VOLVO 960 1982 Service Owners Manual

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70019401960 Specifications
Section
2 B 280 Engine
Valve guides are available in three oversizes and are marked with
grooves .
129865
Valve springs
Standard
Oversize 1
Oversize 2
Oversize 3
115083
Rocker arm mechanism
Marking
No groove
1 groove
2 grooves
3 grooves Reamer
5166
5167
5168
Spr ings marked green
Length
mm in
47.1 1.85
40.0 1.57
30.0 1.18
N
o
230-266
613-689
The rocker arm tips are surface hardened and must not be ground
Load
Ibs.
o
52-60
137-154
Clearance, shaft-rocker arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012-0.054 mm
Timing gears
Camshaft
(0.0005-0.0021 in)
~
--~
Engine type ............................. B280E B280F
Left
Right Left
Right
Marking
........................... ...... R R S S
Colour
code ...... ... .................... White
White Green Green
Part number (last three digits)
.............. ... 957 ... 959 . .. 958 . .. 960
1
32608
B280E B280 F
Max lobe lifting height . left and right. inlet
...................... .
exhaust
........... ' " ... .. . 6.08
mm (0.
2396 in) 5 .96 mm (0.2348 in)
5.85 mm (0.2305 in) 5.43 mm (0.2139 in)
Checking camshaft settings (cold engine) :
adjust valve clearance
on 1 st and 6th inlet valves to .......... .
The inlet valves should then open
at:
1st ...... .................... .......................... .
6th . ................................................... .
Journal clearance
............................... ............ . 0.7
mm (0.0275 in) 0.7 mm (0.
0275 in)
4.50 B.T.D.C. 5 0 B.T.D.C .
4.50 B.T.D.C. 5
0 B.T.D.C.
0 .035-0.085
mm
(0.0013-0.0033 in)
89
III .. III .. III ... III ·11 III

70019401960 Specifications
Section
2 B 280 Engine
Crank mechanism
Cranks haft
Max run-out (measured on two centre main bearing journals) ..... .
Crankshaft, end
float ........................................ .
Crank
journals, side clearance ................................ .
Main bearing journal s
Out of round, max. ; ..................... .
Taper, max
............................. .
Diameter
............................... .
Connecting rod bearing journal s
Out of round, max ....................... .
Taper,
max " ............................. .
Diameter
............................ ... .
Connecting rods
0.007 mm
0.01 mm
70.043-70.062 mm
0.007 mm
0.01 mm
59.971-59.990 mm
End float on crankshaft ...................................... .
Max weight difference between can rods
in same engine ........ .
Tightening torque
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must
be oiled prior to assembly.
Crankshaft pulley ........................ ................... .
Camshaft gear
.............................................. .
Carrier
plate (use new bolts) ................................. .
Spark
plugs (do not oil) .. .................................... .
Valve cover ........................................... ...... .
Connecting
rod bearings ..................................... .
90 0.02
mm
0.070-0.270 mm
0.20-0.38 mm
(0.0002 in)
(0.0003
in)
(2.7575-2.7583
in)
(0.0007 in)
(0. 0027-0.0106 in)
(0.0078--0.0149
in)
115089
Out of round
(0.0002 in)
(0.0003 in)
(2.3629--2.3636 in)
0.18--0.32
mm
2.5 grams
Nm
240-280
70-90
45-50
12±2
15
1 Oil threads
Taper
(0.0071-0.0126 in)
ft. lb.
177-206
52-66
33-37
9±1.5
11
2 Tighten No.1 bolt to 25 Nm (18 ft.lb)
3 Tighten
No.2 bolt to 25 Nm (18 ft.lb) + angle­
tighten 75°
4 Angle -tighten No. 1 bolt 75°
5 Check/tighten both bolts to 50 Nm (37 ft.lb)

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6
l1S 650
Tightening sequence for cylinder head bolts
147795
A. 1900-B. Ear lier type
115091
Tightening sequence for main bearings
(vi a lower crankcase)
7QOl9401960 Specifications
Section 2 B 280 Engine
Cylinder head
Tighten all bolts in stages:
1 Tighten bolts to 60 Nm (43 ft Ib). ? a Loosen bolt 1, tighten it to 20 Nm :(15 ft Ib). b Angle-tighten to 106° using special tool 5098. c' Repeat this for remaining bolts in sequence shown. c Loosen and tighte n each bolt in turn. 3 Adjust valves. 4 Warm-up engine.
5 Allow engine to cool for 2 hrs. 6 Angle-tighten each bolt a further 45°.
1990-
Asbestos-free gaskets, fixed-washer bolts (fig. A).
Tighten all bolts in stages
1 Tighten bolts to 60 Nm (44 ft.lb) 2 a Loosen bolts
b Tighten bolts to 40 Nm (30 ft.lb) c Angle-tighten bolts 160°-180° 3 Adjust valves
Main bearings
Tightening all nuts in stages:
1 = 30 Nm (22 ft Ib) 2 = Slacken nut 1 3 = Tighten nut 1 30-35 Nm (22-26 ft Ib) 4 = Angle-tighten nut 1 73°-77°
5 = Slacken and retighten the other nuts in the order specified in stages 2-4
Side fastening screws
Tightening torques
The 4 fasteners which hold No.2 and 3 main bearings to
engine block should be tightened to 20--25 Nm (15-18 tt)
after the main bearing nuts have been tightened to the
spec ified torque.
91
lit '\1 lit II lit .\1 lit ·11 III

70019401960 Specifications
Section 2 B 280 Engine
Group 22 Lubricating system
General
Oil capacity and quality, see page 12.
Oil pressure, warm engine , new oil cleaner:
at 15 rls (900 r/min), minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 MPa
50 rls (3000 r/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 MPa
Lubricating oil pump
End float ...... ........................ ..................... .
Clearance between tooth tip and pump housing wall (excl.
bearing clearance) .
......................................... .
Backlash (excl. bearing clearance) ............................ .
Bearing clearance , driveshaft ....
............................. .
idler shaft ................................. .
Relief valve spring, length under various loads:
unloaded
..................... ................. ........... .
loaded to 90 N (9.0 kp) .................................... .
92
0.025-0.084 mm
0.020-0.095 mm
0.17 -0.27 mm
0.015-0.053 mm
0.015-0.051 mm
89.5 mm
56.5-60.5 mm
(14.2 psi)
(57 psi)
(0.0010-0 .0033 in)
(0.0008-0 .0037 in)
(0.0066-0 .0106 in)
(0.0006-0 .0021 in)
(0.0006-0.0020 in)
(3.52 in)
(2.22-2.38 in)

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70019401960 Specifications
Section
2 8280 E ngine
Group 23 Fuel system
CO content , id le speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or
idle speed
• CO should be checked/adjusted when engines is warm and idling
• CO content outside check values shown below = adjust to specified setting value
• CO content within check values need not be adjusted provided engine is operating satisfactorily
E ng
ine ty pe CO %1 Id lin g speed
r/s (r/min)
Adjustin g V
o lv o
( c h ec kin g) Mo
no-Teste r
B280E 1.0 (0.5-2 .0) -12.5 (750)
B280F 0.6 (0.2 - 1.0j2 20°_70°3 12.5 (750)
\\\\1""
rpm
1) Pulsair system disconnected and plugged. 135 528 2 ) Lambda -sond disconnected . Measured in front of converter . 3) Lambda-sand connected.
LH JETRONIC 2.2
Air mass meter
Line pressure , pressure
regu lator
Manufacturer's No type I . . . . . . . . . . . . . . . . . . . .. 00 6
II ................. . . . 615
Volvo
PIN ... ............................ 1 336 354-4
Resistance:
• between terminals 2 and 3. . . . . . . . . . . . . .. 2 .5-4.0 0
•
between terminals 2 and 6 . . . . . . . . . . . . . .. 0-1000 0
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 215
Volvo
PIN . ......................... ..... 1 271 135 -4
Line pressure ................. kPa (psi)
Rest pressure
................ kPa (psi) 250 (36)
150-250
(28-43)
93
'" III ill III ,II
,'N III 'II

70019401960 Specifica~ions
Section 2 B 280 Engine
Injectors
0280150 ...
135 790
Coolant temperature sensor
0280130 ... 135791
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 032
Volvo PIN ............................... 1 346 030 -8
Resistance at:
-10°C (14°F) ....................... 8.10-10.77 kG
+20°C (68°F) ........................ 2.28-2.72 kG
+80°C (176°F) ......................... 290-364 G
Air control valve
94
Early type
Bosch No. . . . . . . . . . . .. . .. 725
Volvo PIN ............ 1 271 100-8
Injected quantity. . . . . .. 170 cm3/min
at a line pressure of . .. 250 kPa
(36 psi)
l'l. 4
2
0'. I\. 8
" 6
" 4
" 3 2
'"
1 8
6 ......
4 3 2
0 ' 8
6
4
3 2
Late type
... 734
1 389844-0
170 cm3/min
250 kPa
(36 psi)
..........
"""'-
f".-.
1 0' -30 20 o 0 20 40 60 80 100 120 C 142811
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 501
Volvo PiN ................. .............. 1 317957-7
Resistance between terminals 3 and 4,
and 4 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .. approx 20 n

( ,
Lambda-sond
0258~ 138 112
Fuel pump
&' 0580254 ... 138069
Capacity at a line pressure of 250 kPa (36 psi)
70019401960 Specifications
Section 2 B 280 Engine
Early type
Bosch No ................ 020
Volvo PIN ............ 1 378 123-2
Resistance
of preheating resistors:
Late type
... 034
3501 753-2
cold Lambda sand (20°C = 68°F) ............... 3 n
warm Lambda sand (above 350°C = 662°F) . . .. 13 n
Tightening torque ....... ............ 55 Nm (40 ft Ib)*
* Apply Never seez (PIN 1 161 035-9) to threaded section of sond .
Type I
Bosch No ................ 948
Volvo PIN ............ 1 336 677-8
Type II
... 039
1 389449-8
+20°C (68°F) and 12 V .................................... . 140 litres/hr (37.0 US Galls. per hr)
120 litres/hr (31.7 US Galls . per hr)
95
litres/hr (25.0 US Galls. per hr)
11 V ........•............................
10V .. .................................. .
Current consumption
at a line pressure of 300 kPa (42 psi),
+20°C (68°F) and 12 V .................................... . max 5.0 A
Tank pump
Current consumption . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4 A
95
'" III , II
NI' III ill ,II'
'"
)

70019401960 Specifications
Section
2 B 280 E ngine
General
Group 26 Cooling system
Coolant -compos it ion -gua rantee
Since aluminium is used in ihe 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.
litres
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 U S qts
10.5
Expans ion tank
Pressure valve in cap opens at:
overpressure ...................................... .. ..... .
underpressure
............................................ .
Thermostat
Marking .. .................................................. .
Starts opening at. ........................................... .
Fully open at ............................................... .
Fan belts
kPa
150
7.0
87
86-88° (187-190°F)
9l" (20l"F)
Designation, 760. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HC 38 cog x 1075
780.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HC 38 cog x 1100
96
psi
21
1.0

Group 28 Ignition system
~
~~ ~ 134864
Type ....................................................... .
EZ115K
1-6 -3-5 -2 -4
Firing
order ................................................. .
E ng in e
Ig niti on tim ing Speed rls
type b.t.d
.c. (rpm)
B280E 10° 12 .2-12 .8 (730-770)
B280 F 16° 12 .2-12.8 ( 7 30-770)
Ignit ion coil
Resistance of primary coil
(terminals
1 and 15) . . . . . . . . . . . . . . . . . . . . . . . 0.6-0.8 n
Resistance of secondary coil
(terminal
1 to HT terminal) ..... . . . . . . . . . .. 6 .9-8.5 kn
Spark plugs, glow plugs
Eng in e type Des
ig nation
B
280 E Scandinav ia , B 280 F HR6DC
B
280 E Other markets HR5DC
1317~
PIN
1 269915-3
1
389896-0
Kit num ber
273599-1
270590-3
70019401960 Specifications
Section
2 B 280 E ngine
Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6-0.7 mm (0.0236-0.0276 in)
Tightening torque, (unoiled plugs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft Ib)
Knock sensor
14 6 805
Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (14.5 ft Ib)
97
III ... III II
II' ... II' ·11 II

70019401960 Specifications
Section 2 B 6304 Engine
Section 2 B 6304 Engine
Group 20 General.... . . . . . . . . . . . . . . . . . . . . . . . . .. 98
Group 21 Engine............................... 98
Group
22 Lubricating System. . . . . . . . . . . . . . . . . . .. 101
Group 23 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . .. 102
Group 26 Cooling system . . . . . . . . . . . . . . . . . . . . . .. 106
Group 28 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . 107
Group 20 General
Performance , compression ratios, octane requirements
Engine Notes Compres-Octane
Output
type sion
requirement
Ratio
RON· kWat hp at Nm at
rls rim
rls
B6304F 10,71
) 95 150/100 204/6000 267172
Notes:
1) Unleaded fuel only. Can be run on 91 octane unleaded . • RON stands for Research Octane Number, and is a measure of the ability of the fuel to withstand knocking. MON stands for Motor Octane Number, another way of measuring the same property .
(R+M)/2, also called AKI (Anti Knock Index) is a combination of these two measurements . 95 RON is equivalent to 91 (R+M)/2. 91 RON is equivalent to 87 (R+M)/2 .
Other general data
Number of cylinders ......................................... .
Bore .
.................................................... .. .
Stroke .......................................... .......... . .
Displacement ......................... ................ ...... .
Firing order
............................................... .. .
Compression
(normal rating) 1) • ••••• ••••••••••••••••• •.••••••.•
Weight, approx ............................................. .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 rIm)
6
83.00 mm (3.268 in)
90 .00 mm (3.543 in)
2.922 dm3 (Iitres)
1-5 -3-6-2 -4
1 .3-1 .5 MPa (184-213 psi)
180 kg (397 Ib)
Group 21 Engine Block
Cylinder head
Max torque
kpm at
rim
27.214300
Height, new ............................... ........... mm (in) 129 .00±0.05
Max machining .............. ......................... mm (in) 0.3
(5.0787±0.0020)
(0.0012)
Max warp:
along ......... .... ................................. mm (in) 0.020
across .................................. ...... ..... mm (in) 0 .008
98