tow VOLVO 940 1982 Service Repair Manual

I
70019401960 Specifications
Section 0 General
1
~-
'''''~''''.' .. ~. . . , .... -. . .~. ," _. , . ..... ,. . . . . VOLV o . '
VOLVO _._N
C I, c , ,. .. , . I
4 C 3
r--8280 9A 150 873
740,760 ,940 ,960
T ype p lates
1. P roduc t p la te
Located on right spring turret (-1984) or above right side
headlamp (1985-). See page 8.
2 . Inf ormation on exhau st emissio n co ntr ols
Sweden , Switzerland, USA, Canada and Australia.
Located on bulkhead. Shows idling speed, valve clear­
ances, ignition timing and CO content. '
760 1988-: located on left side suspension tower.
* USA & Canada: not all details included .
3. Tyre p ress ures
1982 : Located on inside of glove compartment lid.
1983-: Rear edge of right front door.
4. Type, m ode l year des ig nat io ns a nd c hass is
numbe r
A. All markets
Stamped
on RH centre door post.
6
B. Scandinavia:
Sedan: Attached to rear boot member .
Estate: Located on rear right of
wheelhouse
C. USA & Canada
Located on top
left of dashboard.
5. Service pla te (1982-1 989 )
74 01760
Early models : Located on front upper member of luggage
compartment.
Later
models: Rear left door pillar.
780: Located on post behind left side door.
Part Brakes Manufactur er Girling front and rear Girling front and ATE rear
DBA front, ATE rear 760,1988-:
Code 1 2 3
Girling, front and rear 4
DBA front and Girling rear 5
(

70019401960 Specifications
Section 2 B 6304 Engine
Valve Guides
Diameter standard .................................... mm (in)
oversize 1
................................... mm (in)
oversize 2
...................... ............. mm (in)
Clearance, valve stem-guide (measured with new valve) ... mm (in)
Min .
................................................ mm (in)
Valve Springs
External diameter ..................................... mm (in)
Internal diameter ...................................... mm (in)
Length at
270 ± 15 N ................................. mm (in)
Length at
670 ± 32 N ................................. mm (in)
Timing gear
Cams haft
Marking
Inlet ..................................................... .
Exhaust
.................................................. .
Max
lift height ................... ..................... mm (in)
Axial clearance ....................................... mm (in)
Crankshaft assembly
Crankshaft
Max out-ol-true ...................................... . mm (in)
Axial clearance ....................................... mm (in)
Radial clearance (main bearings) ....................... mm (in)
Main bearing journals
Diameter ............................................ mm (in)
Out-ol-round, max
.................................... mm (in)
Connecting rod bearing journ als
Diameter ................................... ......... mm (in)
Out-aI-round, max
.................................... mm (in)
Connecting rods
Axial clearance at crankshaft ........................... mm (in)
Tightening torques
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must
be oiled prior to assembly.
Cylinder
head (stage 1) .............................. Nm (ft Ib)
(stage 2) .............................. Nm (ft Ib)
(stage 3) angle -tightening ....................... 0
Bolts should be tightened in sequence Irom center towards ends .. .
Middle section M 10 (stage 1) ........................ Nm (ft Ib)
M 10 (stage 2) ........................ Nm (ft Ib)
M 8 (stage 3) ........................ Nm (It Ib)
M 7 (stage 4) ........................ Nm (It Ib)
M 10 (stage 5) angle -tightening ................. 0
Bolts should be tightened in sequence Irom center towards ends.
100
inlet
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
27.90±0.20
20.10±0.20
34.00
24.50
PC I
PC E
9.00 0.05-0.20
0.004
0.08-0.19
0.024-0.047
65.00 0.004
50.00 0.004
0.15-0.45
20
60 150
20±2
45±4
24±4
17±3
90
exhaust
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
(1.098±0.008)
(0.791 ±0.008)
(1.339)
(0.965)
(0.354)
(0.002-0.008)
(0. 00016)
(0.003-0.0075)
(0.00094-0.0019)
(2.559)
(0.00016)
(1.969)
(0.00016)
(0.0059-0 .0177)
(15)
(44)
(15±1.5)
(33±3)
(18±3)
(12±2)

(
Control to le ra nce (on test bench)
Load
55 A alternator to ............... ............. ....... ... .
.
70A ...................... ........................... . .
80A .................. ...................... .......... .
90A ......... ......................................... .
The
control voltage should now be between 0 and 0.3 Volt lower than
the previous reading.
V 16
15,5 .
15
'"
v
15,5
15 .
14,5 14
13,5
70019401960 Specifications
Section 3 E lectrical system
47 A (rated output x 0.85)
60 A (rated output x 0.85)
68 A (rated output x 0.85)
77 A (rated output x 0.85)
13 30 20 10 0 10 20 30 40 50 60 70 80 90C' 13 30 20 10 0 10 20 30 40 50 60 70 80 90100 110C'
Exte rn al volt age- te m perature 5A load
1:l9000
Int erri al volt age- te mp erature 5A load
G ro up 33 S ta rt er m otor
Bosch GF 12V 1.1 kW (00013111 .. )
V olvo PIN 463856 , 464 316, 464317,1346 707
Direction of rotation (viewed towards pinion) ............... .... . .
Output . . ......................................... , ......... .
Test values , mechan ical
Armature end clearance ....... ................... .......... . .
Brush spring force
.......................................... .
Distance from pinion to ring gear ... .
.......................... .
Frictional torque, armature brake ............................ .. .
Pinion
idling torque ........... .. ...................... ..... .. .
Backlash ..................... .............................. .
Pinion
modulus . .. .............................. ............ .
Commutator , min . diameter
................................... .
Carbon brushes, min
length .. ............................ .... .
Max
radial runout, commutator and armature body ... ........... .
Clockwise
1 .1 kW (1.5 hp)
0.01-0.3 mm
18-21 N
1.0-3.8 mm
25-40 Ncm
14-22 Ncm
0 .
3-0.5 mm
2.12 mm
33.5 mm
13 mm
0 .
05 mm 0.000
4-0
.012 in
4.1-4.7Ib
0 .039-0.149 in
2.2-3.5 in. lb.
1 .7 - 2.6 in. lb.
0.0118-0.0196 in
0.0835 in
1 .319 in
0 .512 in
0 .0019 in
1 39001
123
III III III III III ,11, III ·111 III

70019401960 Specifications
Section 3 Electrical system
Test
values, electr ica l
Unloaded starter motor: 11.5 V and max. 70 A .................. .
Locked starter motor: 7.4 V and
480-560A ..................... .
6.5 V and
410-490A ..................... .
Minimum cut-in voltage, control solenoid
....................... .
Bosch OW 12 V 1.4 kW (0001108 ... )
Volvo PIN 1 357199, 1 398702, 1 398764
3523301, 3523302,
3523303
Direction of rotation (viewed towards pinion) .................... .
Output ...................................................... .
Test values, mechanical
Armature end clearance ..................................... .
Distance
from pinion to ring gear .............................. .
Frictional torque, armature brake
................ ... ........... .
Pinion idling torque
.......................................... .
Backlash
.................... ............................... .
Pinion modulus
............................................. .
Commutator, minimum diameter
.............................. .
Carbon brushes, min length
.................................. .
Max. radial run-out, commutator and armature .................. .
Test values, electr ica l
Unloaded starter motor 11.5 V and max. 75 A ..... .............. .
Starter motor locked, 4.5 V and
625-800 A ..................... .
Lowest cut-in voltage, control solenoid
......................... .
Bosch OW(R) 12V 1,7 kW (0001110063)
Volvo PIN 1 363912
Direction of rotation (viewed towards pinion) .................... .
Output ................................................... .. .
Test values, mechanical
Armature end clearance ..................................... .
Distance from pinion
to ring gear .............................. .
Frictional torque, armature brake
.............................. .
Pinion idling torque
........................................... '
Backlash ................................................... .
Pinion modulus
............................................. .
Commutator, minimum diameter
............................. . .
Carbon brushes, min length .
................................. .
Max. radial run-out, armature
................................. .
commutator
............................... .
Test values, electr ica l
Unloaded starter motor, 11.2 V and max. 95 A .................. .
Starter motor locked, 3.8 V and
650-840 A ..................... .
Lowest cut-
in voltage, control solenoid ......................... .
124 min
125
rls (7500 rpm)
OrIs and min 16 Nm
OrIs and min 15 Nm
8V
Clockwise
1.4
kW (1.9 hpj
0.05-0.4
mm
2 .0-3.0 mm
0.9-1.4 Nm
0.12 -0.18 Nm
0.3-0.6 mm
2.12 mm
31.2 mm
8.0 mm
0.05 mm
min 48 rls (2900 rpm)
OrIs and min 16 Nm
7.3V
Clockwise
1.7 kW (2.3
hpj
0.05-0.04
mm
2-3 mm
0.9-1.5 Nm
0.12-0.18 Nm
0 .3-0.6 mm
2.11 mm
31.2 mm
6mm
0.05 mm
0 .01 mm
min 2800 r/min
OrIs
7.3V
0.0020-0.0158 in
0.0788-0 .1182
3 .9-6.5 in. lb.
2.4-3.4 in. lb.
0.014-0.023 in
0.0835 in
1.229 in
0.315 in
0.0019 in
(0.002-0.016 in)
(0.08-0.12 in)
(8-13
in Ib)
(1.1-1.6 in Ib)
(0.01-0.024 in)
(0.831 in)
(1.23 in)
(0.24 in)
(0. 002 in)
(0.0004 in)

(
Bosch JF 12V 2 kW (0001362 ... )
Volvo PIN 1 257939
Direction of rotation (viewed towards pinion) .................... .
Output ..................................................... .
Test va lu es , mechanical
Armature end clearance ..................................... .
Carbon brush spring force .
.................................. .
Distance from pinion to ring gear ..
............................ .
Frictional torque, armature brake .............................. .
Pinion
idling torque ........................................ .. .
Backlash ...... ............................................. .
Pinion
modulus ............................................. .
Commutator, minimum diameter
.............................. .
Carbon brushes, min
length .................................. .
Max .
radial run-out, commutator and armature .................. .
Test v alues , e lec tric al
Unloaded starter motor, 11.5 V and max. 95 A .................. .
Starter motor
locked, 4.5 V and 700-880 A .................. ' .. .
Lowest cut-in
voltage, control solenoid ......................... .
Bosch EV 12V 2,2 kW (0001218 ... )
Volvo PIN 1 328392
Direction of rotation (viewed towards pinion) .................... . ,/ Output ..................................................... .
Test values , mechan ical
Armature end clearance ..................................... .
Distance from pinion to ring gear
.............................. .
Frictional torque, armature brake .............................. .
Pinion
idling torque .......................................... .
Backlash.. . . .. ,.,',.,." ..... " .. " ..... , ..... ,., .. ,., .. .. .
Pinion
modulus. , .... , . ... , . , ............... ........ , .... , .. .
Commutator, minimum diameter
.. , , .. , .. , ....... , .... , . , .. , .. .
Carbon brushes, min
length, , ........... , .... , .... , .... , .. , .. ,
Max. radial run-out, armature .. , .. , . . , , , .............. , . , .. , .. .
commutator
....... , ..... , .. , , .... , . , .. , .. .
Test va lu es , e lectr ica l
Unloaded starter motor, 10.5 V and max. 160 A ... , .... . , . , .. , .. .
Starter motor
locked, 3.0V and 720-950 A " ., ........... , ..... .
Lowest cut-in
voltage, control solenoid, , , , ....... , .. , .. , . , .. , .. ,
70019401960 Specifications
Section 3 Electrica l system
Clockwise
2 kW (2.7 hpj
0.01-0.3 mm
23-25 N
2.5-3 mm
0.44-0,74 Nm
0.27-0 .39 Nm
0.35-0.60 mm
2.12 mm
42,5 mm
8.5 mm
0,05 mm
(0.0004-0 .012 in)
(5,2-5.6 Ib)
(0.1-0 .12 in)
(3.9-6 .5 in Ib)
(2.4-3.4 in Ib)
(0.014-0.024 in)
(0.0835 in)
(1.67 in)
(0.33 in)
(0.002 in)
min 108 rls (6500 rpm)
OrIs and min 44 Nm
7.5V
Clockwise
2,2 kW (3.0 hpj
0.05-0.3 mm
2-3 mm
1.0-1.5 Nm
0,27-0.35 Nm
0 .3-0.6 mm
2,12 mm
28 ,9 mm
7.0 mm
0 .05 mm
0,01 mm
min
70 rls (4200 rpm)
OrIs and min 25 Nm
7.8V
0.0020-0.0118 in
0.079-0.118 in
8.8--13.2 in Ib
2.4-3.1 in Ib
0.0118--0.023 in
0.0835 in
1.139 in
0.276 in
0 .0019 in
0,0004 in
125
J

70019401960 Specifications
Section
3 Electrical system
HITACHI 12 V 1.4 kW 5114-232 A
(Volvo PIN 1 357373)
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 kW (1.9 hpj
Test values , mechanical
Armature axial clearance ..................................... .
Brush spring tension
........................................ .
Pinion modulus ... .......................................... .
Idle clearance .............................................. .
Minimum diameter of commutator
.................... ......... .
Minimum
length of brushes .......................... ......... .
Test values, electr ica l
Unloaded starter motor, 12 V and max. 60 A .................... .
Starter motor under
load: 10.3 V, 200 A ........................ .
Starter motor
locked: 6 V and max. 650 A ...................... .
Lowest cut-in
voltage, control solenoid ........ ... .............. .
HITACHI 12 V 2.0 kW 513-91
(Volvo PIN 1 328391)
Direction of rotation (viewed towards) .......................... .
Output ..................................................... .
Test values, mechanical
Armature end clearance ..................................... .
Brush spring force
.......................................... .
Pinion modulus ............................................. .
Pinion backlash ............................................. .
Commutator, min diameter ..
................................. .
Carbon brushes, min
length .................................. .
Test values, electr ical
Unloaded starter motor, 11 V & max 140 A ..................... .
Loaded starter motor, 8.8
V, 300 A. ............................ .
Locked starter motor, 3
V, max 880 A .......................... .
Minimum cut-in
voltage, control solenoid ....................... .
126
0 .03-0.1 mm (0.0012-0.0039 in)
13.7-17. 7 N (1.4-1.8 kp)
2.12 mm
0.3-1.5 mm (0.012 -0.060 in)
39 mm
(0.1536 in)
11 mm (0.433 in)
min. 117
rls (7000 rpm)
min 37
rls (2200 rpm) and min. 4.6 Nm
OrIs and min. 19 Nm
8V
Clockwise
2.0
kW (2.7 hpj
0.2-0.5 mm (0.0079-0.0197 in)
26.5-32.4 N (6.0-7.3 Ib)
2.12 mm (0.0835 in)
0.3-1.5 mm(0.0118-0.0591 in)
35
.5 mm (1.40 in)
9 mm
(0.35 in)
min 65
rls (3900 rpm)
min 25
rls (1 500 rpm) and min 8.3 Nm
OrIs & min 24.5 Nm
8V

70019401960 Specifications
Section 3 Electrical System
760 1988-19 90
,----------BL-Y ---------,
I 11/3 4 GR-R ~ ~ 1
: 3 -+~---'----'-<>e+-q=-OA-HlCg~:~ ~:~~--l '3M ~ •
. ~
BL- Y II/II 11/2 4
3/2:10
4/9:3
5/12:2
7/1: 1
3/2:3
3/2:
13
4/9:5 5/3:3
Fus e Circuit
protected
Left parking light
Numberplate lights
2 Right
parking light
3 Left
main beam
4 Right
main beam
5
SRS test point
6 Left
dipped beam
7 Right
dipped beam
8
Foglight, front
9
Foglight, rear
10
Instrument and control
lighting
11 Revers ing (back -up) light
Turn signals
Cruise control
12 DIMIDIP
13 Heated rear window
Heated door mirrors
132
BL- R OR
3/2 : 12
GN-5 B -3/3:2
GN-5 B -3/3:4
6/31
pf-2/13:2
19/4
15/7
F u se Circuit
protected
14 1 frcircuit in relay box
-
bulb failure sensor, rear
- exhaust temperature
sensor
- overdrive
- power windows
- power sunroof
- fasten seat
belt reminder
16 Spare
17 Spare
18 Radio
19 ECC
Power door mirrors
Tailgate wiper
Power seats
Cigar
lighter
20 Horn
Windscreen wipers
Headlight wipers
21 ETC
Glow plugs, diesel
CIS
22 Spare
A 100)
1/1 Battery
211 Main headlight relay
2111 Electric cooling fan, relay
2113 Motronic, LH-Jetronic, relay
3/1 Ignition switch
3/2 Light switch
3/3 Mainldipped beam switch
4/9 SRS crash sensor
5/3 3-pole combined instrument
connection
5/12 12 -pole combined instrument
connection
6/31 Fuel pump
7/1 Bulb failure sensor, rear
11/1 -35 Fuses
15/1 Positive terminal
15/3 3G-circuit in fusebox
15/7 Ground connection via door switch
19/4 Clock
A Connector, left A-post
(Connector, right A-post, B 280 ElF)
Fuse
Circuit protected
23 Spare
24 Spare
25 Hazard warning lights
Central locking
26 3G-circuit in fusebox
-
clock
- courtesy lighting
- door warning lights
27 Brake lights
28 ECC heater fan
ECC
29 Power aerial
Towing bracket lights
30 Tank
pump
Lambdasond
31 Fuel injection
Main
fuel pump
32 Amplifier, radio
33 Radio
34
Power windows
Power sunroof
35 Heated seats
Power seats

70019401960 Specifications
Section
3 Electrical System
780 1989-1990
Fuse Circuit protected
No. Rating
1
2
3
4
5
6 7
8
9
10
11
12
13
134 Main
fuel pump ........
. .................. 25 A
Central lock, hazard warning lights, main
beam
flash ....... ........................ 25 A
Foglights, front & rear ...................... 15 A
Brake
lights, power boot (trunk) release ...... 15 A
Glove box light, clock, radio engine compo
light, courtesy light, boot light, power radio,
door open warning
lights, vanity mirror light,
door instep light, central lock relay ........... 15 A
ECC
..................................... 30A
ECC heater fan
Heated front seats
......................... 30 A
Power windows
............................ 30A
Fasten seat belt reminder , turn signals,
heated front seats, power windows .......... 15 A
Heated rear window, heated door mirrors,
power sunroof
.............. ............... 30 A
Fuel tank pump, heated Lambdasond
(B 280 F, B 230 FT) ......................... 15 A
Reversing (back-up)
lights, cruise control,
15-circuit card in central electrical unit,
overdrive
.......... ....................... 15 A
Glow plugs (diesel), fuel valve (diesel),
boost pressure limiter (turbodiesel) , electric
cooling
fan ................................ 15A
780 1989-1991
Fuse Circuit protected
No.
14 Power door mirrors, cigar lighter,
radio, reading lamps (rear), ECC, power fuel
Rating
tank flap release .......................... 15 A
15 Horn, windscreen wash/wipe, headlight
wiper, power front seats .... ................ 25 A
16
Amplifier , front ............................ 15 A
17 Main beam
(left), indicator lamp main beam .. 15 A
18 Main beam (right), fog
light. ................. 15 A
19 Dipped beam,
left ......................... 15 A
20 Dipped beam, right .
....................... 15 A
21 Parking lights (left), front & rear,
numberplate light, lighting for: ashtray
(front), heater
control panel switch, heated
rear window switch, power sunroof switch,
instrument
lighting & switches to left of
steering
wheel ...... ...................... 15 A
22 Parking
lights (right), front & rear
Relay, front & rear foglights, auto.
trans
selector panel light, lighting for:
heated front seat switches, storage box
between front seats, rear ashtray
........... 15 A
23
Relay, power front seats (1989)
Amplifier, rear ......................... 15 A (25)
24 Power driver seat
.......................... 30 A
25 Rear
foglight (USA/CON) ................... 15 A
26 Power passenger seat
..................... 30 A
Additional fuses
ABS: one 10 A fuse incorporated in the transient surge pro­
tector at the
pedal mounting
Radio
amplifier (front & rear); two 30 A fuses next to battery
(not
Italy)
B 230 FT high output: one 10 A fuse mounted on left sus­
pension tower