VOLVO 960 1982 Service Repair Manual

TP 30518/10 SAN DIEGO \'OLVO
Specifications
700 1982-1991
940/960 1991
Volvo Cars North America

(
)
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
(
/
4

(
70019401960 Specifications
Section
0 General
E
A
c B
132410
Dime ns io n s 7401760 780 944 /964 945/965
mm in mm in mm in mm in
A. Wheelbase .............................. . ...... . 2770 109 2770 109 2770
109 2770 109
B. Overall
length ................................... . 4785 188.4 4794
189 4871 191.8 4844 190.7
C. Overall width .................................... .
1760
69.3
1770 69.7
1750 68.9 1750 68.9
D. Track,
front ..................................... . 14701
) 57.9 1470 57.9 1471 57.9 1471 57.9
rear
................. ..................... . 14602
) 57.5 14602
) 57.5 1460 57.5 1460 57.5
E
. Overall height3
) ...... .........................•.•. 1410 55.5 1400 55.1 1410 55.5 1440 56.7
1) _ Dec. 1984: wheelbase = 1460 mm. 2) 760/960 4-door, 780 1988-Track
rear 1520 mm 59.9 in 3) Depending on type of tyre.
Weight 740
760 780
Approximate weight of car without occupants, fuWfuel tank 1270-1460 kg 1330-1500 kg 1500 kg
(2798-3120Ib) (2930-33051b) (3305 Ib)
944 945 964 965
1327-1463 1363-1496 1484-1576 1438-1527
,-(2924-3223Ib) (3003-3296Ib) (3270-3472lb) (3168-3364Ib)
The weight varies depending on variant and equipment
Fuel tank .................................... .
760/780 -1987,740, standard, 944/945/965 ........... .
increased-capacity
............... .
760 4 -door ., 780 1988-, 964
Litres
60
82
80
US. gal
15.8
21.6
21.1
5
I

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
(

(

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
I
J

70019401960 Specifications
Section 0 General
Product plate
1982-1 989
A Type approval *
B Vehicle identification
number (type designation) **
C
1 Gross vehicle weight
C
2 Max train weight Ca Max axle load: front C
4 Max axle
load: rear
D Special vehicle
numbers
E Market code
F
Colour code
G Interior code
H Country of manufacture
147941 * Certain countries.
199 0 -W 944
II '. 1.'DE Irl ~========:~===;:=:::;::;W::::,::::EW'::;:::::=r== ;==============ill, , , ,I, ,1'1 II' , , I I EEl ~===========;II 3 3 + El EEl
;==============ill 6 7 71 7 7 1 I II a a a al a al I ~===================; 11999919911
1 99 0 W 945-
199 1-
[ '.11'10E III S I.'/ FD E"I
148098
,I, ,1,1,1,1,1
EEl ~I ======== I
,I, ,I 21 21 I 31
41441414 1 I IEEl
515 161616161
71 7 7 1 71 71 71 I
Iiaia alai I 191
14 8099
The chass is code~has seven positions :
pos 1-2 Front spring, shock absorber, brake disc and caliper
pas 3 Front anti -roll bar
pas 4 Rear shock absorber
pas 5 Rear spring
pas 6 Rear anti -roll bar
pas 7 Bump rubber
the ch ass is code sh ould be inte rp reted as follow s: ~
9X27A24
E
8
Bump rubber:
Rear
anti -roll bar:
Rear spring:
Rear shock absorber:
Front
anti -roll bar:
front spring:
shock absorber:
brake disc:
brake
caliper:
** T ype designation codes, see next spread.
A-C4 As before
1 = Version
2 = Chassis type
3 = Market code
4 = Emission
5 = Steering gear
6 = Brakes
7 = Interior fittings code
8 = Colour code
9 = Special variant (if applicable)
A-C4 As before
1 = Version
2 = Market code
3 = Brakes
4
= Chassis code (see below) 5 = Emission
6 = Interior fittings code
7 = Colour code
8 = Special variant (if applicable) 9 = Steering gear
1330853 -1
3516572 -9
1273977-7
1329507 -6
1330218 -7
1329822-9 I
2 74040 -5
1359906 -3
1359557-4, 1359558- 2
(