brake VOLVO 960 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
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
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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
(

Volvo PIN for each code
Pos Front Shock Brake Brake Pos
1,2 spring absorber,
disc caliper 1,2
front
31 1329822-9 274040-5 1359906-3 1329640-5 EG
1329641-3
42 1329822-9 1329648- 8
1359908-9 1329642-1 EN
1329643-9
44 1329824-5 3530274-
4 1359908-9 1329642-1 ER
1329643-9
54 1329822-9 274040-5
1359906-3 1329866-6
ET
1329867-4
( 5L 1329824-5
271105-9 1359906-3 1329866-6
1329867 -4
5M 1293449-3 271105-9 1359906-3 1329866-6
1329867-4
Pos
5P 1329823-7 271105-9 1359906-3 1329866-6 3
1329867-4
1
5Y
1329822- 9 274040
-5
1359906-3 1329866-6
2
1329867-4
3
9A 1329822-9 274040-5 1359906-3 1359557-4
1359558-2 4
9F
1329823- 7 271105-9
1359906-3 1359557-4 5
1359558-2 6
9X
1329822- 9 274040-5
1359906-3 1359557-4
1359558-2 7
A2 1329822-9
1329648-8 3516567-9 3516565-3 8
3516566-
1 A
A3 1329823-7 3530274-4 3516567-9 3516565-3 B
3516566-1
A4 1329824-5 3530274-4 3516567-9 3516565-3
3516566-1
A5 1387678-4 3530274-4 3516567-9 3516565-3
3516566-1
A9 1387677-6 3530274-4 3516567-9 3516565-3
3516566-1
03 1329824-5 271105-9
1359908-9 3516517-4 Pos
3516518-2 6
07 1329823-7 271105-9
1359908-9 3516517-4 1
3516518-2 2
DC 1329823-7 3530274-4 1359908-9 3516517-
4
3
3516518-2
E2 1329823-7 3530273-6 1359908-9
3516513-2
3516514-1
EE 1329824-5 271105-9 1359908-9
3516513-2
3516514-1
EJ 1293449-3 271105-9 1359908-9 3516513-2
3516514-1
Spring,
front
1329822- 9
1329823-7
1387677-6
1387678-4
Anti-roll
bar, front
1330220-3
1330218- 7
1330221-1
1330219-5
1359808-1
1359807-3
3530276-9
3530277- 7
3516447-4
3516446-6
Anti-roll
bar, rear
3516573-7
3516572-9
3530751-1
70019401960 Specifications
Section
0 General
Shock Brake Brake
absorber, disc
caliper
front
271105-9 1359908-9
3516513-2
3516514
-1
271 105 -9 1359908-9 3516513-2
3516514-1
271 105-9
1359908-9 3516513-2
3516514-1
271105-9 1359908-9 3516513-2
3516514-1
Pos Shock ab-Pos Spring,
4 sorber,
rear 5 rear
1 1329501-9
4 1273759-9
5 1329505-0
7 1273977-7
7 1329507-6 A 1273977-7
9
1329504- 3 C 1359710-9
C 1329500-1 E 3530199-3
F 1330332-6
9 1387836-8
G 1330702-0
H 3516668-5
J 3530200-9
N 3542466-2
M 3530283-5
Pos Bump
7 rubber
4 1330853-1
5 1359653-1
6 1387181-9
9
Itl tit
til til
Itl - til til -til
til

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70019401960 Specifications
Section 2 B 19, B 23 Engines
Group 23 Fuel system
CO-content , idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or
idle speed
• CO should be checked/adjusted when engine 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
Engine Rem ar ks CO co ntent Id le spee d
type r/s (r/m in)
CO m ete r % Volv o
Adjusting Mono tes te r
(checking)
8 19E 1.0 (0.5-2.0) -15 .0 (900)
819ET 2.0 (1.0--3.0) -15.0 (900)
823E 1.0 (0.5-2.0) 1 -15 .0 (900)
823ET 1.5 (1.0--2 .5) -14.2 (850)
823FT USA + Canada 0.6 (0.4-0
.8f 20--70°3 12.5 (75W
Japan 0.6
(0.4-0.8)2 20--70°3 15.0 (900)
I) Pulsai r system disconnected and plugged. 2) Lambda-sond disconnected. 3) Lambda -sond connected . 4) AC switched off. Engine speed increases to 15.0 rls (900 r/min) when AC is reconnected.
Page CI system (819 ElE T, 823 E ). . . . . . . . . . . . . . . . . .. 22
Motronic
(823 ET) ... ......................... 25
LH -Jetronic
(823 FT) . . . . . . . . . . . . . . . . . . . . . . . . .. 28
. ~
135528
21
III IN III
III III
III III
III
J

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70019401960 SpecHications
Section
2 B 200, B 230 Engines
Group 23 Fuel system
Petrol/gasoline engines . CO content, idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or id-
le.speed
•
CO should be checked/adjusted when engine 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
Engine Remarks
type Co-meter % Setting
B200K 1
.5
B200E 1.0
B200F not adjustable -
B200ET 1.5
B204E 0 .8
B204FT not adjustable -
B204GT not adjustable (1990) -
B230A 2.0
B230K Switzerland -1986 1 .5 Other markets -1986 1.0 1987-1.0
B230 E 1
.0
B230ET Scandinavia , Switzerland, I Australia 1.54
)
Other markets 1.0
B230F Japan -1988 0.6
Other markets -1988 0 .6 1989-not adjustable -
B230FB not adjustable -
B230FT Japan -1988 0.6
Other markets -1989 0 .6 1990-not adjustable -
B230GT (1990 not
adjustable) 1.0
B234F not adjustable -
B234G 0.8
I) Pulsair system disconnected and plugged, as applicable 2) Connected Lambdasond . Measured in front of catalytic con­verter . 3) Disconnected Lambdasond . Measured in front of catalytic con-
verter 4) 1988-only for 760 with manual gearbox . 5) 1990, connected Lambdasond. 6) AC switched off. Idle speed should rise to 15.0 r ls (900 rpm) when AC is switched on again
CO leveP
Idle speed
Volvo rls (r/min)
Checking Mono Tester
Manual Automatic
1.0-2
.5 15.0 (900)
0 .5-2.0
15.0 (900)
0.4-0.8
2 ) 12.9 (775)
1.0-2.5 15.0 (900)
0.6-1.0 15.0 (900)
0.4-0 .8
2
) 13.3 (800)
0.4-0.8
5 ) 13.3 (800)
1.5-3 .0 15.0 (900)
1 .
0-2.5 13.3 (800) 15. 0 (900)
0 .5-2.0 13.3 (800) 15. 0 (900)
0.5-1 .5 13.3 (800) 15. 0 (900)
0.5-2.0 15.0
(900)
1.0-2.54
) 15.0 (900)
0 .5-2.0 15.0 (900)
0 .4-0.8
3
) 20-7004
) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0 .82
) 12.9 (775)
0.4-0 .82
) 12.9 (775)
0.4-0.83
) 20-7004 ) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0.82
) 12.5 (750)
0 .
5-2.05
) 12.5 (750)
0
.4-0.82 ) 14.2 (850)
0 .5-1.1
14.2 (850)
Page
Carburetted engines
(8200 K, 8230 NK) .. ....... 44
CI-system (8200/230 E) ........................ 48
Motronic (8200/2 30 ET) ...... ... .. .. .......... . 51
Constant idle speed system (8200/230 ET) ....... 54
LH-Jetronic (8200/230 F/FT/GT) ................. 55
Regina (8230 F USA) .......................... 58
LH-Jetronic 2.4
(8204 E, 8204 GT, 8204 FT, B 234 F/G) .. ........ 61
43
I
I
III 'III III III III ,III III ,III III

(
70019401960 Specifications
Group 23 Fuel system
CO content , idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or
idle speed
• CO should be checked/adjusted when engine 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
Eng
ine Market CO%
type
Adjusting Volvo
(checking) Mono-Tester
B28A 2.5 (2.0-3.5) -
B28E 2.0 (1. 0-3.0)1 -
B28F USA, Canada, Australia 1.0 (0.7-1.3)2 42
° (39-45°)3
Japan 1.0 (0.7-1.3) 2 42° (39-45°)3
1) Pulsair system disconnected and plugged. 2) Lambda-sand disconnected . 3) Lambda-sand connected. 4) AC switched off. Idle speed increases to 15.0 rls (900 r/min) when AC is switched on again .
Section 2 B 28 Engine
\\\\Iffll
rpm
1 35 528
Idling speed
r/s (r/min)
15.0 (900)
15.0 (900)
12.5 (750)4
15.0 (900)
75
II' .. III .. II' ... II' ... II'

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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

(
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)