IMPORTANT: Valves are stellite-flashed and must not be machined . They may only be ground in against seat. IMPORTANT! Scrapping valves. Exhaust valves in turbo en­gines are sodium filled and must not be mixed with ordinary
scrap iron without first removing the sodium.
Min: 7,935
Inlet valve
44,5°
44,5 °
Min: 7,945
144027
Exhaust valve turbo engines (8 19 ET, 823 ET/FT)
Exhaust valve E-engines (8 19 E, 823 E)
17
III' III III
III
III ,111 III ·111 III

70019401960 Specifications
Section 2 B
19, B 23 Engines
Tightening torques
Apply to oiled nuts and bolts.
Oegreased (washed) parts must be oiled prior to assembly.
Main bearings ....................... ' ....................... .
Connecting rod bearings,
old bolts ............................ .
new
bolts ......... .................. .
Flywheel (use new bolts) ..................................... .
Spark
plugs (unoiled) .............. ; ......................... .
Camshaft sprocket
............... ........................... .
Intermediate shaft sprocket ................................. .. .
Camshaft bearing caps .
............................ ......... .
Crankshaft center
bolt ....................................... .
Cylinder head , tighten in stages:
134266
Bolts should be replaced if center section shows signs of ex­tension. Do not re-use bolts more than 5 times . If in doubt, fit
new bolts.
Nm
110
63
70
70
25±5
50
50 20
165
1 = 20 Nm (14 ft Ib)
2 = 60 Nm (43 ft Ib)
ft Ib
80
46
51
51
18±3.5
36
36 15
120
3 = Angle-tighten 900 in one motion
'7--3---­
o 0
000
8-4-2-
--9
o
115326
Tightening sequence for cylinder head bolts
Group 22 Lubricating system
General
Oil capacity and quality, see page 12.
Oil pressure at 33 rls (2,000 r/min) with warm engine
and new
oil filter ...... .............................. MPa (psi) 0.25-0.60 (35-85)
Oil pump
Axial clearance .................. ..................... mm (in)
Radial clearance (excluding bearing clearance) .......... mm (in)
Backlash (excluding bearing clearance) ................. mm (in)
Bearing clearance, drive shaft
.......................... mm (in)
idling shaft ..... ........... .......... mm (in)
Relief valve spring length under different loads
~~~ 115083
20
Lengths
39.2 mm (1.5445 in)
26.25 mm (1.0343) in)
21.0 mm (0.8274 in)
0.02-0.12
0.02-0.09
0.15-0.35
0.032-0.070
0.014-0.043
Load
o
(0.0008-0 .0047)
(0.0008-0.0035)
(0.0059-0.0138)
(0.0013-0. 028)
(0.0006-0.0017)
46-54 N (10.1-11.9 Ib)
62 -78 N (13.6-17.2 Ib)
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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 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·