Documente Academic
Documente Profesional
Documente Cultură
700 1982-1991
940/960 1991
TP 30518/10
70019401960 Specifications
Contents
2
General
12
Lubrication
11111
1
1111
1111
IIII !
1111
11111
1111
1111
1111
1111
11111
1111
11111
1111
111 11
1111
1111
1111
;:::::::
15
B 19, B 23 Engines
1111
1,1.....
1111
II,'....
~:,:,:,:
35
1111
,......1
1,'....1
1......1
1111
1111
1111
11"
B28 Engine
69
,II',
III'
I:':':':
B280 Engine
86
'"'
'"'
~1111
....,'.
,...."1
III'
1111
B 6304 Engine
98
:11,1I:':',~
11
,"'III'
'"
111 1
' .,..
1111
......1
108
,11'
"'1
,II'
""
"'"'
IIII
....I~
118
Electrical System
111
11 11
,III
"''"
"'
I II I
1111
Power Transmission
138
1111
11'
1111
IIII
II 1
III
11....1
III
Brakes
153
111/
,II
til.
'"I
III
1111
.'.'111
,III
155
111/
,II
11.'.'1
Itt'.'1
'llt
lit
' II
159
160
It.'I'1
It.'.'1
III
IIt l
'III
II ~
III
til
"'1
1
""1
,....
'~I~'~
70019401960 Specifications
Section 0 General
Section 0 General
General data
740
Modell
year
Designation
1984
3372081679"
1985
81680215754"
1986
1987
Engine type
Gearbox
Final drive
ratio
819E,819ET,
823E,024
AW70, AW71,
M46, M47,
ZF4HP22
3.54:1, 3.73:1
3.91 :1
1-6969
8200K,8200E,
8200 ET, 8230 A,
8230E,8230F,
8230 K, 8230 ET,
8230 FT, 024, 024 T
AW70, AW71,
M46, M47,
ZF4H22
1-90199
697062099
8200K,8200E,
8200 ET, 8230 A,
8230E,8230F,
8230 K, 8230 ET,
8230FT, 024, 024 T
AW70, AW71,
M46, M47,
ZF4HP22
90200190699
62100116099
8200K,8200E,
8200 ET, 8230 E,
8230 ET, 8230 F,
8230 FT, 8230 K,
024,024 T, 024 TIC
AW70, AW71,
M46, M47
ZF4HP22
3.31:1 , 3.54:1
3.73:1, 3.91:1
4.10:1
1988
190700294099
116100176799
8200K,8200E,
8200 ET, 8230 E,
8230 ET, 8230 F,
8230 FT, 8230 K,
024,024 T, 024 TIC
AW70, AW71,
M46, M47,
ZF4HP22
1989
K""
France:
o (zero)
294100396999
176800242699
8200 K, 8200 E,
AW 70, AW 71, AW 72, 3.31 :1, 3.54:1,
8200ET, 8204 E, 8230E, M46, M47,
3.73:1, 3.91 :1,
8230 ET, 8230 F
4.10 :1
ZF4HP22
8230 FT, 8234 F, 8230 K
024, 024T, 024TIC
1990
L
France:
o (zero)
397000499199
242700316299
M
France:
o (zero)
499200-
316300-
8200E,8200F,
AW70, AW71,
8200 FT, 8230 E, 8230 F, M46, M47,
8230 F8, 8230 FT,
ZF4HP22
024,024 T, 024 TIC
1991
Chassis number
744
745
* 744 and 764 models from 1984 and 1985 were grouped in same chassis number series .
** Sweden : K from chassis number 3422551208548.
70019401960 Specifications
Section 0 General
760
Model
year
Designation
Chassis number
764
765
Engine type
Gearbox
Final drive
ratio
1982
1-3799
B28E
AW71, M46
1983
380033719
AW71, BW55
M46
1984
3372081679"
AW71, BW55,
M 46, ZF4HP22
1985
81680215754"
1-999
B 28 A, B 28 E, B 28 F,
B 230 K, B 230 ET,
B 230 FT, D 24 T
AW71, M46,
M 47, ZF4HP22
3.54:1 , 3.73:1
3.91 :1
1986
1-16999
10008499
AW71, M46,
M 47, ZF4HP22
1987
1700037399
850016299
AW71, M46,
M47, ZF4HP22
1988
3740058499
1630023499
3.54:1, 3.73:1,
3.91 :1
1989
K""
France:
o (zero)
5850076899
2350031119
3.54:1, 3.73:1,
3.91 :1
1990
L
France:
o (zero)
76900-
31200-
III
'III
III
III
III
'III
III
'III
III
744 and 746 models from 1984 and 1985 were grouped in the same chassis number series .
.. Sweden: K from chassis number 67303/27155.
780
Engine type
Gearbox
Final drive
ratio
1-1199
D24TIC
M46
3.54:1
1200-3299
M46, AW71
1988
3300-6499
M46, AW71
3.54:1, 3.73:1,
3.91 :1
1989
K"
France :
o (zero)
6500-8999
M46, AW71
3.54:1, 3.73:1
1990
L
France:
o (zero)
9000-11299
M46, AW71
D24TIC
3.54:1, 3.73:1
1991
11300-
AW71
3.73:1
Model
year
Designation
1986
1987
Chassis number
70019401960 Specifications
Section 0 General
940
Model
year
Designation
1991
M
France:
o (zero)
Chassis number
944
945
1-
1-
Engine type
Gearbox
Final drive
ratio
B200E, B200F,
M46, M47, AW 70,
B200FT, B204 E, B230 E, AW 71, ZF4HP22
B 230 FB, B 230 FT,
B230GT, B234 F, B234 G,
D24, D24 T, D24 TIC
Engine type
Final drive
ratio
960
Model
year
Designation
1991
M
France:
o (zero)
Chassis number
964
965
1-
1-
Gearbox
M46, AW71,
B 204 FT, B 230 GT,
B 230 FT, B 280 E, B 280 F, AW30--43
B 6304 F, D 24 TIC
3.54:1, 3.73:1
3.91 :1
70019401960 Specifications
Section 0 General
B
1324 10
Dimensions
7401760
mm in
780
mm in
944/964
mm in
945/965
mm in
2770 109
4785 188.4
1760 69.3
1470 1) 57.9
14602) 57.5
1410 55.5
2770 109
4794 189
1770 69.7
1470 57.9
14602) 57.5
1400 55.1
2770 109
4871 191.8
1750 68.9
1471 57.9
1460 57.5
1410 55.5
2770 109
4844 190.7
1750 68.9
1471 57.9
1460 57.5
1440 56.7
1) _
2)
3)
Weight
740
760
780
1270-1460 kg
(2798-3120Ib)
1330-1500 kg
(2930-33051b)
1500 kg
(3305 Ib)
944
,-
945
964
965
1327- 1463
1363-1496
1484-1576
1438-1527
(2924-3223Ib) (3003-3296Ib) (3270-3472lb) (3168-3364Ib)
Litres
US. gal
60
82
80
15.8
21 .6
21.1
70019401960 Specifications
Section 0 General
1
VOLVO
_._ N
~
''' ' '..~'' ' '. '
4C
~.
,.
,.
I,
..
,
I
_..
.. .
.~.
,.
....- .
,"
VOLV o
r--
'
9A
8280
150 873
B. Scandinavia:
Sedan: Attached to rear boot member.
Estate: Located on rear right of wheelhouse
C. USA & Canada
Located on top left of dashboard.
Located on bulkhead. Shows idling speed, valve clearances, ignition timing and CO content. '
760 1988-: located on left side suspension tower.
3. Tyre pressures
1982: Located on inside of glove compartment lid.
1983-: Rear edge of right front door.
Part
Brakes
Manufacturer
Code
2
3
760, 1988-:
4
5
70019401960 Specifications
Section 0 General
3
~
... .
---
".. u...
7B
143980
780
Carburettor
Fuel pump
Clutch
\
SU
Pierburg
Solex
Pierburg
Bosch
AC-oelco
Sofabex
Fichtel & Sachs
Verto/Valeo
Bosch
Cam Gear
Zahnrad Fabrik (ZF)
2
3
2
3
4
5
2
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.
3
1
2
3
__ - G.- 819, B 23
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 .
70019401960 Specifications
Section 0 General
Product plate
1982-1989
147 941
Type approval *
C4
Vehicle identification
number (type designation)**
C1
C2
Ca
E
F
G
H
* Certain countries.
** Type designation codes, see next spread.
1990 - W944
II
'.1.'DE Irl
~========:~===;:=:::;::
;W::::,::::EW'::;:::::=r==
EEl
II' , ,
~===========;I I
;==== ==========ill 6
I I
El EEl
7 717 71
II a a a al a al I
~===================;
119999 1991 1
148098
A-C 4 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)
1990 W9451991-
,I, ,1 ,1,1, 1, 1
,I, ,I 21 21 I 3 1
41 441414 1 I IEEl
EEl ~
I = = = = = = = = 515
16 1616 161
I
717 71 717171 I
Ii ai a al ai I 19 1
A-C 4 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
148 099
The chassis
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
9X27A24
Bump rubber :
1330853-1
3516572-9
Rear spring:
1273977-7
1329507-6
1330218-7
1329822-9 I
274040-5
1359906-3
1359557-4, 1359558-2
70019401960 Specifications
Section 0 General
Itl
Shock
absorber,
front
Brake
disc
Brake
caliper
Pos Spring,
1,2 front
Shock
absorber,
front
tit
til
til
Itl
-til
til
-til
til
Brake
caliper
Brake
disc
31
1329822-9
EG 1329822-9
42
EN 1329823-7
44
ER 1387677-6
54
1329822-9
ET 1387678-4
5L
1329824-5
5M 1293449-3
1329823-7
5Y 1329822-9
9A 1329822-9
5P
1329823-7
9X 1329822-9
9F
A4
A5
A9
Pos Anti-roll
3
bar, front
1330220-3
1329501-9
1273759-9
1330218-7
1329505-0
1273977-7
1330221-1
1329507-6
1273977-7
1330219-5
1329504-3
1359710-9
1359808-1
1329500-1
3530199-3
1359807-3
1330332-6
1387836-8
3530276-9
1330702-0
3530277-7
3516668-5
3516447-4
3530200-9
3516446-6
3542466-2
3530283-5
03 1329824-5
Pos Anti-roll
6
bar, rear
07 1329823-7
3516573-7
1330853-1
3516572-9
1359653-1
3530751-1
1387181-9
3516518-2
E2
Pos Bump
rubber
EE 1329824-5
EJ
1293449-3
70019401960 Specifications
Section 0 General
l~
Manufacturer's code
Vehicle type
Engine type
TTL----
Chassis number
Assembly plant
Model year
designation
Transmission
YV1DH6923C1001234
11"--------
Chassis number
Assembly plant
Model year
designation
Check number
10
2 = 2 door
4 = 4 door
5 = 5 door
70019401960 Specifications
Section 0 General
Engine type
Model year
designation
Transmission
C = 1982
2 = M46
1111
'III
1111
III
1111
'II'
1111
,III
21 = B200 FT
77 = 024
o=
23 = B200K
81 = B230A, B234G
1 = Sweden (VTV)
0= 1983
3 = M47
24 = B19E, B200E
82 = B230GT
2 = Belgium (VEC)
E = 1984
5 = ZF4HP22, AW 71 l -87
25 = B204FT
83 = B230K
3 = Canada (VCl)
F = 1985
4 = Thailand (TSA)
G = 1986
6 = AW70l, AW71l,
AW 72l, AW 30-43
5 = Malaysia (SMA)
H = 1987
7 = AW :70, AW 71
8 = BW55
Assembly plant
Sweden (VKAV)
27 = B200F
85 = B230FB
28 = B204GT
J = 1988
29 = B204E
87 = B230FT
K = 1989
62 = B28A
88 = B230F
7 = Indonesia
(ISMAC)
A = Sweden
(Uddevalla)
M = 1991
68 = B28E, B280E
89 = B234F
69 = B 28 F, B 280 F
95 = B6304F
75 = 024TIC
o=
1111
l = 1990
Italy, Bertone
76 = D24T
11
70019401960 Specifications
Section 1 Service and maintenance
MA X
MAX
MIN
M'N
13590 1
Diesel engines
USA, Canada,Japan
-22 -4
14
10
!
20
30
4 0C
32
50
68
86
104 of
S AE 5 W/30
~ I
iprttWn:WS AE 10W/30ti'i'iW,iJl>
I<
- 22 -4
14
32
50
68
1----~
S A~E~5~W~V=3~0--~--L-~
)
86
104 of
S AE 15 W/4 0
14138 1
141375
Other markets
Other markets
10
20
I
32
50
68
30
40C
I
86
104 of
-3P -2p
-1,0
- 212 -4
14
SAE 5 W/30
Q W 2p 3p
32
50
68
86
~O
104 of
1< :::SAE1Q~Jii
::I:i:1SD:flQWZ401t ::::It:I:,
<
t.:.::':::ISil\E(1S:WZ4l::: :ttit
SAE 20W/40
SAE 15W/ 40
k"
I<-..
SAE 20W/40
SAE 30
SAE 30
I<
SAE40
SAE40
137 642
142444
Synthetic or semisynthetic oils may be used if their specifications comply with the oil quality requirements.
Volvo does not reco mmend additio nal o il additives, as they can adversely affect the
eng ine.
Note! SAE 1SW/40 and SAE 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.
12
70019401960 Specifications
Section 1 Service and maintenance
Excl. oil
filter
Incl. oil
filter
Difference
in volume
max.- min.
3.35 (3.6)
3.5 (3.7)
5.0 (5 .2)
6.0 (6.3)
5.5 (5.8)
5.0 (5.2)
3.85 (4.1)
4.0 (4 .2)
5.75 (6.1)
6.5 (6 .9)
6.0 (6.3)
6.0 (6.3)
1.0(1.1)
1.0 (1 .1)
1.0 (1.1)
1.0 (1 .1)
1,0(1 .1)
1.0(1.1)
Itt
I
I
Carburettor
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 ..... . ....... . ... . .. . .... .. .. .
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)
Volvo Thermo Oil (PIN 1 161 243-9) is recommended for vehicles driven in
areas where ambient temperature seldom drops below -10C (+14F), or
high mileage vehicles such as taxis.
NOTE! Do not mix oil types.
Automatic transmission
1324 14
III
:1:1:1
11.'.1
liN
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
70019401960 Specifications
Section 1 Service and maintenance
Rear axle
134142
I
I
Steering gear
134143
14
70019401960 Specifications
Section 2 B 19, B 23 Engines
20
21
22
23
25
26
28
j'"
Group 20 General
:,
I.t
129750
Engine
type
Remarks
819E
819ET
823E
Scandinavia, Switzerland
Other markets
823ET
823FT
1)
2)
3)
4)
5)
Compression ratio
Octane
requirement
Max torque
Output
kWat
r/s
Nm at
r/s
kpm at
r/min
117/6000
158/50
16.1/3000
10.0:1
98
7.5:1
98
110/92
150/5500
230/60
23.4/3600
10.3:1
10.0:1
96
98
95/88
96/90
129/5250
131/5400
190/50
190/60
19.4/3000
19.4/3600
9.0:1
98 1
127/95
173/5700
250/57
25.5/3400
117/88
160/5300
1575/5300
250148
25.5/2900
1844/2900
8.7:1
91
86/100
"
hp at
r/min
2 3
819
823
4
88.9 (3.503)
80 (3.152)
1.99
1-3-4-2
0.9 (128)
0.2 (28)
165 (363)
170 (375)
4
96 (3.782)
80 (3.152)
2.32
1-3-4-2
0.9 (128)
0.2 (28)
165 (363)
170 (375)
With hot engine, throttle wide open and starter motor cranking at
15
70019401960 Specifications
Section 2 B 19, 823 Engines
ma x
o 25mm
Cylinder block
129826
Bore
8 19
823
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 .784D-3 .7844)
96.3
(3 .7942)
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
= Diameter to be measured at right angles to gudgeon pin at
distance C from bottom of piston.
13755 1
Engine
type
8 19 E
8 19 ET
823E
823ET
823FT
5156
5106
5707
562 7
5627
1)
(18.40.2)
(18.20.2)
(20.40.3)
(19.8 0.3)
(19 .80.3)
Dimension mm (in)
73.9 (2.912)
71.0 (2.797)
76.4 (3.010)
8.4 (2 .657)
8.7 (2 .657)
46.7
46.0
46.4
46.4
46.7
C
(1.840)
(1.812)
(1.828)
(1.828)
(1.840)
7
7
8
12
12
(0.276)
(0.276)
(0.315)
(0.423)
(0.423)
16
70019401960 Specifications
Section 2 B 19, B 23 Engines
Piston rings
12952 1
Ring gap
129 520
Upper
Camp. rings
Lower
Camp. rings
Oil scraper
rings
0.040-0.072
(0.0016-0.0028)
0.060-0.092
(0.0024-0.0036)
0.040-0.072
(0.0016-0.0028)
0.040-0.072
(0.0016-0.0028)
0.030-0.062
(0.0012-0.0024)
0.030-0.065
(0.0018-0.0026)
0.35-0.65
(0.0014-0.0026)
0.40-0.65
(0.0158-0.0256)
0.35-0.55
(0.0014-0.0022)
0.40-0.65
(0.0016-0.0256)
0.25-0.60
(0.0010-0.0024)
0.30-0.60
(0.0118-0.0236)
Valves
Valve clearance
Checking
'Adjusting
0.30-0.40
(0.012-0.Q16)
0.35-0.45
(0.014-0.018)
0.35-0.40
(0.014-0.016)
0.40-0.45
(0.016-0.018)
Adjusting shim, thickness ....... . . ... .... ..... .... ... ...... mm
(in)
Valves
IMPORTANT: Valves are stellite-flashed and must not be
machined . They may only be ground in against seat.
3.30-4.50
(0.1300-0.1773) in increments of
0.05 (0.002)
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.
44,5
44,5
Min: 7,945
Min: 7,935
144027
Inlet valve
III '
III
III
III
III
,111
III
111
III
70019401960 Specifications
Section 2 B 19, B 23 Engines
Valve seat
D+O,17mm
~\
i~
13 3646
11 3945
Exhaust
Inlet
Valve guides
Inner diameter ... ... .... . . . ... . . . . .. . . . .. . . . . . .. . .... . ... mm
(in)
Height above upper face of cylinder head . ........ . .. . ...... mm
(in)
Clearance, valve stem-guide (measured with new valve),
new . .... . .. . . . . .... . .......... . ............. . . . .... . . mm
(in)
max . ............... . . . .. . .. . .... . .. . . .~ .. ,,~... .... "" .... ...mm
(in)
Valve guides are available in three oversizes, marked
with grooves.
Inlet valve
Exhaust valve
8.000-8.022 mm
(0.3152-0.3161 )
15.4-15.6
(0.6068-0.6146)
8.000-8.022
(0.3152-0.3161 )
17.9-18.1
(0 .7053-0.7131 )
0.030-0.060
(0.0012-0.0021 )
0.15
(0.0059)
0.060-0.090
(0.0024-0.0035)
0.15
(0.0059)
Standard
Oversize 1
Oversize 2
Oversize 3
I.
032,5
.1
No groove
1 groove
2 grooves
3 grooves
5161
5162
5163
11 3946
Marking
wu
I,.. 025,9 1
rn~
..g======'lb
Type 1
Type 2
B 19 E, B 23 E, B 23 ET
B 19 ET, B 23 FT
Type 1
Type 2
Length
mm (in)
Load
N (Ib)
Length
mm (in)
Load
N (Ib)
45.0
(1.77)
38.0
(1.50)
27.0
(1.06)
45.5
(1.79)
38.0
(1.50)
27.5
(1.08)
280-320
(62-70)
710-790
(156-174)
280-320
(62-70)
702-782
(154-172)
135065
18
70019401960 Specifications
Section 2 B 19, B 23 Engines
Timing gears
Camshaft
Letter stamped on
end ot camshaft
Engine type
B 19E
B19ET
B23E
B23ET
B23FT
Camshaft
Marking
A
T
A
B
T
10.5
9.9
10.5
10.6
9.9
13
4
13
19
4
(0.4137)
(0.3901)
(0.4137)
(0.4176)
(0.3901)
0.7
0.7
0.7
0.7
0.7
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
0.030-0.071
0.15
0.1-0.4
1111
:111
111 /
III
III '
,III
III '
111
III
B.T.D.C
B.T.D.C
B.TD.C
B.TD.C
B.iD.C
(0.0012-0.0028)
(0.0012-0.0028)
(0.0344-0.0158)
Intermediate shaft
Radial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.020-0.075 (0.0008-0.0030)
0.20-0.46 (0.0079-0.0181)
Crankshaft assembly
Crankshaft
Max out-ot-true ....... .. ....... ............ .. mm
Axial clearance, max ..................... .... mm
Radial clearance (main bearings) .............. mm
Connecting rod bearings,
axial clearance ....... . ... . . ........... .... . mm
radial clearance . .... . ...................... mm
(in)
(in)
(in)
0.05 (0.0020)
0.25 (0.098)
0:028-0.083 (0.0011-0.0033)
(in)
(in)
0.15-0.35 (0.0059-0.0138)
0.024-0.070 (0.0009-0.0028)
(in)
(in)
(in)
(in)
(in)
0.07 (0.0028)
0.05 (0.0020)
63.451-63.464 (2.5000-2.5005)
63.197-63.210 (2.4900-2.4905)
62.943-62.956 (2.4800-2.4805)
(in)
(in)
(in)
(in)
(in)
0.05 (0.020)
0.05 (0.020)
53.987-54.000 (2.1271-2.1276)
53.733-53.746 (2.1171-2.1176)
53.479-53.492 (2.1071-2.1076)
Taper
Connecting rods
Axial clearance at crankshaft .............. .... mm (in)
Max weight deviation between connecting rods
in same engine
0.15-0.35 (0.0059-0.0138)
Out-of-round
10 gms
Flywheel
Axial throw, max ............... ... ........... mm (in)
0.02 mm/100 mm
(0.0008/3.94 in diameter)
19
"1
I
~J
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.
Nm
ft Ib
110
63
70
70
255
50
50
20
165
80
46
51
51
183.5
36
36
15
120
1 = 20 Nm (14 ft Ib)
2 = 60 Nm (43 ft Ib)
3 = Angle-tighten 90 0 in one motion
' 7 - - 3 - - - - --9
o 0
o
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.
000
8-4-211 5326
General
Oil capacity and quality, see page 12.
0.25-0.60 (35-85)
Oil pump
Axial clearance . .. . .. . .. . .. . . ... . . ..... . ........ . ..... mm
Radial clearance (excluding bearing clearance) ... . ... .. . mm
Backlash (excluding bearing clearance) .... . ............ mm
Bearing clearance, drive shaft ... . ... ... . .... .. ... .. .. .. mm
idling shaft ... . . . ..... .. .. . . ........ . mm
(in)
(in)
(in)
(in)
(in)
0.02-0.12
0.02-0.09
0.15-0.35
0.032-0.070
0.014-0.043
(0.0008-0 .0047)
(0 .0008-0.0035)
(0.0059-0.0138)
(0 .0013-0.028)
(0.0006-0.0017)
~~~
11 5083
20
Lengths
39.2 mm (1.5445 in)
26.25 mm (1.0343) in)
21.0 mm (0 .8274 in)
Load
o
46-54 N (10.1-11.9 Ib)
62- 78 N (13.6-17.2 Ib)
70019401960 Specifications
Section 2 B 19, B 23 Engines
.
~
Engine
type
I)
3)
4)
CO content
Volvo
Monotester
8 19E
1.0 (0.5-2.0)
8 19ET
2.0 (1.0--3.0)
823E
823 ET
USA + Canada
Japan
IN
III
III
III
III
III
III
Idle speed
r/s (r/m in)
CO meter %
Adjusting
(checking)
823FT
2)
Remarks
III
135528
15.0 (900)
15.0 (900)
15.0 (900)
14.2 (850)
12.5 (75W
15.0 (900)
Page
CI system (819 ElET, 823 E). . . . . . . . . . . . . . . . . . . 22
Motronic (823 ET) .. . . . . . .. ...... .. .. . .. .. . .. . 25
LH-Jetronic (823 FT) . . . . . . . . . . . . . . . . . . . . . . . . .. 28
21
700/919!~o,(}) .spe(jifiJjations
CI system (B 19 E, B 19 El, B 23 E)
Pressures
B19E, B23 E
B19ET
450-530 (64-75)
150-240 (21-34)
520-580 (74-82)
240-320 (34-46)
345-375 (49-53)
345-375 (49-53)
Control pressure
warm engine . ..... . .. . ......... ...... ... . . ..... . . . kPa (psi)
warm engine and charge pressure of
45 kPa (6.4 psi) . ............ ... . . .. .... ........ ... kPa (psi)
295-325 (42-46)
\
2.5
250
2.0
200
1.5
150
1.0
100
0.5
50
10
20
30
40
50
60
70
32
50
68
66
104
122
140
158
80
176
DC
e
132943 2
Volvo PIN
463971-2
1 336 077-1
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-30
(1
0438140 .. .
Injectors
Type of injector fitted to engine depends on engine type.
Identification number (last three digits of part number) is
stamped on side of injector.
"'n
0437502 . ..
132945
22
Bosch number
B 19 E, B23E .. . ... 015
B 19 ET ... .. ....... 020
Volvo PIN
1 276037-7
1 306499-9
70019401960 Specifications
Section 2
B1!9,:'B~3
Engines
Start injector
Type of start injector fitted to vehicle depends on engine
type. Identification number (last three digits of part number)
is stamped on side of injector.
Injection time is controlled by thermal timer
0280170 ...
134 264
819E, 823 E
. . . 413
1 276498-1
85 cm 3/min
819ET
.. . 415
1 269585-4
135 cm 3/min
EEHEEEHEEEl33=EEEEEEEEEEEEE
2 _
134738
- 20
-4
- 10
14
0
32
__
10
50
20
68
30C
86
OF
134739
0280140 .. .
Manual
.. . 106
1 346476-3
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-60 (1
Fully open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30C
Fully closed at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. + 70C
134740
III
III
'11
II.
'II
Nt'
U,I
70019401960 Specifications
Section 2 B 19, B 23 Engines
Air-flow sensor
Metering disc rest position
Carry 01
gine, fw
Fuel pump
&
Bose
Volvi
0580254 .. .
138069
Tank pump
24
70019401960 Specifications
Section 2 B 19, B 23 Engines
Motronic (B 23 ET)
Control unit
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 012
Volvo PIN .. ... . ...... ... ... ... . . . .... .. . 1 317 025-3
1111
III
III'
III
III
,III
III
,III
III
0261200 ...
137 662
0280160 ...
135789
Injector
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 355
Volvo PIN ....... .... ................ .. .. 1 306 966-1
Injected quantity at a line pressure of
300 kPa (42 psi) . . . . . . . . . . . . . . . . . . . . .. 300 cm 3/min
0280150 ...
135790
25
70019401960 Specifications
Section 2 B 19, B 23 Engines
Start injector
Bosch number .... ... . .... .
Volvo PIN ..... . ... . . .... .. .
Injected quantity . .... .... .. .
0280170 .. .
134 264
Sec
8
J+:q:::q:::q:::q:::m
i-+-'f-+-I-H-+++++
6 I-+-H-H"-H-H-H
Injection time
Cut-out temp
134738
f-+-IH--t-++++++
-2 0
-4
- 10
14
Injection timl
Tolerance, time . ..... . .
temperature.
Auxilary air'valve
0280140 ...
134740
0280130 .. .
135791
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 026
Volvo PIN .. .... . . .. . .. ..... . ............ 1 332 396-9
Resistance at:
-1O oe (- 14F) . ... .. . . .... .. .. . .. 8260-105600
+20 o e (68F) ...... .. .. . . .. ....... . 2280-27200
+80 o e (175F) . . ............ . . . ...... . 290 - 364 0
26
-2
t~
70019401960 Specifications
Section 2 B 19, B 23 Engines
n _
INII
1111
III
1111
,III
1111
,III
1111
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 001
Volvo PIN ....... .. ............. . ... ... . .1 317 273-9
Resistance at:
+20C (68F) ... .. .... . ............. 985-1 0150
+40C (104F).. .. . .. .. . .. .. .. .. ... 1 080-1 110 0
+130C (266F) ......... ..... .. ... 1 550-1 6200
137 283
0261210 ... .
137665
Fuel pump
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 025
Volvo PIN ..... : . .. ...... ............ . ... 1 336 679-4
0580464 ...
135 793
Tank pump
Current consumption. . . . . . . . . . . . . . . . . . . . . . . . .. 1-2 A
27
70019401960 Specifications
Section 2 B 19, B 23 Engines
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 507
Volvo PIN .... . .. ....... .. .. ....... .. . ... 1 332 184-9
0280160 ...
135789
Injectors
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 357
Volvo PIN ... .... . ... . .. ... ... . .......... 1 332337-3
Injected quantity at a line pressure of
300 kPa (42 psi) ........ . . . ........... 300 cm 3/min
0280150 .. .
135790
28
70019401960 Specifications
Section 2 B 19, B 23 Engines
n
III
IN
III
11
III
III
III
III
40000
--
20000
10000
8000
6000
il
4000
2000
0280130 ...
1000
800
13579 1
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 026
Volvo PIN ....... . ... . . ..... .. . . . . . .... .. 1 332 396-9
Resistance at:
-10C (- 14F) . . ..... . . ..... . .... . . 8260-10560
+20C (68F) ......... . .. .... ... . ... 2280-2720
+80C (175F) ... . . .... ..... .. . ... .... . 290-364
600
400
2 00
100
-30 -20
-22 -4
20
40
60
80
100
120C
32
68
104
140
176
212
248F
135 792
Lambda-sond
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 006
Volvo PIN . . ... . ........ .. . . .... . ..... . .. 1 346 738-6
Resistance of ballast resistor at:
Cold sond (20C = 68F) . . . . . . . . . . . . . . . . . . . . .. 3
Warm sond (above 350C = 660F) .. ... ... .. . . 13
70019401960 Specifications
Section 2 B 19, B 23 Engines
Fuel pump
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 025
Volvo PIN . ..... . . ..... .... .. . . .. . . . . .. .. 1 336 679-4
0580464 ...
135793
max 6.5 A
Tank pump
,'."
30
70019401960 Specifications
Section 2 B 19, B 23 Engines
B 19ET
B23ET
B23FT
3500
60-70 (8.5-10.0)
64-70 (9 .1-10.0)
3500
45-53 (6.4-7.5)
50 (7.1)
3000
46-54 (615-717)
48-54 (6.8-7.7)
85-95 (12.1-13.5)
65-75 (9 .2-10.7)
15-25 (2.1-3.6)
4)
1)
2)
3)
4)
sfJ
Nm
45
89mm
45Nm
135780
31
70019401960 Specifications
Section 2 B 19, B 23 Engines
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion tank
Pressure valve in filler cap opens at:
overpressure .. . ..... ' .......... . .. . .................... . .. .
underpressure . ... ............... . .. . ........--: . ...... ..... .
Thermostat
Marking ......... .... ..... .. ... . ... ..... ....... ............. .
Starts to open at ...................... . ............ ..... ... . .
Fully open at ... .. .. . ... ........ .. .. .... ....... .. . . . . ....... .
Type 1
87
86-88C
(187-190F)
9rC (207F)
Type 2
92
91-93C
(196-199F)
102C (216F)
1983
HC 38x925
HC 38 cogX925
1984
HC 38x913
HC 38 cogX913
Fan belts
Designation (Volvo PIN), early type ..... : . ..... .. . ........... . . .
late type ... .. . .. . . .......... ......... .
32
70019401960 Specifications
Section 2 B 19, B 23 Engines
fif!}jJ~
~
1348~
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
III
III
III
III
11 1
III
,11 '
III
8reakerless
1-3-4-2
'111
750 r/min
41 .7 rls
2500 r/min
819 E*
819 ET*
823E*
10?
15
10
28-33
23-26
28-33
823ET
823FT
101)
122)
Engine type
12.5 rls
Ignition coil
B 19 E, B 19 El,
131753
B23ET
B23E, B23FT
0.6-0.90
6.5-8.5 kO
0.50
6.0 kO
Engine type
Designation
W6DC
W7DC
WR7DC
PIN
Kit number
1 306604-8
1 306605-5
1 346541-4
273596-7
273597-5
271 409-5
Knock sensor
II
146804
11 Nm (8 ft lb.)
20 Nm (14 .5 ft lb.)
33
70019401960 Specifications
Section 2 B 19, B 23 Engines
Distributor
Engine type
Ignition system
Distributor
Volvo PIN
Bosch No
819E,823E
819ET
823ET
TZ-28 H
TZ-28 H
Motronic"
1 336689""
1 336694
1 317298
0237020075
0237020031
0237501 003
823FT
EZ-K"
1 332587
0237506001
* Computerized ignition system (Le. distributor does not have a mechanical advance or vacuum unit).
** Modified distributor: same values as 1 336690 (8230 A).
B19E, B23E
0237020075
1 336689
Clockwise
B19ET
0237020031
1 336694
Clockwise
12.51.5
6.7-9.2
(400-550)
20-26
(1200-1560)
33.3--39
(2000-2340)
26.7
(1600)
12.51.5
6,7-11,7
(400-700)
12,8-16
(770-960)
17.5-22.3
(1050-1340)
40
(2400)
Positive
7.51
105-140
175-215
235
Positive
7.51
105-145
175-220
250
Negative
2.51
105-180
135-210
225
Centrifugal governor
Advance, total, degress (distributor) ......... ....... . .. ........ .
Advance begins at distrib. rev/sees . ... . .............. ...... ... .
distrib. rev/min) ............................ .
Data: 5 at distrib. rev/secs ............. . . ......... . . . .. .. ... .
(distrib. rev/min) ... . . . . .... ..................... . .
10 at distrib. rev/secs .... .. . ....... .. . .. ... . ...... .. ... .
(distrib. rev/min) . ... . . .. ... . . .. ......... . ....... . .
Advance max at distrib. rev/sees ....... ... .... . ..... .. ........ .
(distrib. rev/min) ............................. .
Vacuum governor
Control direction ..................................... . .... . . .
Control, total degrees (distributor) ........ ',' ................... .
Control commences at mm Hg ...... . .... .. ............. . .... .
Data: 5 at mm Hg .... . ..... ........... . .................... .
max control at mm Hg ............................ . ..... .
Direction of rotation ....... . ........ . .............. . .. . .. .... .
Max control, distr. degrees . .. .......... .. ............... . . ... .
Control begins at mm Hg .. . ... . . . .. . ........... .. .. . ... ..... .
Data: 1 at mm Hg ..... . ...... ... ... .. ......... ... ...... . . .. .
Max control mm Hg . .. . ............. . ..... . . . . . .......... . . . .
Ignition advance
I: ~.
l r~ IO~O,
10
20"
40~
Is<'
JO~
! ,
20
3000
2000
1"
30
'I)''ll~ C
I ,!!
40
50
4000
.. I
,,,I,
60
r/min
5000
,,!
70
.. i , , ,
80
,I
90
lr ~Ii'
.
B19E, B23E
rls
10
I,
20
, I"
30
20
10
i t )
300
200
100
PRESSURE
10
20
30
40
i i i
100
200
300
VACUUM
s'
10'
0'
-5'
- 10'
,='
li :
+
90
",I
,I,
I, I,
,
R
I
9lhiO~237~020~O~31~~~~~ij~~~
J:
40
20'
80
""~~
r/min
- ij
WiTI:l:
1+
,.
70
60
++~
ISO 3 0'
10'
SO
40
30
40'
SOOO
I
4000
I
3000
I ,,1
2000
l~?O
20'
- 10" - 20'
34
cce:;p
B19ET
-10
kpa
I
mm Hg
138223
- 20'
40
1
300
30
20
I
200
10
I
100
PRESSURE
20
10
I
100
30
i
200
VACUU M
40
I
300
kp'
I
mmHg
138222
70019401960 Specifications
Section 2 B 200, B 230 Engines
20
21
22
23
25
26
28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine block . . .. ... ...... . ... . .. . ......
Lubricating system .......... . . .. .. .......
Fuel system ........ . . . ..... . ...... . . . .
Intake and exhaust systems. . . . . . . . . . . ..
Cooling system. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system. . . . . . . . . . . . . . . . . . . . . . . . .
1/
Group 20 General
(
31
32
38
39
60
62
63
.....
III
III
III
III
111
III
'111
III
j.
""
""
129750
Engine
type
B200K
Remarks
Europe, manual
automatic
Overseas
B200 E
B200 F
1990
1991
Compresslon ratio
Octane
requirement
RON"
Output
kWat
hp at
Nm at
kpm at
rls
r/min
rls
r/min
10.0
10.0
8.5
98
98
93
76/90
78/90
74/90
103/5400
106/5400
100/5400
165/45
170/45
165/45
16.8/2700
17.3/2700
16.8/2700
10.0
95 1.71
89/95
121/5700
158/80
16.1/4800
10.0
10.0
95 21
95 21
80/98
82/95
110/5900
11115700
155/48
158/57
15 .8/2900
16.1/2800
B200ET
8.5
98
118/92
160/5500
245/58
25 .0/3500
B204 E
9.7
95 11
102/100
139/6000
181/80
18.4/4800
8.2
95 2)
140/88
190/5300
280/49
28 .5/2950
8.2
95 11
147188
200/5300
290/49
29 .6/2950
B204FT
B204GT
Max torque
I
I
I
B230A
Scandinavia
10.3
98
82/83
112/5000
192/42
19 .6/2500
B230K
-1986 Europe
Overseas
1987-
10.3
9.0
10.5
98
93 11
95 11
84/87
80/87
86/87
114/5200
109/5200
117/5200
192/42
185/42
194/42
19.6/2500
18.9/2500
19.8/2500
B230 E
10.3
95 1.71
96/92
131/5500
190/55
19.4/3300
B230 ET
9.0
98
134/97
182/5800
260/57
26.5/3400
9.8
9.8
95 21
95 21
85/90
85/90
114 31 /5400
116/5400
183/42 51
183/4251
13541/2500 61
18.7/250061
9.3
95 21
96/92
130/5500
185/49
18.9/2950
8.7
8.7
8.7
8.7
95 21
95 21
95 21
95 21
119/88
115/80
121180
121/80
160 31 /5300
156/4800
162 31/4800
165/4800
253/48
242/55
264/57
264/57
18rl/2900
24.7/3300
19541/3450
26 .9/34 50
8.7
95 11
125/80
170/4800
265/57
27.0/3450
114/95
153 31/5700
203/75
150 41 /4450
114/95
117/97
155/5700
159/5800
203/75
210/74
20.7/4450
21.4/4450
B230 F
USA, Canada
Other markets
B230FB
B230 FT
B230 GT
B234F
USA, Canada
10.0
95 21
B234 FIG
Other markets
LH-drive, man gearbox - 1989
10.0
10.0
95 2.81
95 21
11
21
31
41
I
I
35
70019401960 Specifications
Section 2 B 200, B 230 Engines
(Ib)
with turbocharger .. ...... .. ..... . .... . . . .. . ........ .. kg
1)
B200
B204
B230
B234
4
88.9
80
1.99
1-3-4-2
0.9 (128)
0.2 (28)
140-150
(308-330)
165 (363)
4
96
80
2.32
1-3-4-2
0.9 (128)
0.2 (28)
140-150
(308-330)
160-165 (352-363)
With hot engine throttle wide open and starter motor cranking at
Cylinder block
Bore
B200
B230
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)
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)
Rebore if wear exceeds 0.1 mm (0.004 in) and oil consumption is very high.
Pistons
Piston diameter (A)
Standard (C) . .. ......... . ............. .. ..... . .. .. ....... mm
(D) ........ .. ............ ......... . ............. mm
(E) ................... .. ....... . .. . .. . ... . . .... . mm
(G) ........ ........ . ......... . .. ..... . .. .. . .. .. mm
Oversize 1 ... .. .... . ... .. .. . .. .......... . ...... .... ... . . mm
2 .. . ...... .............. . . .. . .... mm
B200
B230
88.88-88.89
88.89-88.90
88.90-88.91
88.92-88.93
89.27-89.28
89.65--89.66
95.98-95.99
95.99-96.00
96.00-96.01
96.02-96.03
96.28-96.29
96.58-96.59
8200/204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B230K 1987-..... . . ... . . .. .. . .. . ........ .... ...... ..... ....
8230 others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8234............. . .............. . ..........................
13.4 mm
13.5 mm
7 mm
11 mm
16 g
14 g
.,....
0.003-0.027 (0.0001-0.0011)
0.010-0.030 (0.0004-0.0012)
(fJ
...
-,.
B
~r
~~
143981
70019401960 Specifications
Section 2 B 200, B 230 Engines
Piston rings
129521
Axial clearance
Ring gap
129520
Upper
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)
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)
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)
B204/234
B200/230
103.5
(4.078)
102.7*
(4.078)
146.1
(5.756)
145.6
(5.737)
max
o 25mm
Valve clearance
B200/230
Checking
Adjusting
0.30-0.40
(0.012-0.Q16)
0.35--0.45
(0.014-0.018)
0.35--0.40
(0.014-0.016)
0.40-0.45
(0.016-0.018)
129 826
3.30-4.50 (0.1300-0.1773)
in increments of 0.05 (0.002)
37
III
III
ill
III
ill
IN
liN
70019401960 Specifications
Section 2 B 200, B 230 Engines
Valves
IMPORTANT: Exhaust valves are stellite-flashed and must not
be machined . They may only be ground in against seat.
Min : 7,945
144 027
Inlet valve
Valve seats
D+O,17mm
~F -~
11 3945
133 646
Inlet
Exhaust
Note: When replacing valve seats the interference between
the seat and its bore should be 0.17 mm (0.0067 in) ie valve
seat diameter should be 0.17 mm greater than
diameter of bore in cylinder head. 8204/234: 0.10-0.14 mm
(0.0039-0 .0055 in).
Valve gu ides
Inner diameter . ................ . ... . .. . ............ . ..... mm
(in)
Height above upper face of cylinder head .... . ... . .......... mm
(in)
Clearance, valve stem-guide (measured with new valve),
new 8200/8230 .... .. . .. ............ . . . .. .. ....... .. .. mm
(in)
8204/234 . .. ... . . ..... ..... . .. . ... . .. . ........ .. ..... . .. mm
(in)
max ..... ... .. ... . . ......... ... ... ... .... ....... . .... . mm
(in)
Inlet valve
Exhaust valve
8.000-8.022
(0.3152-0.3161 )
15.4--15.6
(0 .6068-0.6146)
8.000-8.022
(0.3152-0 .3161 )
17.9-18.1
(0 .7053-0.7131 )
0.03-0.06
(0 .0012-0.0024)
0.03-0.06
(0.0012-0.0024)
0.15
(0.0059)
0.06-0.09
(0.0024--0.0036)
0.04--0 .07
(0.0016-0 .0028)
0.15
(0 .0059)
Standard
Oversize 1
Oversize 2
Oversize 3
Marking
Reamer
No groove
1 groove
2 grooves
3 grooves
5161 *
5162
5163
*8204/234 : 5373
Adjusting shim
Thickness .. .. ...... . ......... . ..... .. ...... . . .. .. . ... mm (in)
38
3.3-4.5 (0 .13-0.18)
at increments of 0.05 (0 .002)
70019401960 Specifications
Section 2 B 200, B 230 Engines
Valve springs
Different types of valve springs are
in use as follows.
~LF~
:. 0 32 ,5'1
Type 1
1. 026 ,2 "I
1,025,9 "1
~~
146816
Length
mm (in)
Load
N (Ib)
45.0
(1.77)
38.0
(1.50)
27.0
(1 .06)
Type 2
-.
280-320
(62-70)
710-790
(160-178)
Type 3
Length
mm (in)
Load
N (Ib)
Length
mm (in)
Load
N (Ib)
45.5
(1.79)
38 .0
(1.50)
27.5
(1.08)
43.0
(1 .69)
37.0
(1.46)
26.5
(1.04)
280-320
(62-70)
702-782
(154-163)
212-252
. (48--56)
600-680
(135-153)
III
II
ill
II,
II'
/I ,
III
\'.'1
Profile letter stamped on
end of camshaft
Timing gears
Camshaft
Camshaft
B200 K
B200 E
B200 ET
B200 F
B204E
B204 FT/GT
B230 A
B 230 K - 1986
1987B230 E
B230 ET
B230 F
Profile
Inlet/exhaust valve
should open at*
10.35 (0.4078)
11.37 (0.4480)
9.9 (0.3901)
9.5 inlet
10.5 exhaust
9.38 (0.3696)
9.38 (0.3696)
6.81 (0.0268)
7.45 (0.0294)
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
(0.0276)
(0 .0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0 .0276)
8 B.T.D.C.
11 B.TD.C.
4 B.T.D.C.
6 A.T.D.C.
44 B.B.D.C.
5.1 B.T.D.C
37.1 B.BD.C.
12.9 A.T.D.C.
31 .2 B.B.D .C.
10.5 (0.4137)
10.65 (0.4196)
9.9 (0.3901)
11.37 (0.4480)
10.5 (0.4137)
9.5 (0.374) inlet
10.5 (0.4137) exhaust
11.37 (0.4480) inlet
10.65 (0.4196) exhaust
9.9 (0.3901)
9.38 (0 .3696)
9.38 (0.3696)
0. 7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
(0.0276)
13 B.T.D.C.
10 B.T.D.C.
4 B.T.D.C.
11 B.T.D .C.
13 B.T.D .C.
6 A.T.D.C.
44 B.L.D.C.
7.7" B.T.D.C.
50.1 B.L.D.C;
4 B.T.D.C.
5.1 B.TD .C.
37.1 B.B.D.C .
V
T
M
u, (inlet)
u (exhaust)
F I (inlet)
F A (exhaust)
A
X
T
V
A
B230 FB
VX3
B230 FT
B234F
T
u, - (inlet)
u - (exhaust)
B.TD.C.
= before top
B.L.D.C.
(in)
(in)
(in)
(in)
0.030-0.071 (0.0012-0.0028)
0.15 (0.0059)
0.1-0.4 (0.0344-0.0158)
0.05-0.40 (0.0019--0 .0158)
0.020-0.075 (0.0008--0.0030)
0.20-0.46 mm (0.0079-0.0181)
39
70019401960 Specifications
Section 2 B 200, B 230 Engines
Length
Load
o
153 N
340 N
144B!Hi
Camshaft belt
Coolant
temp.
Checking limits'
Used belt
New belt
Used belt
New belt
20C
3.20.3
3.80.3
3.40.2
3.80.2
40C
3.90.3
4.40.3
4.00.2
4.30.2
8rC
5.1 0.2
5.50.2
4.70.2
4.90.2
Crankshaft assembly
,/
Crankshaft
Max out-at-true . ...... .. ... .. ... .. . .. . . ... . . ... .. .. .. . mm
Axial clearance, max ............. .... . ..... . ........ . . mm
Radial clearance (main bearings) early type . .. .. . . .. . .. . mm
late type .............. . mm
Connecting rod bearings, radial clearance ............... mm
(in)
(in)
(in)
(in)
(in)
0.040 (0.0016)
0.080-0.270 (0.0032-0.0106)
0.024-0.072 (0.0009--0.0028)
0.024-0.064 (0.0009--0.0025)
0.023-0.067 (0.0009--0.0026)
0.006 (0.0002)
0.006 (0.0002)
Early type
Late type
55 (2.1574)
54.75 (2.1572)
54.50 (2.1473)
63 (62.987-63.000) mm
62.75 (62.737-62.750) mm
62.50 (62.487-62.500) mm
t
Taper
(in)
(in)
(in)
(in)
(in)
(in)
(in)
(in)
0.025(0.0010)
0.025 (0.0010)
49.00 (1.9306)
48.984-49.005 (1.9300-1.9308)
48.75 (1.9207)
8.734-48.755 (1.9208-1.9209)
48.50 (1 .9109)
48.484-48.505 (1.9103-1 .9111)
115 089
Out-ot-round
70019401960 Specifications
Section 2 B 200, B 230 Engines
Bearings
Main bearings
Two types of main bearings are in use. Upper and lower
shells on same journal must be same type.
Connecting rod bearings
Matched shells are used in production:
Shells are colour-coded (red, blue, yellow) as follows:
136753
Colour code
:11 '
III
II,
III
'III
III
,11 '
III
(
Connecting rods
Axial clearance at piston ............. . . . ............... mm (in)
Max weight deviation between connecting
rods in same engine ............ .. . ...... ..... ...... . gms (oz.)
0.15-0.45 (0 .0059-0.0177)
20 (0.7)
Flywheel
Axial throw, max ... . ... . . . .. ....................... .. . mm (in)
Nm
ftlb
110
20
angle-tighten 90
70
25
50
50
20
60
angle-tighten 60
80
14
51
18
37
37
15
43
8204/234
Reinforcing strut ......................... . .... . .... . .. . ... .. .
Camshaft - idler pulley .......... . . .. ............ ......... . .. .
Camshaft - tension roller ........ . .. ....... ..... . .... . ....... .
Balance shaft housing, assembly on bench ......... ........... .
Balance shaft housing, installation, stage 1 ........ .... .. ...... .
stage 2 .... ........ . ..... . . .
stage 3 ............... . .... .
stage 4 ... . ......... . .. .. . . .
Balance shaft pulley ..... .. . . . .. . . ... ... .. . ........ ... .. . .... .
Balance shaft - tension roller .. .. . . .. .............. ..... .... .. .
Crankshaft pulley, stage 1. . . .... ..... . ... .......... ... ....... .
stage 2 .. . . ..... .. .. . .............. ..... .. . .
25
25
50
5
20
Slacken
10
Angle-tighten 90
20
50
60
Angle-tighten 60
18
18
37
35
18
7
15
48
44
Bolts can be reused provided length does not exceed 55.5 mm (2.187 in)
41
70019401960 Specifications
Section 2 B 200, B 230 Engines
8204/234
20
11
11
20
15
7
8
15
angle-tighten 60
8200/230
8204/234
1 = 20 Nm (14 ft Ib)
2 = 60 Nm (43 ft Ib)
3 = angle tighten 90 in one movement
1 = 20 Nm (15 ft Ib)
2 = 40 Nm (30 ft Ib)
3 = Angle tighten 115
~'--~3---1---5,---w9'~
134 266
~O
O~
-~8,---.....
4-2
n s 125
Tightening sequence for cylinder head bolts
Oil pump
Axial clearance . . ... . ..... .. .. . . . . . . ... . . . . . .. . ...... . .. . mm
(in)
Radial clearance (excluding bearing clearance) . . .. ...... mm (in)
(in)
Backlash (excluding bearing clearance) ...... . ...... ... ..... mm
(in)
Bearing clearance, drive shaft ........ . . .. .. . ........ . ..... mm
(in)
idling shaft .... . ........ .. . .. . . . . . . ..... mm
(in)
8200/230
8204/234
0.02-0.12
(0.0008-0.0047)
0.02-0.09
0.0008-0.0035)
0.15-0.35
(0.0059-0.0138)
0.032-0.070
(0.0013-0.028)
0.014-0.043
(0.0006-0.0017)
0.05-0.10 (0.0020-0.0040)
8204/234
Load
42
Length
Load
o
(40-48 N (9-11 Ib)
55-67 N (12-15 Ib)
70019401960 SpecHications
Section 2 B 200, B 230 Engines
Engine
type
Co-meter %
Setting
CO leveP
Volvo
Checking
Mono Tester
1.5
1.0-2.5
15.0 (900)
Remarks
B200K
Idle speed
rls (r/min)
Manual
Automatic
1.0
0.5-2.0
15.0 (900)
0.4-0.8 2 )
12.9 (775)
B200ET
1.5
1.0-2.5
15.0 (900)
B204E
0.8
0.6-1.0
B200E
B200F
B204FT
B204GT
not adjustable
not adjustable
not adjustable (1990)
B230A
B230K
Switzerland -1986
Other markets -1986
1987-
B230 E
B230 ET
Scandinavia, Switzerland,
I Australia
Other markets
0.4-0.8
0.4-0.8 5 )
13.3 (800)
2.0
1.5-3.0
15.0 (900)
1.5
1.0
1.0
1.0-2.5
0.5-2.0
0.5-1 .5
1.0
0.5-2.0
15.0 (900)
1.54 )
1.0
1.0-2.54 )
0.5-2.0
15.0 (900)
15.0 (900)
0.6
0.6
13.3 (800)
13.3 (800)
13.3 (800)
15.0 (900)
15.0 (900)
15.0 (900)
20-7004 )
20-7004 )
15.0 (900)
12.5 (750)6)
12.9 (775)
20-7004 )
20-7004 )
15.0 (900)
12.5 (750)6)
12.5 (750)
B230FB
not adjustable
0.4-0.82 )
B230 FT
Japan -1988
Other markets -1989
1990- not adjustable
0.6
0.6
-
0.4-0.8 3 )
0.4-0.8 3 )
0.4-0.8 2)
B230GT
1.0
0.5-2.05 )
12.5 (750)
B234F
not adjustable
0.4-0.8 2 )
14.2 (850)
0.8
0.5-1.1
14.2 (850)
13.3 (800)
0.4-0.8 3)
0.4-0.8 3 )
0.4-0.82 )
B234G
15.0 (900)
2
Japan -1988
Other markets -1988
1989- not adjustable
B230F
III
'III
III
III
III
,III
III
,II I
III
12.9 (775)
I)
2)
Page
Carburetted engines (8200 K, 8230 NK) .. .. ..... 44
CI -system (8200/230 E) . ... . . ... ... .. .... . .. ... 48
Motronic (8200/230 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
70019401960 Specifications
Section 2 B 200, B 230 Engines
15-27 (2.1-3.8)
B200K
Solex-Cisac carburettor
~_m_m_
.....
2,7mm
---~~
--n
:
'~I
1'1I~1 ~:,1
I{
IJ.........j I
Adjusting vacuum servo
Choke fully in
44
70019401960 Specifications
Section 2 B 200, 230 Engines
ENGINE B 230 A
Pierburg (OVG) 175 COUS Carburettor
Meterin g needle
designation
NC
0,5--1,5 mm
= 0.020-0.059 in
III
III
ill
III
III
II,
ill
III
III
= 0.020 in
25 mm = 0.985 in
20.8-22.5 rls
(1250-1350 rpm)
136755
45
70019401960 Specifications
Section 2 B 200, B 230 Engines
Cam No.6
Switzerland
automatic .... ...... ... . . 4.8 mm
(0.189 in)
Other markets . . .. . . . .... 4.0 mm
(0.158 in)
50/120 Switzerland
140
47.5/120 Other markets
45/145
65
(pressed in cover)
136 782
140
(pressed
in cover)
Carburettor
Switzerl and
designation . ..... .... . . 7.17952.44
PIN .................. 1 332364-7
Other markets
7.17952.40
1 317036-0
Float level
x 140 Switzerland,
x 137.5 Other markets
85
x 117.5 Switzerland
x 112.5 Other
100
markets
143982
46
70019401960 Specifications
Section 2 B 200, B 230 Engines
- - -.-- - - - - ,
Cam No. 6
.J
~~~iiiiI"
47,5/115
III
III
'II
III
,II
1',',1
III
140
45/130
65
(pressed in cover)
136782
Carburettor
designation ... .. .. . .... 7.17952.51
PIN . . ................ 1 357 108-8
140
(pressed
in cover)
Float level
142,5
100
143982
47
III
70019401960 Specifications
Section 2 B 200, B 230 Engines
'.
Control pressure
warm engine ............. kPa (psi) 345-375
(49-53)
cold engine, see diagram
. .. 004
463 971-2
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-30
(2
Injectors
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 015
Volvo PIN . . ........ ... .... . ... .......... 1 276037-7
"n
0437502 ...
132 945
Start injector
Early type
Bosch No ............ .... 413
Volvo PIN.. .. .. . .. ... 1 276 498-1
Late type
... 445
3 517 065-3
Injected quantity. . . . . . . . . . . . . . . . . . . . . . . ..
0280170 ...
134264
48
85 cm 3/min
70019401960 Specifications
Section 2 B 200, B 230 Engines
35C
2mmmwm_
1341111
- 20
-4
- 10
14
0
32
10
50
20
68
30C
86
of
"
""
.""
"
134739
II
11
II
'
,.,'
Bosch No
Volvo PIN
. .. 106
. .. 114
... 112
. .. 118
1 346476-3
1 346477-1
1 346478-9
1 357448-8
02.80140 '.. .
134740
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-60 0
Fully open at. . . . . . . . . . . . . . . . . . . . . . . . . . -30C (-22F)
Fully closed at. . . . . . . . . . . . . . . . . . . . . . .. +70C (158F)
The auxiliary air valve is controlled electrically and should
be fully closed after 5 minutes driving at 20C (68F) ambient temperature.
Carry out check at maximum control pressure (in hot engine, fuel pump running).
49
70019401960 Specifications
Section 2 B 200, B 230 Engines
Fuel pump
Type I
Bosch No .. . .. " .. . 948
Volvo PIN. . . . . .. 1 336677-8
Type "
.. . 935
1 389448-0
Type '"
.. . 934
1 389 447-2
0580254 .. .
138069
Pump capacity at a line pressure of 500 kPa (71 psi), 20C (68F)
and 12V .... ..... . . ... .. . .............. .. .. ....... .. ..... .
11 V . .... .......... . ..... ..... ..... . .. ............. .. .
10V .... . ... ... ..... .. ... .. ............ . . .. ...... .... .
max 8.5 A
Tank pump
Current consumption. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 A
50
70019401960 Specifications
Section 2 B 200, B 230 Engines
:B 230 ET
. . . 035
1 306 967-9
Resistance :
between terminals 6 and 22 of temperature sensor
at -10C (14F) ..... . ... . ... .. . . .. 8260-10560 {1
+20C (68F) ....... .... .. . ...... .... 2280-2720 {1
+50C (122F) . . . . . . . . . . . . . .. . . .. . . . . . 760-910 {1
between terminals 6 & 9 . . . . . . . . . . . . .. 500-1 100 {1
between terminals 6 & 7 . . . . . . . . . . . . . . . . . . 8-200 {1
0280160 ...
B230ET
Early type
Bosch No ........... .. ... 225
Volvo PiN ... .. ....... 1 357 705-1
... 226
1 357710-1
Late type
Bosch No . . . .. .... .. .. ... 292
Volvo PiN ... .... . .. .. 3 517 063-8
. . . 294
3 517 064-6
300 (42)
200-300
(28-43)
135 789
150-250
(21-36)
Avstangningstryck
. . . . . . . . . . . . . . . . 150-250 kPa
(1 ,5-2,5 kp/cm 2 )
200-300 kPa
(2,0-3,0 kp/cm 2 )
Injectors
B 200 ET
0280150 ...
B 230 ET
Bosch No . . . . . . . . . . . .. . .. 802
Volvo PIN . . . .. ... ... . 1 346 699-0
. . . 357
1 332 337-3
300 cm 3/min
300 kPa
(42 psi)
135790
51
til
III
til
II I
til
'111
til
111
til
70019401960 Specifications
Section 2 B 200, B 230 Engines
Start injector
Early type
Late type
... 444
3517066-1
134264
2 _
.. 35C
Cut-out
temperature
Injection
time
- 10
14
0
32
10
50
20
68
30C
86
F
134 739
1400
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 001
Volvo PiN . .................. ...... ..... 1 317273-9
Resistance:
+20C (68F) ..... ... ............ .. ... 985-10150
+40C (104F) . . . .. .. . . .. . . . . .. . .. .. 1080-1110 0
+ 130C (266F) . . . . . . . . . . . . . . . . . . . .. 1550-1620 0
137283
52
7001940/960 Specifications
Section 2 B 200, B 230 Engines
40000
20000
10000
8000
6000
4000
2000
1000
0280130 ...
800
600
135791
400
200
100
20
40
60
80
100
120C
-22 -4
32
68
104
140
176
212
240F
135 792
Resistance:
-10C (14F) . . , . , ..... ..... .. ....... .. .. .. ... , .. , , . ... ... .
+20C (68F). , . , . . . ..... . . . , ... . . . , , . . . ... , , , . ... , ....... .
+80C (176F) , .... , , .. .... , , . , , , , ... , .. . .. . . ... , . , . , . . , .. .
Impulse sender
-30 -20
8 100-10770 n
2280-2720 n
292-364 n
0261210", _
13-7665
FuelPum~
Bosch No , , .. , . .. , ... , , , . . , . . , .. , .. , . , . .
, , . 025
Volvo PIN . . . .. , , ... , , .. . ... , .... . , . . , .. 1 336679-4
0580464 ...
135793
max 6,5 A
Tank pump
Current consumption .... , .. , , ..... , ... , . ,
1-4 A
53
70019401960 SpetifnJations
'Section 2
0280220 ...
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 016
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 346567-9
136607
.n
40000
20000
10000
8000
6000
4000
0280130 . . .
135791
2000
1000
800
60 0
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 032
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 346030-8
400
20 0
100
-30 - 20
20
40
60
80
100
120C
-22 - 4
32
68
104
140
176
212
240F
135 792
Resistance :
8100-107700
2280-27200
292-3640
Early type
Late type
54
70019401960 ! Specifications
Section 2 B 200, B 230 Engines
LH 2.4
136774
...016
3 517 020-8
Resistance:
between terminals
2 and 3 . . . . . . . . . . .. 3.5-4.0
between terminals
2 and 6 .. . ........ . 0-1000
2.5-4.0
B200F
B 230 F (LH 2.2) B 230 FT/GT
B 230 F (LH 2.4)
Pressure regulator
0280160 ...
Early type
Bosch No .. ... . .... ... 225
Volvo PiN . . ..... . .. 1357705-1
. .. 226
1357710-1
Late type
Bosch No .... . . ... . ... 292
Volvo PiN .. .. . ... . . 3517063 ~ 8 .
. .. 294
3517064-6
Line pressure
kPa (psi) ..... . ..... 250 (36)
300 (43)
200-300
(28-43 psi)
135789
Injectors
Bosch No .. . . . . . . . .
Volvo PiN . ...... . . .
Injected quantity
at a line ...... .. .. .
pressure of ....... .
Early type
Late type
... 209
1326427-9
.. . 734
1389844-0
170 cmJ/min
250 kPa
(36 psi)
170 cmJ/min
250 kPa
(36 psi)
Bosch No .. . ..... . .
Volvo PIN .. . .. .... .
Injected quantity
at a line ... .... . . . .
pressure of . .... .. .
... 762
3517572-8
185 cm 3/min
300 kPa
(43 psi)
B230FT
(LH 2.2)
Bosch No .. .. . . ... . ... 357
Volvo PiN ......... . 1332337-3
Injected quantity
at a line ... . . . .... . 300 cmJ/min
pressure of . .... .. . 300 kPa
(43 psi)
B230FT/GT
(LH 2.4)
. .. 804
3517283-2
300 cmJ/min
300 kPa
(43 psi)
55
70019401960 Specifications
Section 2 B 200, B 230 Engines
0280170 . ..
3517130-5
160 cm 3/min
loU cmo/mln
. .. 446
134264
,..
(B 230 FT only)
5.5-6.50
n
40000
20000
10000
8000
6000
4000
0280130 ...
135791
2000
1000
800
600
LH 2.2
Bosch No. . . . . . . . . . . .. . .. 026
Volvo PIN ... . ........ 1 332396-9
LH 2.4 "
400
... 032
200
1 346030-8
Resistance:
-10C (14F) . ....... . ... . .......... 8.10-10.77 kO
+20C (68F) ..... . .. . .. . ....... . .... 2.28-2.72 kO
+80C (176F) ......................... 290-3640
100
-30 -20
-22 -4
20
40
60
80
100
120C
32
68
104
140
176
212
248F
135792
Late type
... 520
3517067-9
56
LH 2.4
... 516
1 389618-8
approx 8 0
70019401960 Specifications
Section 2 B 200, B 230 Engines
Lambda-sond
8200F
8230F
LH 2.4
8230F
LH 2.2
Bosch No . . . . . . .. . .. 009
Volvo PIN . . . . . . .. 1 346962-2
Replacement part. (... 006)
8230FT
LH 2.2
Bosch No . . ... . .. 006
Volvo PIN . . . .. 1 346 738-6
... 034
3501753-2
8230FT
LH 2.4
8230GT
.1990
... 090
3531400-4
... 085
3517778-1
III
II,
III
II '
III
'II
III
,II
III
57
70019401960 Specifications
Section 2 B 200, B 230 Engines
B 230 F: REGINA
(USA only)
Pressure regulator
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 389564-4
Line pressure. . . . . . . . . . . . . . . . . . . . . .. 300 kPa (43 psi)
Shut-down pressure . . . . . . . . . 200-300 kPa (28-43 psi)
Injectors
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 389563-6
Injected quantity. . . . . . . . . . . . . . . . . approx. 170 cm 3/min
at a line pressure of. . . . . . . . . . . . . . . .. 300 kPa (43 psi)
146334
Start injector
Bosch No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 446
Volvo PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3517130-5
Injected quantity. . . . . . . . . . . . . . . . . . . . . . . . 160 cm 3/min
0280170 ...
134 264
n.
4
2
0'
I\.
'\
"-'\..
4
3
2
0280130 .. .
135791
"'"
8
6
4
3
........
I""'-..
"
2
0'
8
6
4
3
""
1~30 -20
20
40
60
80
100
120
142811
58
70019401960 Specifieations
Section 2 B 200, B 230 Engines
145630
II.
III
III
III
III
III
kO
III
63.0
40 .0
25.0
16.0
10 .0
"' I'\.I\.
6.3
,
I\.
4.0
2.5
i'..
'i'.
1.6
1.0
0.63
'"
0.40
0.25
0.16
0.10
40
I'. .
145631
-20
20
40
60
80
100
120
DC
145720
146338
Lambda-sond
Volvo PIN ... . . . ..... . . ... .. . . . ... .. . .. . . 3517394-7
Resistance of preheating resistors :
cold Lambda (20C = 68F) .. . .... ... . ....... .. 30
warm Lamds sand (above 350C = 662F) ..... . 130
Tightening torque . . . . . . . . . . . . . . . . . . .
55 Nm (40 ft Ib)*
59
70019401960 Specifications
Section 2 B 200, B 230 Engines
Fuel pump
B230 F
Early type
Bosch PIN. . . . . . . . . . .. . .. 022
Volvo PIN . . ... . . . .. . . 1 306932-3
B230 FT/GT
Late type
... 039
1389449-8
... 025
1336679-4
0580464 ...
135793
max 6.5 A
max 5.0 A
((
145697
Volvo PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump capacity at a line pressure of 350 kPa (50 psi)
+20C (68F) and 13.5 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current consumption at a line pressure of 350 kPa (50 psi)
+20C (68F) and 13.5 V.. . . .. . . .. ... . . . . . . . .. . . .. . . . . . . . . . .
3531 165-3
95 litres/hr (25.1 US Galls. per hr)
8.8 A
Tank pump
Current consumption . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 4 A
60
70019401960 SpeCifications
Section 2 B 200, B 230 Engines
B 204 E/B 204 GlIB 204 FT/B 234 G/B 234 F: LH-JETRONIC 2.4 .
Air mass meter
8204E
Bosch PiN ............ ... 007
Volvo PIN . ........... 1346645-3
8204GT/FT
. . . 012
3517569-4
[ 0280212 ...
Resistance:
between terminals
2 and 3 ..... .... ... 3.5-4.00
between terminals
2 and 6 . ........... 0--10000
2.5-4.00
8234F
Type I"
'"
II'
.11
II '
'II
II ,
8234F
Type II"
146044
3501987-6
Resistance:
between terminals
2 and 3 .... ........ 2.5-4.00
2.5-4.00
III
III
. . 010
'"
Others
... 294
3517064-6
Injector
8204 E
0280150 ...
136790
8204GT/FT
8234 FIG
. . . 804
... 749
3517283-2
3501986-8
300 cm 3/min
300 kPa
(42 psi)
214 cm 3/min
300 kPa
(42 psi)
61
146171
I\.
r\.
rf'
8
6
"-
4
3
"-
0280130 .. .
135791
"
"
'8
6
4
3
"-
I"-...
""" ~
2
0'
8
6
4
3
2
0'
30 20
20
40
60
80
100
120 C
142811
Lambda-sond
B204GT
B204FT
B234F
... 034
3501753-2
55 Nm (40 ft Ib)*
70019401960 Specifications
Section 2 B 200, B 230 Engines
Fuel pump
0580464 ...
135793
Tank pump
63
700/940/960 Specifications
Section 2 ' 8200,8230 Engines
8200/230 ET
8230FT
Charg~
3500
45-53 (6.4-7.5)
50 (7.1)
3000
46-54 (6.5-7.7)
48-54 (6.8-7.7)
65-75 (9.2-10.7)
15-25 (2.1-3.6)
Tightening torques
3)
4)
18 Nm (13 ft IW)
/
136772
1)
2)
3)
4)
89mm
135780
64
~Nm
s::L).Nm
70019401960 Specifications
Section 2 B 200, B 230 Engines
Turbo engines
B230 FT/GT
Charge pressure, at full load and . . .... ... '. ........ . .. . . .... r/min
3000
48-54 (6.8-7.7)
51 (7.3)
60-70 (8.5-10.0)
22 (3.1)
Tightening torques
J .
' 1:C@1
,
147 943
Tightening sequence
(Turbocharger - exhaust manifold)
65
70019401960 Specifications
Section 2 B 200, B 230 Engines
Expansion tank
Pressure valve in filler cap opens at; .
overpressure, early type .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
late type without turbo . . . . . . . . . . . . . . . . . . . . . . . . .
with turbo and B 204/234. . . . . . . . . . . . . . .
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
100
150
7.0
psi
11
14
21
1.0
Type 1
87
86-88C
(187-190F)
9rC
(20rF)
Type 2
92
91-93C
(196-199F)
102C
(216F)
kPa
Thermostat
Marking ..................... .. . ... . . ..... . .. ... . .. ... ... . .. .
Starts to open at . ... ... . . . ...... .. .. ... ... .... . .. ..... . .. . . . .
Fully open at ... . ... . ................ . .. ... .. ..... .... ...... .
66
8.5 litres
qts 9.0
9.5 litres
qts 10.0
70019401960 Specifications
Section 2 B 200, B 230 Engines
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breakerless
1-3-4-2
til '
til ,
til
lit
ut
Engine
type
Ignition
timing
b.t.d.c.
Speed rls
(rpm)
Engine
type
Ignition
timing
b.t.d.c.
Speed rls
(rpm)
B200K
B200F
B200E
B200ET
15
.12
12
14
12.5 (750)
12.1- 13.8 (725-825)
14.2- 15.8 (850-950)
14.7-15.3 (880-920)
B230E
B230ET
B230F - 1988
12
10
12
14.2-15.8 (850-950)
14.7- 15.3 (880-920)
12.2- 12.8 (730-770)*'
B204E
B204FT/GT
B230A*
B230K
15
10
7
15
14.2-15.8 (850-950)
13.0-13.7 (780-820)
11.7- 13.3 (700-800)
13.3 (800)
1989B230FB
B230fT/GT
B234F/G
12***
12
12
15
12.1-13.8
12.9
12.2- 12.8
13.3-15.0
t'' '
'111
lit
(725-825)
(775)
(730-770)**
(800-900)
I
I
Ignition coil
131
7~1
B230A
B200E,B200K,B230E
B200ET,
B 230 F, B 230 FB, B 230 K,
B230ET
B 230 FT, B 204 E, B 204 FT/GT,
B234 FIG
B230F
Rex
0.6-0.80
0.50
0.50
6.9-8.5 kO
6.0 kO
5.0 kO
Knock sensor
II
146804
11 Nm (8 ft Ib)
20 Nm (14.5 It Ib)
67
70019401960 Specifications
Section 2 B 200, B 230 Engines
I~~n
~
Engine type
143983
Type I
Designation
Type II
PIN
Set number
PIN
Set number
WR7DC"
1 306605-5
273597-5
1 367528-5
270 746-1
WR6DC**
WR7DC
WR6DC
1 306604-8
1 346 541-4
1 367015-3
273596-7
271 409-5
271 415-2
1 367529-3
1 367528-5
1 367529-3
270 747-9
270 746-1
270 747-9
Type II spark plugs are standard on B 200/230-1988- but can also be used on earlier engines (provided HT leads and ground lead are
replaced at same time) .
.. Up to 1987 W7DC (W6DC , type I).
Distributor
Engine type
B200E, B230K
B 230 E, B 230 F -1988, B 230 FT
-1989
B200K
B200F
Distributor
Ignition system
Volvo PIN
Bosch No
EZ-K
1 336087
0237502001
EZ-K
Renix
EZ 116 K
1 336087
1 336 132
1 336132
0237502001
0237502002
0237502002
EZ 116 K (Rex' )
Motronic
TZ-28 H
1 336 132
1 336 132
1 336690
0237502002
0237502002
0237024013
EZ 116 K
1 367197
0237502003
Centrifugal governor
Advance, total degrees (distributor) . . . . . . . . . . ..
Advance begins at distrib. rev/sees .... . .. .. .. .
distrib . rev/min. . . . . . . . . . . ..
Data: 5 at distrib. rev/sees . . . . . . . . . . . . . . . . . .
(distrib. rev/min) . . . . . . . . . . . . . . . . ..
10 at distrib. rev/sees . . . . . . . . . . . . . . . . ..
(distrib. rev/min) . . ... . . .. . ... . . . ..
Advance max at distrib. rev/sees . . ... ...... . ..
(distrib. rev/min) . . . . . . . . . . . . . .
12,5 1
7.5-10.5
(450-630)
16.5-20.5
(1000-1250)
25-29
(1500-1750)
31.7
(1900)
68
rrr~,o
l
Positive
7.51
105-145
165-210
240
'0
500
6,0~;;.
1000
1500
2000
2500
3000
3500
4000 rlmin
40. 20"~mmWmfmm~mmfffi=mmm
Vacuum governor
Control direction ... . .. .... .. . . . . . . ... . ...... .
Control, total degrees (distributor) . ..... . . . . . . .
Control commences at mm Hg ......... .. .. . . .
Data: 5 at mm Hg . . . . ... . ..... . .. ... . .. . ... .
max control at mm Hg .. . .... . . ... ... .. .
~.
Ii'
- 10' -ft
20
30
i i i
100
200
40
3bo
50
i
460
60
j
kpa
mm iHg
136 780
70019401960 Specifications
Section 2 B 28 Engine
Section 2 B 28 Engine
Group
Group
Group
Group
Group
Group
Group
20
21
22
23
25
26
28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine................................
Lubricating system ... .. ... .. .. . .. . ......
Fuel system .. ..... . . ... . . . . . . . . . . . . . ..
Intake and exhaust systems ............ .
Cooling system ................... . .....
Ignition system. . . . . . . . . . . . . . . . . . . . . . . ..
69
70
74
75
82
83
84
129756
/ ......
Group 20 General
~
l.t
'\
129750
Engine
type
1)
3)
4)
Output
Octane
requirement
Max torque
hp at
r/min
Nm at
rls
kpm at
r/min
'"
91-93
96/88
130/5250
212150
21.6/3000
B28E
9.5:1
98 1)
115/95
156/5700
235/50
24.0/3000
B28F
8.8:1
91 2)
100/92
136/5500
1344)/5500
215/46
21 .9/2750
1593 )/2 .700
ft. lb.
Horse power
ill
,'....
N,'
III
kW at
rls
8.8:1
B28A
2)
Compression
ratio
"''"
6
91 mm (3.582 in)
73 mm (2.874 in)
2.849 dm3 (Iitres)
1-6-3-5-2-4
0.8-1 .1 MPa (114-156 psi)
150 kg (330 Ib)
With hot engine, throttle wide open and starter motor cranking at
4.2-5.0 rls (250-300 r/min) .
69
70019401960 Specifications
Section'-2 " B 28 Engine
Cylinder liners
Bore, liners marked 1 (A-marked piston) .... .. . ........... . .... .
2 (B-marked piston) ....... . ............. .. .
3 (C-marked piston) ... ................... .
Liner height above block face:
checking (runing engine, old shims) ... . ........... .. .. . . . . . . .
adjusting (new shims) .............................. ... . ... .
91.00-91.01 mm
91.01-91.02 mm
91.02-91.03 mm
3.5826-3.5830 in
3.5830-3.5835 in
5.5835-5.5838 in
0.14--0.23 mm
0.16-0.23 mm
0.0055-0.0091 in
0.0063-0.0091 in
6 grams
0.020-0.040 mm
90.970-90.980 mm
90.980-90.990 mm
90.990-91.000 mm
0.0007-0.0015
3.5814-:3.5818
3.5818-3.5822
3.5822-3.5826
Pistons
Max weight difference between pistons in same engine .......... .
Piston float .... . ..... . ................... . ................. . .
Piston diameter A-marked pistons ......... .
B-marked pistons .. . ..... . .
C-marked pistons ... . .. .. .
'"
((0))
in
in
in
in
~L-f
135676
Piston rings
/,
I
111111111 ~III
'--
cylinder
115085
129520
Upper
Lower
compression
ring
Oil ring
compression
ring
Side clearance (measured with ring on piston) ...... .. .. . .... mm
in
Ring gap when checked in 91 mm (3.5826 in) cylinder,
(see fig) ........ . ..... ... ..... ... ........ . . . ........ . .... mm
in
0.045-0.074
0.0017-0.0029
0.025-0.054
0.0009--0.0212
0.009--0.233
0.0003-0.0091
0.40-0.60
0.0157-0.0236
0.40-0.60
0.0157-0.0236
0.40-1.45
0.0157-0.0570
0.020-0.041 mm
0.010-0.016 mm
70
0.0007-0.0016 in
0.0003-0.0006 in
70019401960 Specifications
Section 2 B 28 Engine
Valve system
Valve clearance
Inlet valves, cold engine . .. . ....... . .. . .......... .... . . . . . . .. .
warm engine . . . ...... . . . ............ . . .. ....... . :
Exhaust valves, cold engine . . .. . . ........... . .. . . . .......... . .
warm engine .. . .... . .... . ... . ... . ... ... . . .. . . .
0.10-0.15
0.15-0.20
0.25-0.30
0.30-0.35
mm
mm
mm
mm
0.004-0.006
0.006-0.008
0.010-0.012
0.012-0.014
in
in
in
in
7,965-7,980
7,975-7,990
44
129851
Inlet valve
Exhaust valve
Valve seats
I:i~~'
130021
Valve guides
Inner diameter . . . . .. ....... ... . . .... . . . . ........... . ........ .
Press-in measurement to cylinder head contact surface against
block:
inlet ..... . ... . ..... . ....... . ..... .. ...... . ..... . . . . . .. . .. .
exhaust . . ..... . .. .. . ... . . ...... ... .... . ... . .... .. ........ .
Clearance in cylinder head . .. . .. . . ... .. .. . .. . ........ . . ..... . .
8.000-8.022 mm
0.3149-0.3158 in
39.5-40.5 mm
36.9-37.9 mm
0.052-0.095 mm
1.5551-1 .5944 in
1.4527-1.4921 in
0.0020-0.0037 in
71
70019401960 Specifications
Section 2 B 28 Engine
..
Standard
Oversize 1
Oversize 2
Oversize 3
Marking
Reamer
No groove
1 groove
2 grooves
3 grooves
5166
5167
5168
129865
Valve springs
Springs marked green
Length
115083
mm
47.1
40.0
30.0
in
1.85
1.57
1.18
Load
lb.
230-266
613-689
52-60
137-1 54
(0.0005-0.0021 in)
0.012-0.054 mm
Timing gears
Camshaft
Engine type . .. ... .. .. ............. ... ...
740~
Letter
B28A, E
Left
Right
Left
Right
..
.615
. .. 977
B28A, E
Max lobe lifting height. left and right. inlet .. ... . .. .. .... ... . .. .. .
exhaust. . ........... . .... "
Checking camshaft settings (cold engine):
adjust valve clearance on 1st and 6th inlet valves to .......... .
The inlet valves should then open at:
1st .. . ... .... ............ . .......................... .. . .
6th . . , .... . ............................................ .
Journal clearance ............... .. ................. ......... .
End play, new .............................................. .
max . ............. ................ ... ... .. . ....... .
72
B28F
. . .616
..
.978
B28F
(0.2142 in)
(0.2339 in)
0.7 mm
(0.0275 in)
83 B.T.D.C.
83 B.T.D.C.
0.035-0.085 mm
(0.0013-0.0033 in)
0.070-0.144 mm
(0.0027-0.0056 in)
0.5 mm
(0.0196 in)
1 3 B.T.D.C.
1 3 B.T.D.C.
70019401960 Specifications
Section 2 B 28 Engine
Crank mechanism
Crankshaft
Max run-out (measured on two centre main bearing journals) ..... .
Crankshaft, end float .... . ... . ....... . ............. . ....... . . .
clearance (main bearings) . . ....................... .
Crank journals, side clearance . . . . . .. . ......... . ..... . ...... . .
clearance .. ..... . . ...... .... .. . ............ . . .
0.02 mm
0.070-0.270 mm
0.038-0.088 mm
0.20-0.38 mm
0.030-0.080 mm
0.0007 in
0.0027- 0.0106
0.0014-0.0034
0.0078-0.0149
0.0011-0.0031
in
in
in
in
.
.
.
.
0.007 mm
0.01 mm
70.043-70.062 mm
69.743-69.762 mm
0.0002 in
0.0003 in
2.7575-2.7583 in
2.7457-2.7465 in
115089
Out-of-round
t't'.
-II
II
II
II '
,II
II'
,II
II '
.
.
.
.
0.007 mm
0.01 mm
52.267-52.286 mm
51.967-51.986 mm
0.0002 in
0.0003 in
2.0577-2.0585 in
2.0456-2.0466 in
Taper
Connecting rods
End float on crankshaft (both can rods fitted) ..... . .... . .... . . .. .
Max weight difference between can rods in same engine ........ .
0.20-0.38 mm
2.5 grams
0.0078-0.0149 in
0.05 mm
0.0019 in
Flywheel
Axial throw, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must be oiled prior to assembly.
Nm
ttlb
45-50
240-280
70-90
45-50
122
15
33-37
177- 206
52-66
33-37
91.5
11
73
70019401960 Specifications
Section 2 B 28 Engine
Cylinder head
Tighten all bolts in stages:
1 Tighten bolts to 60 Nm (43 ft Ibs)
2 a
Loosen bolt 1, tighten it to 20 Nm (15 ft Ibs)
b
Angle-tighten to 106 degrees using special tool 5098.
Repeat this for remaining bolts in sequence shown.
c
Loosen and tighten each bolt in turn.
3 Adjust valves.
4 Warm-up engine.
5 Allow engine to cool for 2 hours.
6 Angle-tighten each bolt a further 45 degrees
11 8650
Main bearings
L~~::~:~'~I~:
I
i61I~-
1111i@1lf11-
---,---,---,---,-
115091
0.1 MPa
0.4 MPa
(14.2 psi)
(57 psi)
0.025-0.084 mm
0.0009-0.0033 in
0.110-0.185 mm
0.17-0.27 mm
0.015-0.053 mm
0.015-0.051 mm
0.0043-0.0072
0.0066-0.0106
0.0006-0.0021
0.0006-0.0020
89.5 mm
56.5-60.5 mm
3.52 in
2.22-2.38 in
74
in
in
in
in
70019401960 Specifications
Section 2 B 28 Engine
\\\\Iffll
rpm
135 528
Engine
type
Market
CO%
Adjusting
(checking)
1)
2)
3)
4)
2.0 (1 .0-3.0)1
1.0 (0.7-1.3)2
1.0 (0.7-1.3)2
42 (39-45)3
42 (39-45)3
12.5 (750)4
15.0 (900)
B28E
USA, Canada, Australia
Japan
II '
15.0 (900)
2.5 (2.0-3.5)
....
...
II '
II I
Volvo
Mono-Tester
B28A
B28F
Idling speed
r/s (r/min)
..
II'
II '
15.0 (900)
75
70019401960 Specifications
Section 2 B 28 Engine
Carburettor PIN
Throttle valve
marking
Metering needle
119943
SU-HIF 6 carburettor
1.1-1.7 mm
(0.0433-0.0670 in)
6 mm (0.2364 in)
SAE 10W-40
(SAE 1OW-50)
(0.0079-0.0118 in)
0.5-1.5 mm
(0.0197-0.0591 in)
---*
~~
.==tt
25 mm (0.9850 in)
Fuel pump
Fuel pressure measured at same level as pump at 50 rls
(3000 r/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
70019401960 Specifications
Section 2 B 28 Engine
CI-SYSTEM (8 28 E, 8 28 F)
Pressures
470-550 kPa (67-78 psi)
240-320 kPa (34-45 psi)
Type of control pressure regulator fitted to vehicle depends on engine type and model year. Identification number is stamped in top of
regulator (last three numbers).
0438 140 . ..
Volvo PIN
269 837-1
1 269779-3
1 336678-6
1 269779-3
Bosch PIN
... 038
... 099
. . . 128
. .. 099
Resistance,
at temp below 12C (53F) . . . . . . . . . . . . . 31.5-38.5 0
at temp above 18C (64F) . . . . . . . . . . . .. 12.6-15.4 0
2
kp/cm
kPa
3.5
350
3.0
300
'2.5
2 50
2.0
200
1.5
150
1.0
10 0
0 .5
50
FFFffi+flFfFm+R=R=FfFmm+!=FfFl+R
3.5
3.0
2.5
250
2.0
200
1.5
150
1.0
100
0.5
50
10
32
50
20
q
<C'
30
40
50
60
70
86
104
122
104 ....
15 P
BO
176
.. F
13294317
32
10
50
20
68
30
86
40
104
50
122
60
140
70
158
80
176
oc
of
132 943/5
77
lilt
III
lit
III
.Iltl
III
'II'
III
lilt
70019401960 Sp~cifications
Section 2 B 28 Engine
kPa
kp / cm
400
3,5
350
300
2,5
19.5-21 .70
9.8-11.0 0
2
kPa
(Torr)
835
855
875
895
915
935
955
975
980
626
641
656
671
686
701
716
731
735
500
4.5
450
400
3.5
350
300
250
200
1.5
150
10
20
30
50
68
86
3.6 psi)
137 667
1013
950
900
850
800
750
700 mba,
760
713
675
638
600
563
525 mm Hg
(Dry)
137668
Injectors
Opening pressure . .... ... .. . kPa (psi) 350-410 (50-58)
No leakage permissible below .... ... 290 (41)
Identification number
on side of injector.
Bosch number
0437502022
Volvo PIN
1 269713-2
127 182
Start injector
Injection time. (Controlled by thermal timer during cold
starting and by impulse relay during hot starting.)
Cold starting, below +35C (95F). Max time (at -20C
(-4F), 7.5 secs. The hotter the engine, the shorter the
time.
0280170 ...
134 264
B28E
B28F
... 404
... 400
462865-7
115 cm 3/min
269292-9
165 cm 3/min
70019401960 Specifications
Section 2 B 28 Engine
Sec
-20 C 7,5sek
135562
-.20
-4
- 10
14 .
o
32
10
50
20
30
68
86
of
. 134739
Volvo PIN
1 266910-7
1 346477-1
1 269319 ~ 8
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40--60 0
Fully open at. . . . . . . . . . . . . . . . . . . . . . . . . . -30C (-22F)
Fully closed at. . . . ... ...... '. ' . . . . . . . .. + 70C (158F)
0280140 . ..
134740
79
70019401960 Specifications
Section 2 B 28 Engine
Fuel pump
&
0580254 . ..
Bosch No
828 E, early type . . .. . .. 963
late type . ... .. ... 948
828 F . ... .. .... . ... ... 948
Volvo PIN
1 306028-0
1 336677-8
1 336677-8
138069
max 9.5 A
Tank pump
Current consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
1-4 A
70019401960 Specifications
Section 2 B 28 Engine
0280220 ...
Bosch No
136607
1 274452-0
1 274711 -9
1 274452-0
Itl
It
It
III
It
III
III
It
II I
Temperature sensor
ohms
100000
80000
60000
40000
30000
I\..
"I\..
20000
0 280130 .. .
135791
10000
8000
80sch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 028
Volvo PIN ..... .. .... . .. .... .... .. ....... 1 306 024-9
6000
""-
'"
4000
3000
Resistance at:
-10C (14F) ... . . .... ....... .. ... 32000-530000
+ 20C (68F). . . . . . . . . . . .. . .. . . . . .. 8500-11 500 0
+ 80C (176"F) . . . . .. . . . . . . . . . . . . . . . . . 770-1 320 0
2000
"-
1000
800
"I"
........
.........
600
400
-10
20
40
60
80
14
32
68
104
140
176
100
"c
212 "F
133374
Volvo PIN
1 317957-7
1 276 871-9
1 317957-7
81
70019401960 Specifications
Section 2 B 28 Engine
(B28F ONLY)
Control unit
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 050
Volvo PIN ... ......... . .. .. . ....... ...... 1 274368-8
Duty cycle
disconnected sand . . . . . . . . . . . . . . . . . . . . . . . . . 42-48
grounded thermal switch . . . . . . . . . . . . . . . . . . .. 51-57
grounded microswitch* . .. . ..... .. .......... 51-57"
grounded pressure differential switch .... . ..... 82~
* B 28 F USA 1983 models designed for high altitude use:
microswitch must be disconnected at all times.
135 202
Lambda-sond
Bosch No . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 037
Volvo PIN . ............... . . .. . . .. . .. .... 1 274367-0
Tightening torque. . . . . . . . . . . . . . . . . .. 55 Nm (40 ft Ib)*
* Apply 'Never-Seez' PIN 1 161 035-9 to entire thread length.
82
70019401960 Specifications
Section 2
B28 Engine
til
tt
til
II
III
'11
II I
tt
II '
128187
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
litres
10.0
US qts
10.5
kPa
psi
11
21
1.0
Expansion tank
Pressure valve in cap opens at:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
overpressure, early type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
late type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
150
7.0
Thermostat
Marking ......... . ....... . .................................. .
Starts opening at. . ........ . ........ . ....... . . ............... .
Fully open at ............................................... .
92
91-93C (196-199F)
102C (216F)
Fan belts
Designation, type 1 ... .. : .......... . ............. .. .. .... .... .
type 11. ...................... .. ............... .
type III (not B 28 F USA) ......... . ............... .
HC 38 x 1100
HC 38 cog x 1100
HC 38 cog x 1075
83
70019401960 Specifications
Section 2 B 28 Engine
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enginetype
Ignition timing
b.t.d .c.
Speed rls
(rpm)
8 28A*
8 28 E*
8 28F*
10
10
23
Breakerless
1-6-3-5-2-4
Ignition coil
1317S3
Engine type
Designation
PIN
Kit number
HR6DC
1269915-2
273599-1
84
70019401960 Specifications
Section 2 B 28 Engine
Distributor
Ignition system
Engine type
B28A, B28E
B28F
TSZ-4
TSZ-4
Distributor
Volvo PIN
Bosch No
1269191
1269380
0237402013
0237402017
B28A, E
0237402013
1 269 191
Clockwise
540-660
0.3 mm
B28F
0237402017
1 269380
Clockwise
540-660
0.3 mm
131
7.fr-9.6
(450-575)
12.fr-15.4
(750-925)
23.3-32.5
(1400-1950)
40
(2400)
111
8.fr-10
(500-600)
12.4-15.3
(740-920)
30-50
(1800-3000)
33.3
(2000)
Positive
7,51
160-210
200-240
300
Positive
101
10fr-135
11 fr-145
210
Centrifugal governor
Advance, total, degrees (distributor) . . .. . . . . . . ...... ....... .... .
Advance beg ins at distrib. rev/sees ... .............. .. ......... .
distrib. rev/min ...................... . ...... .
Data: 5 at distrib. rev/sees ... .. . .. . ...... .. . ..... ... . . .. _... .
(distrib. rev/min) . .. ... . .... ... ...... . .... . . ..... . .
10 at distrib. rev/sees .. . .......... . . . ..... . ............ .
(distrib. rev/min) . ... .... . ... .. .. ... . ... . ........ . .
Advance max at distrib. rev/sees . . . . ......... . .... .. ....... .. .
(distrib. rev/min) ..... . .. . ... ... ........... . .. .
'III
III
ttl
'"
:':':':
I'NI
Vacuum governor
Control direction ... ....... ..... . ... . ..... .. ....... ........ .. .
Control, total degrees (distributor) . . .. ... .. . .. ................. .
Control commences at mm Hg .. .. ..... ... . .......... . ....... .
Data: 2 at mm Hg ................ ..... . ........... . ...... . . .
max control at mm Hg ...... . ....... .... ..... .......... . .
Ignition advance
.,r~'
30' 15'
500
1000
0'
- 10'
--+;r
2500
3000
4000 r min
3500
IT
ffi rtt~
1 G~
50~
40~ 2Cf~
2,0.
3.0 ,
1500 2000
l~OO
6,0~~,
4,0
, 5,0
I
2500 3000 3500
4000 rjmin
,1{,llrD
-IT ~ I
I=l=l11-,+-1
f:=:t 17/
-+
I
.-
I-t-
+r
-'
cf' ~
-s
2000
It ~~
~ !=t tl-
+
,I='
20' 10
,.
1500
60I -~
, .tlsO
10
0
I
if
-10'
-s
0237402017
20
100
0'
30
I
200
300
60
50
40
I
400
kpa
I
mmHg
10
20
30
i i i
100
200
135969
B28A, B28E
40
I
JOD
50
60 kpa
Iii
400
mm Hg
135356
B28F
85
70019401960 Specifications
Section 2 B 280 '
Engine .
20
21
22
23
26
28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine.. . .. .. .. ........... .. .. .. .. . .. .
Lubricating system. . . . . . . . . . . . . . . . . . . . . .
Fuel system ...... . ...... ... ..... .. . . ..
Cooling system ... ... .. ...... .. . ... ... ..
Ignition system. . . . . . . . . . . . . . . . . . . . . . . ..
IL
Group 20 General
86
87
92
93
96
97
j.
1'\
129 750
Engine
type
Compression Octane
ratio
requirement
Output
kW 'at
B280 E
Scandinavia
B280 E
Other markets
B280 F
1)
2)
3)
4)
10.0:1
Max torque
hp at
r/min
Nm at
rls
rls
kpm at
rlmin
Min 95 1)
115/88
156/5250
245/53
25.0/3200
Min 95 1)
125/90
170/5400
240175
24.5/4500
108/85
147/5100
145/5100 3
235/63
24.0/3750
173/37504
10.0:1
9.5:1
Min 91
With hot engine, throttle wide open and starter motor cranking at
4.2-5.0 rls (250-300 r/min) .
86
6
91 mm (3.582 in)
73 mm (2.874 in)
2.849 dm 3 (Iitres)
1-6-3-5-2-4
0.8-1 .1 MPa (114-156 psi)
150 kg (330 Ib)
70019401960 Specifications
Section 2 B 280 Engine
Max warp:
Maximum warp is 0.05 mm (0.002 in) per
100 mm (4 in) length.
Note: Do not level a warped cylinder head,
replace it!
n~Ql;J
129860
Cylinder liners
91 .00-91.01 mm
91.01-91.02 mm
91 .02-91.03 mm
0.14-0.21 mm
(3.5826-3.5830
(3.5830-3.5835
(3.5835-3.5838
(0.0055-0.0083
0.098-0.134 mm
0.118-0.1 54 mm
0.138-0.194 mm
(0 .0039-0.0053 in)
(0.0046-0.0061 in)
(0 .0054-0.0076 in)
in)
in)
in)
in)
"'
lit
ill
lit
,11
tit
ill,
til
Itil
Pistons
Max weight difference between pistons in same engine ..... . . . .. .
Piston float .... .. .... . ..... .. ... ....... .... .... . . .. ..... .. . . .
Piston diameter, A-marked pistons .... .. . . .
B-marked pistons . .... . .. .
C-marked pistons ..... ... .
((0))
~
6 grams
0.070-0.090 mm
90.920-90.930 mm
90.930-90.940 mm
90.940-90.950 mm
t
~~
135 676
Piston rings
Upper
com pression ring
0.045-0.074
Side clearance (measured with ring on piston) . . . ..... . .. . . . . mm
in . 0.0017-0.0029
Ring gap when checked in 91 mm (3.5826 in)
0.40-0.60
(cylinder, see fig) .......... . ... .. ............ ... . . . .. . . .. . mm
in
Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.0157-0.0236
0.007-0.017 mm
Lower
compression ring
Oil ring
0.025-0.054
0.0009-0.0212
0.009-0.233
0.0003-0.0091
0.40-0.60
0.0157-0.0236
0.40-1.45
0.0157-0.0570
(0.0003-0.0007 in)
87
70019401960 Specifications
Section 2 B 280 Engine
Valve system
Valve clearance
Inlet valves, cold engine ........... .. ............. .. .. . ...... .
warm engine .... . . . .. ...................... .. . . . .
Exhaust valves, cold engine .. ... . ............................ .
warm engine .. ....... . ...... ... .. ... . ........ .
0.10-0.15
0.15-0.20
0.25-0.30
0.30-0.35
mm
mm
mm
mm
(0.004-0.006
(0.006-0.008
(0 .010-0.012
(0.012-0.014
in)
in)
in)
in)
7,973-7,995
7,965-7,980
45,3
129851
Inlet valves
Exhaust valves
Valve guides
20-24mm
18 -22 mm
' Il'I====JI,
141 RClfj
' ':1~:J'
130021
Valve guides
Inner diameter ... . ... ... ....... .. .. ... ........... . ... . ...... .
Press-in measurement to cylinder head contact surface against
block:
inlet . ............ ..... ............. . .................... . .
exhaust ....... .. ........... . .... .. .. . ................. ... .
Clearance in cylinder head .......................... .... ..... .
88
8.000-8.022 mm
(0 .3149-0.3158 in)
46-47 mm
36.9-37.9 mm
0.053-0.098 mm
(1.8124-1.8518 in)
(1.4527-1.4921 in)
(0.0020-0 .0037 in)
70019401960 Specifications
Section 2 B 280 Engine
Valve guides are available in three oversizes and are marked with
grooves.
Standard
Oversize 1
Oversize 2
Oversize 3
Marking
Reamer
No groove
1 groove
2 grooves
3 grooves
5166
5167
5168
129865
Valve springs
47.1
40.0
30.0
1.85
1.57
1.18
Load
Ibs.
230-266
52-60
613-689
137-154
....
...
III
III
III
III
11
II I
0.012-0.054 mm
(0.0005-0.0021 in)
Timing gears
Camshaft
~
--~
B280F
B280 E
Right
Left
Right
S
R
R
S
Green
White
Green
White
... 957 . .. 959 . .. 958 . .. 960
132608
B280E
Max lobe lifting height. left and right. inlet ........ ........... . .. .
exhaust .... . ...... ' " .. . . . .
Checking camshaft settings (cold engine) :
adjust valve clearance on 1st and 6th inlet valves to ...... . ... .
The inlet valves should then open at:
1st ... . . . . . ........... . ... . .. .. . . . .... . ......... . .... . . .
6th . . .... .. .. ....... .. ............ . ................. . .. .
Journal clearance ............ . . . .......... .. .. . . . ......... . . .
B280 F
4.50 B.T.D.C.
50 B.T.D.C.
4.50 B.T.D.C.
50 B.T.D.C.
0.035-0.085 mm
(0.0013-0.0033 in)
89
70019401960 Specifications
Section 2 B 280 Engine
Crank mechanism
Crankshaft
Max run-out (measured on two centre main bearing journals) .. . .. .
Crankshaft, end float .................... . . ... .. . . .. ....... .. .
Crank journals, side clearance ... ......... .... . ... . .. . ...... .. .
0.02 mm
0.070-0.270 mm
0.20-0.38 mm
(0.0007 in)
(0.0027-0.0106 in)
(0.0078--0.0149 in)
0.007 mm
0.01 mm
70.043-70.062 mm
(0.0002 in)
(0.0003 in)
(2.7575-2.7583 in)
115089
Out of round
0.007 mm
0.01 mm
59.971-59.990 mm
(0.0002 in)
(0.0003 in)
(2.3629--2.3636 in)
Taper
Connecting rods
End float on crankshaft ...................................... .
Max weight difference between can rods in same engine ........ .
0.18--0.32 mm
2.5 grams
(0.0071-0.0126 in)
Nm
ft. lb.
Tightening torque
Tightening torques apply to oiled nuts and bolts. Degreased
(washed) parts must be oiled prior to assembly.
90
240-280
177-206
52-66
70-90
45-50
33-37
122
91.5
15
11
1 Oil threads
2 Tighten No.1 bolt to 25 Nm (18 ft.lb)
3 Tighten No.2 bolt to 25 Nm (18 ft.lb) + angletighten 75
4 Angle-tighten No. 1 bolt 75
5 Check/tighten both bolts to 50 Nm (37 ft.lb)
7QOl9401960 Specifications
Section 2 B 280 Engine
Cylinder head
Tighten all bolts in stages:
1990-
1
2a
b
c
lit
'\1
lit
II
lit
.\1
lit
11
147795
A. 1900-
III
B. Earlier type
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
115091
91
70019401960 Specifications
Section 2 B 280 Engine
0.1 MPa
0.4 MPa
(14.2 psi)
(57 psi)
0.025-0.084 mm
(0.0010-0.0033 in)
0.020-0.095 mm
0.17- 0.27 mm
0.015-0.053 mm
0.015-0.051 mm
(0.0008-0.0037
(0.0066-0.0106
(0.0006-0.0021
(0.0006-0.0020
89.5 mm
56.5-60.5 mm
(3.52 in)
(2.22-2.38 in)
92
in)
in)
in)
in)
70019401960 Specifications
Section 2 8280 Engine
Engine type
CO %1
Idling speed
r/s (r/min)
1)
2)
3)
\\\\1""
Adjusting
(checking)
Volvo
Mono-Tester
B280 E
1.0 (0.5-2.0)
12.5 (750)
B280 F
20_703
12.5 (750)
rpm
135 528
'illIIIIII"
,II
,'N
III
'II
LH JETRONIC 2.2
Air mass meter
Manufacturer's No type I . . . . . . . . . . . . . . . . . .
. .. 006
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
250 (36)
150-250
(28-43)
93
70019401960
Specifica~ions
Injectors
Early type
Late type
... 734
170 cm 3/min
1 389844-0
250 kPa
(36 psi)
0280150 ...
135 790
0' .
I\.
8
6
4
3
2
0280130 .. .
135791
Bosch No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 032
Volvo PIN ..... . .......... .. ..... . ... . ... 1 346 030-8
Resistance at:
-10C (14F) .................. . .... 8.10-10.77 kG
+20C (68F) ...... .. ... . . ... ....... . 2.28-2.72 kG
+80C (176F) ......... . ... . ... ... ... . . 290-364 G
"
""
'"
1
8
6
4
3
......
..........
"""'-
2
0'
8
6
f".-.
4
3
2
10'
-30 20
20
40
60
80
100
120
1428 11
94
70019401960 Specifications
Section 2 B 280 Engine
Lambda-sond
Early type
Late type
... 034
3501 753-2
n
n
0258~
138 112
,
(
Fuel pump
Type I
Bosch No .. .. .. ... . ... ... 948
Volvo PIN ..... ....... 1 336 677-8
&'
Type II
'",IIIII
... 039
1 389449-8
NI'
III
ill
,II'
'"
0580254 .. .
138069
max 5.0 A
Tank pump
Current consumption . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4 A
95
70019401960 Specifications
Section 2 B 280 Engine
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
litres
10.0
US qts
10.5
kPa
psi
150
7.0
21
1.0
Expansion tank
Pressure valve in cap opens at:
overpressure .. ..................... ....... . ..... . . . . . .. .. .
underpressure ..... . ....... . .... .. . ... . .. ............ . .... .
Thermostat
Marking . . . .. ....... . ................ .. . . .... . .............. .
Starts opening at. .... . .. ..... .... . .................. . ....... .
Fu lly open at .................... . ... ..... .. ...... . . . ....... .
87
86-88 (187-190F)
9l" (20l"F)
Fan belts
Designation, 760. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
780. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
HC 38 cog x 1075
HC 38 cog x 1100
70019401960 Specifications
Section 2 B 280 Engine
~
~~
134864
Engine
type
Ignition timing
b.t.d .c.
Speed rls
(rpm)
B280 E
B280 F
10
16
12.2-12.8 (730-770)
12.2-12.8 (730-770)
EZ 115K
1-6-3-5-2-4
..
..
II I
Ignition coil
II I
II
II '
II'
11
II
1317 ~
Engine type
Designation
PIN
Kit number
HR6DC
HR5DC
1 269915-3
1 389896-0
273599-1
270590-3
Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque , (unoiled plugs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock sensor
146 805
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Nm (1 4. 5 ft Ib)
97
70019401960 Specifications
Section 2 B 6304 Engine
20
21
22
23
26
28
General.... . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine. ... . .. . . . ... . . . ......... ... ...
Lubricating System . . . . . . . . . . . . . . . . . . ..
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . ..
Cooling system . . . . . . . . . . . . . . . . . . . . . ..
Ignition system . . . . . . . . . . . . . . . . . . . . . . . .
Group 20 General
Performance, compression ratios, octane requirements
Engine
type
Notes
B6304F
Compression
Ratio
Octane
requirement
RON
10,7 1)
95
Output
Max torque
kWat
rls
hp at
rim
Nm at
rls
kpm at
rim
150/100
204/6000
267172
27.214300
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.
6
83.00 mm (3.268 in)
90.00 mm (3.543 in)
2.922 dm 3 (Iitres)
1-5-3-6-2-4
1.3-1 .5 MPa (184-213 psi)
180 kg (397 Ib)
With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls
(250-300 rIm)
(in)
(in)
129.000.05
0.3
(in)
(in)
0.020
0.008
(5.07870.0020)
(0.0012)
98
98
101
102
106
107
70019401960 Specifications
Section 2 B 6304 Engine
Cylinder block
Bore
Standard (marked
(marked
(marked
(marked
(in)
(in)
(in)
(in)
83.00-83.01
83.01-83 .02
83.02-83.03
83.04-83.05
(3.2677-3 .2681 )
(3 .2681-3.2685)
(3.2685-3 .2689)
(3.2693-3.2697)
82.98--82.99
82.99--83.00
83.00-83.01
83.02- 83.03
350 5
10
(3.2669--3.2673)
(3.2673-3.2677)
(3.2677- 3.2681 )
(3 .2685-3.2689)
(12.5 0.2)
(0.4)
Pistons
Piston diameter
Diameter to be measured at right angles to gudgeon pin and
16 mm from bottom of piston.
Piston rings
Itl
It
Itl
Upper
camp. rings
0.05-0.085
0.0020-0.0033
0.2-0.4
0.008--0.016
Lower
camp. rings
0.03-0.065
0.0012- 0.0026
0.2-0.4
0.008--0.016
Oil scraper
rings
0.02-0.055
0.0008- 0.0022
0.25-0.5
0.009--0.020
Valve system
Hydraulic
Valves
Length inlet . . .. . . . ......... . .... .. ..... . ..... . ....... mm (in)
exhaust .... . ...... ... ... .. ..... . . ... ......... . mm (in)
Matching surface angle . .. ... . . .. . .. . . ............... . ... ... . 0
Edge height, new valve .. . ................ . .. . .. ... . ... mm (in)
min after machining . .... . . . ........ . . . .... mm (in)
Max machining of valve stem ... . ... ... . .. . . . . ... ....... mm (in)
104.050.18
103.300.18
45.5
1.5
1.2
0.4
(0.059)
(0.047)
(0.016)
inlet
32.61 (1.284)
33.11 (1.304)
45.25
20.25
60.25
1.4-1.8 (0.055-0.071)
exhaust
28.61 (1 .126)
29.11 (1 . 146)
45.25
15.25
60.25
1.8--2.2 (0.071-0.087)
(4.0960.007)
(4 .0670.007)
Valve Seats
Diameter standard ... ... . . . .... . .... . ...... . . ....... . . mm (in)
oversize ... . . . . . ........................... . mm (in)
Matching surface angle ............ ... ......... . . . .. . .. . ..... 0
Reduction angle, upper .... . .... . . . .......... . .. . .... . ....... 0
lower ..... . ..... . .. .. . . .. . . .. .. .... ........ 0
Width ............. . ....... .... .. . ........ . . . . . . . .... mm (in)
99
....1
'11
...ItlItl
70019401960 Specifications
Section 2 B 6304 Engine
Valve Gu ides
Diameter standard ............ . ........ . .............. mm
oversize 1 .. . ... ... .. ..... .. . . . . .... . ........ mm
oversize 2 ...... ... . ... ..... . . .. .. ....... .. . . mm
Clearance, valve stem-guide (measured with new valve) ... mm
Min . ............... .. . ...... . ...... . .... ..... ....... mm
inlet
exhaust
(in)
(in)
(in)
(in)
(in)
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
12.00 (0.4724)
12.1 (0.4764)
12.2 (0.4803)
0.06 (0.0024)
0.03 (0.0012)
(in)
(in)
(in)
(in)
27.900.20
20.100.20
34.00
24.50
(1.0980.008)
(0.791 0.008)
(1.339)
(0.965)
Valve Springs
External diameter ..... . ...... ..... .. .... ... ... .. . . .... mm
Internal diameter.. ... . .............. . ................ . mm
Length at 270 15 N ..... . .. .. ... . . .... . ............. mm
Length at 670 32 N .......... . ........ . ... ..... .. ... mm
Timing gear
Camshaft
Marking
Inlet .............. ... ......... . ....... .... ....... . ...... . .
Exhaust ......... . ............. . ......... ... ........... ... .
Max lift height ....... . ..... ..... . . . .... ........ .... .. . mm (in)
Axial clearance ....... .... .. ........ . ....... .. ... . .... mm (in)
PC I
PC E
9.00
0.05-0.20
(0.354)
(0.002-0.008)
0.004
0.08-0.19
0.024-0.047
(0 .00016)
(0.003-0.0075)
(0.00094-0.0019)
65.00
0.004
(2.559)
(0.00016)
50.00
0.004
(1.969)
(0.00016)
0.15-0.45
(0.0059-0.0177)
20
60
150
(15)
(44)
202
454
244
173
90
(151.5)
(333)
(183)
(122)
Crankshaft assembly
Crankshaft
Max out-ol-true .... . .. ........... . . ... .... ....... .. . . . mm (in)
Axial clearance ............................ . .. . ....... mm (in)
Radial clearance (main bearings) ....................... 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
70019401960 Specifications
Section 2 B 6304 Engine
Connecting rod bearing caps (stage 1) .... . .. . ... . ... . Nm (ft Ib)
(stage 2) angle-tightening ..... . ...
Crankshaft pulley (vibration damper), center bolt .. . ..... Nm (ft Ib)
Flange bolts, vibration damper (stage 1) ... . . .. . ..... .. Nm (ft Ib)
(stage 2) angle-tightening ........ 0
Driver plate (stage 1) ........ .... .. .... .... . . . . ... ... Nm (ft Ib)
(stage 2) angle-tightening ................. .. .. . ... 0
20
90
30030
35
60
45
50
202
395
244
246
173
203
355
173
385
173
173
152.5
402
405
82
202
202
102.5
386
25
(ft Ib)
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
(ft
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
Ib)
(15)
(221 22)
(26)
(33)
(151.5)
(294)
(183)
(184)
(132)
(152)
(264)
(132)
(284)
(132)
(132)
(11 2)
(291.5)
(294)
(61.5)
(151.5)
(151.5)
(72)
(284)
(18)
I.....'
'.','
"'III
,III
ill
u,1
0.1
0.3
0.5
(14)
(43)
(71 )
82.13
56.1
39.9
(3.233)
(2.21)
(1.57)
101
70019401960 Specifications
./ "
'
"."--
0.4-0.8
12.5 (750)
CO content and idling speed can not be adjusted , only checked. Shift
selector to be in position P when checking.
Motronic 1.8
Control unit
Bosch number . . ..... ......... . . . .. . . . 0261 200362
Volvo part number. . . . . . . . . . . . . . . . . . . . . . . 3 517 623-9
150362
Pressure regulator
Early type
Bosch number . . . . . . . . . . . . . . . . . . . . . . .. 0 280 160 294
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 3 517 064-6
Line pressure .... .. . ............ .. "
Late type
Bosch number . . . . . . . . . . . . . . . . . . . . . . . . 0 280 160 731
Volvo part number ... ... ... . ..... . . .. . . . . . 3547653
o 280
160 ...
145 789
Injector
o 280
150 ...
145677
102
70019401960 Specifications
Section 2 B 6304 Engine
Idling valve
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . 0 280 140 527
Volvo part number . ...... . .. .. ...... .. .. . 3517886-2
Resistance:
between terminals 1 and 3 . . . . . . . . . . . . . . . . . . .. 25 D
150426
....,1
,'.'.I
,',',\
111
'....1
1456BB
Camshaft sensor
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 232 101 009
Volvo part number . ... .. .. ............. . . 1 383966-7
Knock sensor
Bosch number. . . . . . . . . . . . . . . . . . . . . . . . 0 261 231 006
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367 644-0
103
70019401960 Specifications
Section 2 B 6304 Engine
150425
Lambda-sond
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 280 003 119
Volvo part number . ... ..... . ...... . ... ... 3531 251-1
Resistance in preheating resistor :
cold sand, 20C (68F) . . . . . . . . . . . . . . . . . . . . . . . . .. 3 0
hot sand, above 350C (660F). . . . . . . . . . . . . . . . .. 13 0
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
(40 ft Ib)
Apply 'Never-Seez', Volvo part number 1 161 035-9, to
entire thread length.
Fuel pump
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. 0 580 464 039
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 389449-8
o 580
464 ...
145791
Tank pump
VDO number. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 92151034
Volvo part number ........ . .............. 3501 928-0
Current consumption . . . . . . . . . . . . . . . . . . . . . .. 3-4 amp
145792
Sil
Fuel filter
Bosch number. . . . . . . . . . . . . . . . . . . . . . .. a 450 905 601
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 389 450-6
Filters particles down to . . . . . . .. 0.002 mm (0.00008 in)
Tightening torque . . . . . . . . . . . . . . . . . . . . . . .. 20-35 Nm
(15-26 ft Ib)
104
70019401960 Specifications
Section 2 B 6304 Engine
Main relay
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 323592-4
148680
150599
III
II
III
iii
,II
lit
,II
lit
150432
105
70019401960 Specifications
Section 2 B 6304 Engine
General
Coolant-com position-warranty
Since aluminum is used in the engines, active corrosion
protection is necessary in the coolant to help prevent corrosion 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 and is the only
coolant warrantied by Volvo,
Never top-up with water alone, Use genuine Volvo
coolant diluted with clean water in proportions of 50/50,
Under normal conditions the coolant will not need to be
replaced, However, after larger repairs requiring draining
of coolant, refill with new coolants, as the old will have
been exposed to oxidation and contamination ,
Clean cooling system with solvent (PIN 1161328-8)
prior to filling new coolant.
128187
Capacity, , , , , , , , . , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , , , . , , . , ,
(11 ,3 US qt)
150 kPa
7 kPa
(21 psi)
(1 psi)
Expansion tank
Pressure valve in cap opens at:
overpressure , , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , . , , . , , , , , , , ,
underpressure , , , . , , , , , .. , , . , , . , , . , , , . , , . , , . , , . , , , , , . , , , , , , , ,
Thermostat
Marking , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,
starts opening at , , , , , , , , , , , , , . , , , . , , , , , , , , . , , , , , , , , , , , , , , , , , ,
fully open at , , , , , , , , . , , , , , . , , . , , , . , , . , , . , , . , , , , , , , , , , , . , , . , , ,
106
70019401960 Specifications
Section 2 B 6304 Engine
Motronic 1.8
1-5-3-6-2-4
5
COMPONENTS
Made in Germ any
Power stage
Bosch number. . . . . . . . . . . . . . . . . . . . . . ... 0 227 100 203
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367 776-0
150365
Ignition coil
Nippon Denso number . . . . . . . . . . . . . . . .. 029 700-7260
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 531 300-6
Resistance of primary coil
(between terminals 1 and 15). . . . . . . . . . . . . . . . . .. 0.5 [2
Spark plugs
150431
Knock sensor
Bosch number ... . .. .. . .. .... ..... . .. . 0261 231 006
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367644-0
107
III
'IIt
III
II '
III
'I II
III
,II I
III
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
20
21
22
23
25
26
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine.... . . . ... . ..... . . .. .. ... . . . .. .
Lubricating system . . . . . . . . . . . . . . . . . . . .
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake and exhaust systems. . . . . . . . . . ..
Cooling system . . . . . . . . . . . . . . . . . . . . . ..
108
109
114
114
116
117
,/1-'"
Group 20 General
t1
Market
Compression ratio
Output, DIN
1)
Horsepower
2)
Ft Ib
hp at
r/min
kpm at
r/min
23:1
60/78
8214700
145/33
14.8/2000
23:1
79/80
190/40
Other markets
23:1
80/80
108/4800
106'/4800
109/4800
205/42
19.4/2400
1402/2400
20.9/2500
740/760
780
23:1
23:1
90/80
95/78
12214800
129/4650
235/40
250/40
24.0/2400
25.5/2400
024
024TIC
General data
Number of cylinders .. .. ..... .. .... . . . .. . .. . .. ...... . . .. . .... .
Cylinder bore .. .. .. .... ........ .. .. . ....... ... . . .... .. . . ... . .
Stroke . . .. ........... . .. . .. . . ...... . . . .. . . . ... .. . . .. .. ..... .
Displacement ... ... . . . .. . .. .. ..... .. . ... . ... ........... .. .. . .
Firing order . . ........ .. ... . ... .... . .. . .... . . .... . .. . . ... .... .
Compression:
new .................. . . .. . . ... . ... . .. ... ..... .. . . .. . .... .
min .. . ............ ... . ... . . .... . .... . ...... . ... . .. . .. . ... .
max. difference between cylinders ... .. ...... . .... . ........ . . .
Weight, approx., complete engine including engine mounts
alternator and starter motor
D 24 . . . . .. ... .... ... . . . .. .. .. ...... . . . .. .. . . . ..... . approx.
D 24 T .... .. ..... . ..... ..... . ... . . ... . ...... . .... .. approx.
108
'\
'29750
kWat
r/s
024T
It
6
76.5 mm
86.4 mm
2.383 dm3 (Iitres)
1-5-3-6-2-4
3.0118 in
3.4015 in
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Group 21
Cylinder head
Max. warp ..... . .. . .. ... ...... .. .... , .. . .
Cylinder head may not be machined.
It must be replaced if warp exceeds
maximum .
.,
!:,
'
:'
~I
129146
129147
Three different gaskets are used depending on height of piston above cylinder block.
Notches
0.67-0.80
0.81-0.90
0.91-1.02
Gasket
number of
thickness
notches
mm in
1*
2
3
0.026-0.031
0.032-0.35
0.036-0.040
1.4 0.055
1.5 0.059
1.6 0.063
Piston height in same engine must not extend over more than
two classes.
Piston height is measured at the front and back of piston (along
the gudgeon (piston) pin) .
Not D 24 TID 24 TIC
Cylinder block
Bore
Marking
(honing group)
Standard . .. . .. . . , . . . , ... . .. , .. .. . . , .. , ..... ... . .. ... ... 651
Piston diameter
mm
in
Cylinder bore
in
mm
652
653
Oversize 1 .. . ..... .. ... , . .. , .. , ... , .. , . .. , . . , .. , ....... 676
(0.25 mm = 0.010 in) . . . . " .. , . . " .. , . . , ... , .. , . . , .. , .... 677
678
Oversize 2 ...... . . . .... . .. , . . ....... ........ . .. . ....... 701
(0.50 mm = 0.020 in) .... , ..... . , . ... . . , . . .... , ... . ...... 702
703
Oversize 3 ... ...... .. .... . , ... , . .. . . . , . .. , .. ... , ... ... . 751
(1.00 mm = 0.040 in) . .. . .. . .. .. .. . .... . ... , .. , . . , . , . ... . 752
753
76.48
76.49
76.50
76.73
76.74
76.75
76.98
76.99
77.00
77.48
77.49
77.50
76.51
76.52
76.53
76.76
76.77
76.78
77.01
77.02
77.03
77.51
77.52
77.53
3.0110
3.0114
3.0118
3.0209
3.0213
3.0216
3.0307
3.0311
3.0315
3.0504
3.0508
3.0512
,III
3.0122
3.0125
3.0130
3.0220
3.0224
3.0228
3.0318
3.0322
3.0326
3.0515
3.0519
3.0523
.'....1
111
111
111
"'
'"'"
Pistons
Max. weight deviation between pistons in
same engine .. .. ..... . ... . . . ..... .. .. .. ... , . . . 12 grams
Piston float, new .... . .. .. . , ...... , .. , . ...... . . . 0.03-0.05 mm
max .. ... . .. .... . .... . . ...... , .. , .. . 0.13 mm
Piston diameter, see cylinder bore table
Max wear (compared with specified diameter) ... .. 0.04 mm
Piston diameter is measured at right-angles to gudgeon
piston lower edge.
0.0012- 0.0019 in
0.0051 in
0.0016 in
....
+I
t
129835
109
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engine
Pistons rings
~~
-L-J
~L---,-C-.,
129521
""~,
Side clearance
Ring gap
Piston ri ngs
Side clearance
(measured with ring
on piston) new .. . ... .. .
max ..... .. .
Ring gap (measured
in cylinder, see
illustration) new. . . . . . . .
max...... ..
Upper compression
mm
in
Lower compression
mm
in
mm
0.11-0.14
0.2
0.07-0.10
0.2
0.03-0.07
0.15
0.3-0.5
1.0
0.0043- 0.0055
0.008
0.012- 0.020
0.040
0.0028-0.0039
0.008
0.3-0.5
1.0
0.012- 0.020
0.040
Oil scraper
in
0.0012-0.0028
0.006
0.25-0.50
1.0
0.010-0.0197
0.040
Valve system
Valve c learances
Cold engine = engine at room temperature
= intake valves
exhaust valves
mm
Intake valve, warm engine .. . . . . . ... .... . .. ............ . ... .. . .
cold engine . .... . .. . . . ... .. .. . ....... . . . ... . ... . .
Exhaust valve, warm engine .. .. . ... . .. . . . . .. . . ... . .. . ... . . ... .
cold engine . . ... . ... . .. . .. . . " . .. . .... . . ... .. . . .
Shims, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Valve clearances
Checking
in
mm
Setting
in
0.20-0.30
0.008-0.012
0.25
0.15-0.25
0.006-0.010
0. 20
0.40-0.50
0.016-0.020
0.45
0.35-0.45
0.01 4-0.018
0.40
3.00 to 4.25 at intervals of 0.05 mm
(0.012 to 0.167 at intervals of 0.002 in)
0.010
0.008
0.018
0.016
7,97
7,95
129836
~r-i4--
Min. 0,5
13006 1
Exhaust valve
Intake valve
Note: Exhaust valves are stellite plated . Only the valve face
may be ground.
110
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
I!+ (O'O~rIOS)
max 1,5
129843
1,3mm
'- . ~
Valve guides
Inner diameter ..... . .. .. . . ... ... .............. .
Height above cylinder head lower sur1ace ...... .. .
Clearance valve stem - guide (see illustration),
new.. ... . ........... .......... . . .. . ....... .
max .. .. . ...... ... .. . ...... .... .............
8.000-8.015 mm
40.1-40.5 mm
0.3149-0.3155 in
1.5787-1.5944 in
0.3 mm
1.3 mm
0.0118 in
0.0511 in
Valve springs
11 5083
33.9 mm
28.6 mm
18.3 mm
40.2 mm
32.6 mm
22.3 mm
0
67-77 N (15-17.5 Ib)
209-231 N (47-52.2 Ib)
0
167-185 N (38-42 Ib)
433-479N (98-108.3 Ib)
Timing gears
Toothed belts
Belt tension (measured with tool 5197)
Check value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting .. . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-13
12.5
133536
Camshaft
Max. lift height, intake . ... .. .. .... ........ .... . . .. . .. . . .... .. .
exhaust ...................................... .
Bearing clearance, new . .. . ..... .... ... ........ . ..... ...... .. .
End clearance , max. . .... .. . .. ......... ..... ... . . . ..... . .... .
8.5 mm
9.0 mm
0.05-0.10 mm
0.15 mm
0.334 in
0.354 in
0.0019-0.0039 in
0.006 in
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Crankshaft
Max 1) runout, two centre bearings ............... . .... . ........ .
others ..... .. .................. . .. . .. .. ...... . . .
Crankshaft, end clearance, new ... .. .... .. .. . .. . .. . .... .... ... .
max . ... . ........... .. .... ..... . . .. .
main bearing clearance, new ..... . . . ... . .......... .
max ...... . .. .... . ...... ... .
Connecting rod bearings, side clearance, max ........... . .. . ... .
bearing clearance, max ............... .
new ............... .
0.06 mm
0.04 mm
0.07-0.18 mm
0.25 mm
0.016-0.075 mm
0.16 mm
0.4 mm
0.12 mm
0.015-0.062 mm
0.0023 in
0.0015 in
0.0027-0.0071 in
0.0098 in
0.0006-0.0029 in
0.0062 in
0.0157 in
0.0047 in
0.0005-0.0024 in
0.03 mm
0.0012 in
0.05 mm
0.0020 in
58.00 (57.955-57.975) mm
2.2834 (2.2816-2.2824) in
57.75 (57.705-57.725) mm
2.2736 (2.2718-2.2726) in
57.50 (57.455-57.475) mm
2.2637 (2.2620-2.2627) in
57.25 (57.205-57.225) mm
2.2539 (2.2521-2.2529) in
If
-+\
+)
t
Out of round
0.03 mm
0.0012 in
0.05 mm
0.0002 in
47.80 (47.758-47.778) mm
1.8818 (1.8802-1.8810) in
47.55 (47.508-47.528) mm
1.8720 (1.8703-1.8711) in
47.30 (47.258-47.278) mm
1.8622 (1.8605-1.8613) in
Connecting rods
Only to be replaced in sets.
Side clearance on crankshaft, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. weight deviation between connecting rods in same engine. . .
0.4 mm
6 grams
0.0157 in
Flywheel
Warp, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
Taper
115 089
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Tightening torques
Tightening torques apply to oiled bolts and nuts. Oegreased (washed) parts should be oiled prior to assembly.
I'
#'
CD
(IJ
GJ
128149
Note: Loosen the bolts in the reverse order when removing the
cylinder head.
Stage 1
2
3
4
=
=
=
=
5 =
6 =
40 Nm (30 ft Ib)
60 Nm (44 ft. Ib)
75 Nm (55 ft. Ib)
tighten 180. Note : This should be done in
one movement without stopping.
run engine until oil temperature is at least
+50C (112F).
tighten 90. Note: This should be done in one
movement without stopping
Nm
ft lb.
350
20
258
15
75
45
100
20
65
45
55
33
74
15
48
33
'il\
IN
11\
'11
11 \
11
III
5187
Glow plugs
PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 257889-4
22 Nm (16 ft Ib)
113
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
200 kPa
28 psi
o 24TfTlC
024
Length,
mm (in)
Load,
N (Ib)
Length,
mm (in)
49 (1 .93)
22 (0.87)
0
175-195
(39-44)
ca 200 (45)
53.5 (2.11) 0
36 (1.42)
152-162
(34-36)
28(1.10)
229 (37)
25.9*
(1 .02)
19.8*
(0.78)
115 083
Load,
N (Ib)
* Fully compressed
Market
Injecting timing,* mm
Adjusting (checking)
Max
024
-1986
1987-
0.70 (0.65-0.73)
0.80 (0.77-0.85)
12.5 (750)
12.5 (750)
90 (5400)**
90 (5400)
024T
USA+Canada
1982-1983
1984 Federal + Canada
California
1985-
0.80
0.85
0.75
0.75
12.5
12.5
12.5
13.8
90
90
90
90
0.75 (0.72-0.80)
0.90 (0.87-0.95)
13.8 (830)
13.8 (830)
90 (5400)
90 (5400)
0.90 (0.87-0.95)
13.8 (830)
90 (5400)
024TIC
*Injection timing = pump piston stroke at t.d.c.
** - 1985 = 87 (5200).
114
(0.77-0.85)
(0.82-0.90)
(0.72- 0.80)
(0.72-0.80)
(750)
(750)
(750)
(830)
(5400)
(5400)
(5400)
(5400)
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Engine
type
Distributor pump
Bosch VE6/10 F 2400 + designation below
Market
024
VE 6/10 F 2400 . - .
136777
o24T
o24TIC
7401760
Aut
L32-2
L32-3
L116 ~ 3
L144
L144
L135
L194
L116
L116-2
L144-1
L144-1
L135-1
L194-1
L116-1
: 1'IC 2
'TIC 1
TIC 3
780 -86
78087-
Man
TIC 2-1
Injectors
Model and designation: (complete) 024 . . . . . . . . . . . . . . . . . . . . . . . .
024 TITIC Engines . . . . . . . . . . .
Engine type
Injector - .complete
Volvo PIN
Designation
Volvo PIN
E
E
F
H
1 257144
1 328336
1 328073
1 328209
oNO
oNO
oNO
oNO
193
293
1930
1930
1 ,257146
1 328298
1 328096
1 328096
068130201 B
068130201 B
1 328208
1 328 108
oNO SO 1930
oNO SO 293
1 328298
1 328298
Designation
024
136778
024 T (USA+Can .
Austria 1987-)
024 T (Others)
o24TIC
Distributor (Bosch)
068130201
068130201
068130201
068130201
SO
SO
SO
SO
024
12.0-14.0
(1707-1991)
13.0-13.8
(1849-1963)
14.5-16.3
(2062-2318)
15.5-16.3
(2205-2318)
Nm
70
70
45
ftlb
52
52
33
Tightening torques
Injectors, in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
upper-lower sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel injection pump, pump gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
70-77 kPa
10-11 psi
80-85 kPa
90-100 kPa
110-130 kPa
11-12 psi
13-14 psi
13-18 psi
Nm
ftlb
25
20
20
18
20
25
6
6
60
18
15
15
13
15
18
4
4
45
Tightening torques
Use sealing paste (PIN 1 161 035-9) on bolts below.
Mounting nuts, front exhaust manifold-turbo D 24 T .... . .. . ... ... .
D24TIC ........ .... .
Mounting bolts, turbine housing . ..... .. ... .... . ........ . .. . ... .
compressor housing ...... . ... .. . ... . .. . . . ... . .
rear housing (with waste gate) 024 T ......... . . .
D24 TiC . ... .... . .
024 TIC Lock nut, pull rod - pressure actuator ................. .
024 TIC Pressure actuator nuts ..... ........... .. .. . .. . ... .... .
Mounting bolts, turbocharger - exhaust manifold . . . .. ..... . .... . .
116
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
11 .5
(12.2)
11 .5
(12.2)
lit
til '
lit
,",
Expansion tank
111
11,1
111
1111
,11'
100 (14.2)
150 (21)
10(1.4)
Thermostat
Marking ....................... ..... ..... . .......... . ........ .
Starts to open at ............. ... ......... ..... .. ... ......... .
Fully open at ..... . . .............. . ........... . ..... . ....... .
Opening dimension, min .... . ........ ............... .... .. . . . .
Drive belts
Profile
A HC 38 x 1238
B HC 38 x 750
C HC 50 x 913
- -, ,
II
5 \1
--~_/
7401760 - 1986
1
2
3
4
5
87C
87C
102C
8 mm
189F
216F
0.31 in
x length:
A HC 47 cog x 1 150
B HC 38 cog x 1 013
C HC 50 cog x 913
Crankshaft pulley
Alternator
Fan
Power pump
AC compressor
142814
780 1986
Tightening torque
Fan............ . ... ..... .. . .. .. . .. . ... . .. ....... ...... ..... .
Nm
ftlb
6.6
+ 7401760 1987
117
-'
70019401960 Specifications
Section 3 Electrical system
Group 31 Battery
System voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earth connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 V
Negative terminal
Battery capacity
Model
B23ET, B28A1E, B280E
024, 0 24 T -1986
024, 024 T, 024 TIC 1987B 19/23, B 200, B 230, France
B 19/23, B 200/230, not France, B 28 F, B 280 F
Reserve capacity*
RC SAE (DIN)
(66 Ah)
(88 Ah)
Recommended
charging current
600 A
330 A
450 A
125 min
70 min
90 min (55 Ah)
7A
9A
9A
5A
6A
Volvo PIN
Reserve capacity*
RC SAE (DIN)
Recommended
charging current
3515893
3515895
3515897
440 AMP
520 AMP
600 AMP
6A
7A
9A
Cold start current (CCA, SAE) is the discharge current that a battery can deliver for 30 sec at a temperature of -18C (OF) without dropping below 7.2 V.
Reserve capacity (RC, SAE) is the time required at + 2rC (80F) for a steady discharge current of 25 A to reduce the potential of a fully
charged battery to 10.5 V.
118
70019401960 Specifications
Section 3 Electrical system
Group 32 Alternator
132417
Bosch K1 14 V 55 A 20
Max amperage ..... ...... .... .... ... ... .. . . .. ..... . ... . .... .
Max output . ................ . .................... .. ......... .
Max speed .. ....... . ....... ................. . ......... .. .. . .
Direction of rotation . ....... . ....................... . .. . .... . .
Diameter, slip rings, new .................. ... ... . ...... . .... . .
min (after machining) ......... . ............ .
Max permissible runout, slip rings ....... . .. .... ...... ......... .
rotor body .............. . ... .... . ..... .
Carbon brush spring force ........ . . .. . .. .. . . .. . ............. .
Min length, carbon brushes .... . . .... . ............ ... ........ .
Tightening torque, attaching screws ... . ...... . ........ ... ..... .
pulley nut ... . ... ........ . ................. .
55A
770W
225 rls (13500 r/min)
Clockwise
28 mm
1.102 in
26.8 mm
1.055 in
0.03 mm
0.0012 in
0.05 mm
0.0019 in
3-4N
0.6-0.9Ib
5 mm
0.2 in
4 Nm
3 ft Ib
40 Nm
30 ft Ib
Test values
Resistance, rotor winding ........ . ....... . ............... . .. . .
stator .. ... ... .......... .... ........ . ... . ........ .
Amperage at 14 V (min value) . ...... ... . ... . ....... . ......... .
3.4-3.70
0.14-0.15 0 phase'
36 A at 33.3 rls (2000 rpm)
47 A at 50 rls (3000 rpm)
52A at 66.7 rls (4000 rpm)
HI
Bosch N1 14 V 70 A 20
Max amperage ........ .. ... .. ... ................ ...... . .... .
Max output ... .... .......... . . ...... ... . . .. . .............. . . .
Max speed .... .. ...... . ....... . . . . . .. . .... . .. . . ..... .. . .... .
Direction of rotation .... .. .. .. ............................... .
Diameter, slip rings, new ........ . . ......... ... ............... .
min (after machining) ...................... .
Max permissible runout, slip rings . ............. .. ............. .
rotor body ..... . .... . .......... . .... . . .
Carbon brush spring force .................................. . .
Min length, carbon brushes ....... .... ...... . ...... ...... ... . .
Tightening torque, attaching screws . .... ....... . ... .. ......... .
pulley nut .... ..... ... ............. . ...... . .
Itli
til
70A
980W
225 rls (13500 r/min)
Clockwise
28 mm
1.102 in
27 mm
1.063 in
0.0012 in
0.03 mm
0.05 mm
0.0019 in
0.6-0.9Ib
3-4N
5 mm
0.2 in
4 Nm
3 ft Ib
35-45 Nm
30 ft Ib
III
111
III
tli
III
,til
Test values
Resistance, rotor winding ....... .. .... ............ ..... ...... .
stator .................... . ......... .. ....... .. .. .
Amperage at 14 V (min value) . . .............. . ..... . ......... .
3.4-3.70
approx 0.1 0 phase'
46 A at 33.3 rls (2000 rpm)
58 A at 50 rls (3000 rpm)
64A at 66.7 rls (4000 rpm)
119
70019401960 Specifications
Section 3 Electrical system
Bosch N1 14 V 31 /S0A
Max amperage ........... . ... ...... . ... .. .. . .. ...... . . . .. .. .
Max output ................................................. .
Max speed ............... . .... . .. . . ..... ... .. ..... ... ...... .
Direction of rotation ......... .......................... . . .... .
Diameter, slip rings, new .... . ... . . ................. .. . .. ... . . .
min (after machining) ... .. . .. ... .... ..... . . .
Max permissible runout, slip rings ............................ . .
rotor body .... .. . ....... .. . ...... . .. . . .
Carbon brush spring force . .......... . . .............. ........ .
Min length, carbon brushes ...... . ... . ...... . ... ... ..... . .... .
Tightening torque, attaching screws .. .. .. ... .. .... . . .. . . .. . . .. .
pulley nut ..... .. .. . .. . ......... . ... . ...... .
80A
1120W
250 rls (15000 r/min)
Clockwise
28 mm
1.102 in
26.8 mm
1.056 in
0.03 mm
0.0012 in
0.05 mm
0.0019 in
3-4N
0.6--0.9Ib
5 mm
0.2 in
4 Nm
3 ft Ib
45-55 Nm
33-40 ft Ib
Test values
Resistance rotor winding .. . .. . .. .. .. ........ . .. .... . ......... .
stator ..... . ........... .. ........ .. ........... ... .
Amperage at 14 V (min value) .. .... .. .. . ..... .. .............. .
2.9 Q
approx. 0.09 Q phase
31 A at 25 rls (1 500 rpm)
80 A at 100 rls (6000 rpm)
Bosch N1 14 V 34/90 A 20
Max amperage ...... .. .. .. . . .. . .. .... ...... .. . . ........... . .
Max output . .. .. . ..... . . . .... . . . . . ... ................... . . .. .
Max speed ... . ... . . .... . . . . . . ..... .. ....... . . .. .. . .. . ... . . . .
Direction of rotation ..................................... . ... .
Diameter, slip rings, new ...... . .............................. .
min (after machining) ............................... .
Max permissible run-out, slip rings . ......... .. . .. ......... . ... .
rotor body ........................... .
Carbon brush spring force ... . .... . . ............ ... .... .. . . . . .
Min length, carbon brushes .. .. .. ..... . .. . .. .. . ..... . . . .. . .. . .
Tightening torque, attaching screws . .... ... .. . .... ... ...... ... .
pulley nut . .......... ... ...... .. . ... ........ .
90A
1260W
225 rls (13500 rpm)
Clockwise
28 mm
1.102 in
27 mm
1.063 in
0.03 mm
0.0012 in
0.05 mm
0.0019 in
3-4N
0.6--0.9Ib
5 mm
0.2 in
4 Nm
3 ft Ib
35-45 Nm
30 ft Ib
Test values
Resistance, rotor winding ......... ....... .......... ......... . .
stator ... . ............... ... ..................... .
Amperage at 14 V (min value) ................................ .
120
2.8-3.1 Q
0.07- 0.08 Q*
34 A at 25 rls (1 500 rpm)
60 A at 33.3 rls (2000 rpm)
90 A at 100 rls (6000 rpm)
70019401960 Specifications
Section 3 Electrical system
Bosch N1 14 V 31 /100 A
Max amperage .. ....... . ... . .......... ... ... .. . ... . ...... .. .
Max output ... .. ..... .. ..... .. ... .. ................ .... .
Max speed .... . ....... ... ...... . .....
Direction of rotation ...... . .. ... .. . . . ....... . ...
Diameter, slip rings, new .... . . .... . ... ..... .... . ............ . .
min (after machining) . ..... .... . .. ... .
Max permissible run-out, slip rings . . ........... .. .. . ... ...
rotor body . .. .
Carbon brush spring force ... . ............... . .. .. . .. ..
Min length, carbon brushes .... .. .... . ........ ... ........ . ... .
Tightening torque, attaching screws . .. . .. . . . .. .... ... . .. ...... .
pulley nut . ........ .
00
100A
1400W
250 rls (15000 rpm)
Clockwise
28 mm
27 mm
1.063 in
0.03 mm
0.0012 in
0.05 mm
0.0019 in
3-4N
0.6-0.9Ib
5 mm
0.2 in
4 Nm
3 ft Ib
45-55 Nm
33-40 ft Ib
Test values
2.6
ca 0.05 n
31 A at 25 rls (1 500 rpm)
100 A at 100 rls (6000 rpm)
Bosch NC 14 V 60/120 A
Volvo PiN ....... . .. .. .. ................ .
Bosch number . ...... ... ..... . ... ... .. . ..
3523420
0 120465 006
0"
0'
00
00
120A
1680W
300 rls (18000 r/min)
Clockwise
15 mm (0.59 in)
14 mm (0.55 in)
0,003 mm (0.0001 in)
0,005 mm (0.0002 in)
3-5 N (0.3-0.5 kp)
5 mm (0.2 in)
4 Nm (3 ft Ib)
45-55 Nm (33-40 ft Ib)
III
II
III
II
III
-II
III
oil
III
Test values
Resistance, rotor winding ... . .... . . ... . .... . . . ..
stator . . ... ............ . . .. .. .... . .. .... ... ... .. . .
Amperage at 14 V (min value) . . . ...... .. ... . . ..
0
2,6 n
0,02 n
60 Avid 30 rls (1 800 r/min)
120 Avid 100 rls (6000 r/min)
Nippon Denso 80 A
Volvo PiN .. . .... .. .. .. .. .. ..... . .... . . . . ..... . .. ...... . .... .
Nippon Denso number . ..... ... ..... . ..
1398327
100211-8370
80A
1120W
300 rls (18000 r/min)
Clockwise
121
70019401960 Specifications
Section 3 Electrical system
Early type
Late type
In car
On test bench
min 3/ 4
+25C (7r F)
+60-80C
(140-176F)
fully charged
+25C (7rF)
+60C (140F)
14.1-14.8V
13.4-14.2V
14.4-14.8 V
13.8-14.3 V
Test values
Alternator speed .... . . . .... . . . .. .... .. . ........... ... ....... .
Engine speed . . .. ... ... . ........ . .. ..... ... ...... .. ... approx
Alternator load . .. . .. .. . . .. .. .... . . . ... .. ... . ........ .. . . . .. . .
Control voltage, between B+ and D- alternator terminals:
Cold regulator (reading taken within 1 min) . . . . .... . . . ... . .. . ... .
Warm regulator (run min. 15 min at 3000 r/min) . .... . . ......... .
Control tolerance
Load 55 A alternator to . . . .... . . . .. ...... . . . . . . .. . ... . .. . . ... .
70A ..... . ................ .. ..... .. . . .... . . . .... . .. . .. .
90A . . ... ... ... . .... ....... . ..... .. ...... . .. . . . . . .. ... .
The control voltage should now be between 0 and 0.3 Volt lower than
the previous reading .
In car
On test bench
min 3/4
+25C (77F)
+ 60-80C
(140-176F)
fully charged
+25C (7rF)
+60C (140F)
Test values
Alternator speed .. ..... .. . . . ... ... . .. . .. .......... . .... . .. . . .
Engine speed .. . . ... .... . .. .. . .......... . . . . . . ..... ... approx
Alternator load ... ..... .. .. . . .... .... .... . .. ..... . .. ... ... . . . .
Control voltage, between B+ and D- alternator terminals ..... . .. .
Load achieved when engine running .
122
5A
14.1-14.9V
70019401960 Specifications
Section 3 Electrical system
47 A
60 A
68 A
77 A
(rated
(rated
(rated
(rated
output
output
output
output
x
x
x
x
0.85)
0.85)
0.85)
0.85)
V
16
15,5
15,5 .
15
15 .
14,5
(
14
'"
13,5
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'
1:l9000
Extern al voltage-temperature
5A load
139001
Interri al voltage-temperature
5A load
III
III
III
III
III
,11,
III
111
III
(0001 3111 .. )
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
0.0004-0.012 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
123
70019401960 Specifications
Section 3 Electrical system
Test values, electrical
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 ... )
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
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
(0001110063)
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
124
(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)
70019401960 Specifications
Section 3 Electrical system
Bosch JF 12V 2 kW
(0001362 ... )
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)
(0001218 ... )
Clockwise
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
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
70019401960 Specifications
Section 3 Electrical system
1.4 kW (1 .9 hpj
Clockwise
2.0 kW (2.7 hpj
126
70019401960 Specifications
Section 3 Electrical System
Group 35 Lighting
Bulbs
.~<
'I ~
..
w W~
W 2x4,6d W 2.1x9.5d
BAY 15d
VS 7
ffi
SV 8, 5
BA9s
At
j
8 W lkU t ~
BA 155
BA 155
Rating
GE B81
PK 225
9004
P 43t38
Qty
Socket
USA
H4656
H4651
9004/HB1
2
2
2
2
1157 NA
2
2
2
2
2
2
60/55W
35/35W
50W
50/70W
P 45t-38 (H4)
"Sealed Beam"
"Sealed Beam"
"Semi-sealed"
21/5W
5W (4 cp)
4W
4W
21 W (32 cp)
24/2.2 cp
BAY 15d
BA 15s
BA 9s
W 2.1 x9.5d
BA 15s
BAY 15d
5W
21 W (32 cp)
55W
27W
5W (4 cp)
21 W (32 cp)
21/5 W, (3213 cp)
20W
21W
21 W (32 cp)
21 W (32 cp)
4W
W 2.1 x 9.5d
BA 15s
PK 22s (H3)
4 cp
4W
10W
5W
5W
3W
2W
3W
10W
5W
BA 15s
BA 9s
SV 8.5
W 2.1 x 9.5d
W 2.1 x 9.5d
SV 7
BA 9s
W 2.1 x 9.5d
SV 8.5
SV 8.5
2
2
1.2W
1.2W
3W
1.2W
**
W 2x4.6d
W 2.1 x9.5d
W 2 x4 .6d
16
16
3
12
1156
GE 881
BA 15s
BA 15s
BAY 15d
BA 9s
BA 15s
BA 15s
BA 15s
BA 9s
2
2 (4*)
2
2
2 (4*)
2
2
'"'....,
:':':1
':.:.:
2
2
2
2
2
2
4
1
2
780.
H
127
7001940;'960 Specifications
Section 3 Electrical System
Group 37 Fuses
1982-1983
1982-1983
Fuse Circuits protected
number
30
1*
2*
3
4
Fuse
rating
12
25A
13
15A
15A
15A
9
10
11
128
Fuse
rating
25A
14
15
15A
25A
30 A
15A
18
25A
30A
15A
19
20
15A
15A
15A
30 A
15A
15A
22
25A
25A
70019401960 Specifications
Section 3 Electrical System
1984
1984
Fuse Circuits protected
number
Fuse
rating
4
5
7
8
12
Fuse
rating
11
13
14
15
.. . ....... . . .. . . 15A
Headlamp cut-out
19
20
17
18
IN
"I
IIII(
II.
"I
II.
II
22
129
70019401960 Specifications
Section 3 Electrical System
760 1985-1987
740 1985-1988
Fuse Circuits protected
nurnber
4
5
6
7
8
9
10
11
130
760 1985-1987
740 1985-1988
Fuse
rating
25A
13
14
15
16
17
18
19
25A
15A
15A
15A
(15A)
(30A)
30A
Direction indicators ... .......... .. ... .... 15A
Fasten seat belt light
Heated front seats
Power windows
AC
Electric cooling fan
Heated rear window .... . ....... .. .. . . ... 30A
Power sun roof
Power door mirrors
Tank pump ............................. 15A
Heated Lambda-sond
Fuse
rating
20
21
22
23
24
25
26
70019401960 Specifications
Section 3 Electrical System
740 1989-1990
740 1989-1990
Fuse Circuits protected
nurnber
(
2
3
4
5
6
7
8
9
10
11
12
13
Fuse
rating
25A
15
16
17
18
19
20
21
22
25A
15A
15A
15A
30A
25A
30A
15A
Fuse
rating
23
24
25
26
fn'
II I
III
III
III
'11 1
III
11 1
III
30A
15A
15A
15A
131
70019401960 Specifications
Section 3 Electrical System
760 1988-1990
, - - - - - - - - - - BL-Y - - -- -- - - - ,
11/34
GR-R
II / II
1/1
211
2111
2113
3/1
3/2
3/3
~
11 /24
3/2:10
4/9
5/3
3/2: 12
A 5/12
100)
4/9:3
5/12:2
GN-5 B -
7/1: 1
GN-5B -
3/3:2
3/3:4
6/31
pf - 2/13:2
19/4
3/2:3
6/31
7/1
11/1
15/1
15/3
15/7
19/4
Battery
Main headlight relay
Electric cooling fan, relay
Motronic, LH-Jetronic, relay
Ignition switch
Light switch
Mainldipped beam switch
SRS crash sensor
3-pole combined instrument
connection
12-pole combined instrument
connection
Fuel pump
Bulb failure sensor, rear
- 35 Fuses
Positive terminal
3G-circuit in fusebox
Ground connection via door switch
Clock
3/2: 13
4/9:5
5/3:3
15/7
BL-R
OR
Fuse
2
3
4
5
6
7
8
9
10
11
12
13
Circuit protected
Fuse
14
16
17
18
19
20
21
22
132
Circuit protected
Fuse
23
24
25
26
27
28
29
30
31
32
33
34
35
Circuit protected
Spare
Spare
Hazard warning lights
Central locking
3G-circuit in fusebox
- clock
- courtesy lighting
- door warning lights
Brake lights
ECC heater fan
ECC
Power aerial
Towing bracket lights
Tank pump
Lambdasond
Fuel injection
Main fuel pump
Amplifier, radio
Radio
Power windows
Power sunroof
Heated seats
Power seats
70019401960 Specifications
Section 3 Electrical System
780 1988
Fuse Circuit protected
780 1988
Rating
1
2
3
4
5
6
7
8
9
10
11
12
13
Rating
No.
No.
Main fuel pump . .. ......... .. .. . .... . ... . . 25 A
Central locking, system, hazard
warning lights, rear fog lamps ...... ... . . ..... 25 A
Dipped beams, rear foglamps ... . ... .... .... 15 A
Brake lights . . .. ......... . .... .... . . ... .. . . 15 A
Glove compartment lighting, clock, .. ... . .... 15 A
radio, engine compartment lighting,
interior lighting, boot lighting,
electric aerial, door courtesy
lights, vanity mirror
Electrically-heated front seats ....... ........ 30 A
Electronic climate control (ECC) .. ........... 30 A
Electric window winders .. . ... ... . .......... 30 A
Seat belt reminder, direction . ... . ... ...... .. 15 A
indicators, air conditioning ,
electrically-heated front seats,
electric window winders
Electrically-heated rear window, . .... . .... . . . 30 A
electrically-heated rear-view
mirrors, electric sun roof
Fuel pump (tank pi.Jmp), .... . .......... .. ... 15 A
electrically-heated oxygen sensor
(Lambdasond) (B 280 F)
Reversing lights, cruise control .. .. .. ..... . . . 15 A
ignition on, automatic
transmission disengagement
Automatic idling controls .... . . ...... .... .. . 15 A
14
15
16
17
18
19
20
21
22
23
24
25
26
133
,f'
."'I
",
.'"",
.'"",
.'"",
70019401960 Specifications
Section 3 Electrical System
780 1989-1991
780 1989-1990
Fuse Circuit protected
No.
1
2
3
4
6
7
8
9
10
11
12
13
Rating
15
16
17
18
19
20
21
22
23
24
25
26
Rating
Additional fuses
ABS: one 10 A fuse incorporated in the transient surge protector 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 suspension tower
134
70019401960 Specifications
Section 3 Electrical System
740/940 1991
740/940 1991
Fuse Fed by
number
Battery +
Circuits protected
Fuse
rating
Fuse Fed by
number
Fuel pump
Relay, injection system
Ignition system
Lambda-sond preheating
(not B 230 FT)
25 A
13
25 A
15 A
f-----
f-----
15 A
Clock
Radio
Power antenna
Door warning lights
Courtesy lights
Make-up mirror
Glove compartment light
Trunk light
15 A
30 A
30-busbar
(battery+ )
or X-relay,
main beam
30 A
Main relay,
power and
heating,
seats
Ignition
switch 15 I
f-----
f-----
6
7
14
Ignition
switch X
10
15 A
Radio
Power mirrors
Tailgate wash/wipe
Cigar lighter
15 A
Horn
Windshield wash/wipe
Headlight wash/wipe
Power seats (controls)
25 A
f-----
15
16
17
X-relay,
main beam
18
19
Bulb
failure
warning
20
30 A
21
15 A
Main
light relay
22
30 A
23
24
11
Relay, injection
system
Tank pump
Lambda-sond, pre-heating
(not B 230 FT)
15 A
12
Ignition
switch 15
Back-up lights
Overdrive relay, M 46
Bulb failure warning
Exhaust temp. warn. (Japan)
OD, AW71
Cruise control
15 A
I----
Fuse
rating
r----
Ignition
switch 15
Circuits protected
25
Main relay,
power and
heating, seats
30 A
15 A
15 A
15 A
15 A
15 A
15 A
25 A
26
Battery +
Radio, amplifier
ltl
1111
III
II.
'",
Itl
Itl l
,It I
Iltl
15 A
135
70019401960 Specifications
Section 3 Electrical System
960 1991
Circuits protected
Fuse
rating
Fuse Fed by
nurnber
10 A
19
10 A
15 A
15 A
Fuse Fed by
nurnber
1
Light
switch
t---
r---
Main light
relay
Bulb failure
warning ,
t - - - 9-pole
7
6
r--9
960 1991
Light
switch
11
Ignition
switch 151
t---
12
r--13
14
t---
15 A
Foglights front
15 A
Foglights rear
Indicator light, foglights rear
10 A
Ignition
t - - - switch X
18
136
15 A
Horn
Windshield wash/wipe
Headlight wash/wipe
25 A
5A
I---23
5A
10 A
Battery
10 A
(B/memory)
25 A
I---27
15 A
15 A
25 A
10 A
I---28
Clock
Courtesy lights
Door warning lights
Engine compartment lighting
Trunk lighting
10 A
15 A
30 A
Power antenna
Trailer
30 A
t---
29
Tank pump
Lambda-sond
10 A
30
Relay, fuel
injection
31
Battery
25 A
32
Battery
I---33
Amplifier, radio
15 A
Radio
10 A
30 A
30 A
34
Relay, power
windows
t---
35
Reserve
Radio
I---26
Back-up lights
Turn indicators
Cruise control
I---22
25
Reserve
16
17
5A
Reserve
15
t---
Ignition
switch 15
Fuse
rating
15 A
t---
I---20
21
Lighting :
- Instrument panel
- Controls
- Mode selector
- Beam length control
- (Sun roof
- ECC controls
- Radio
- Clock
- Cigar lighter
- Ashtray, front and rear
- Shift selector scale
- Seat heating
- Seat belt locks
10
Ignition
switch X
Circuits protected
5A
70019401960 Specifications
Section 3 Electrical System
Group 38 Instrumentation
Lever-type sensor, increased-capacity tank (1982-85)
Resistance
2961S 0
3620
Resistance
00
2800
Resistance
180
10
Volume
Empty ... .. ...... . . .. . . .. 0 L
Full .. . .... . . .... . . .... . . 20 L
(S US gals)
Volume
Empty extra tank . . . . . . . .. 0 L
Full extra tank
- extra tank lever-type
sensor . .. .. ... . .. . .... 20 L
(S US gals)
- main tank lever-type
sensor . . . . . . . . . . . . . . .. 20 L
(S US gals)
Resistance
00
600
27.S 0
Resistance
00
363-3700
(1982-86)
Temperature
Resistance
fl'l
1\
til
1\
It I
.1\
(1987- )
Temperature
til
Resistance
.1\
til
137
70019401960 Specifications
Section 4 Power Transmission
AW 30-43 LE. . . .
ZF 4HP 22 . .... .
Group 45 Universal joint. . . . . . . . . . . . . . . . . . . . . . . . .
Group 46 Rear axle ....... . .. ... .............. . .
146
149
151
151
Group 41 Clutch
\
~
" ~
-\
'I
Pressure plate, max out-of-true ...... ....... ....... ... ..... 0.2 mm (0.008 in)
/\'~\
dl'?
Clutch fork free travel:
,
~hydraulic ... ", . ... .. ..... . .. ... .. . .. . ......... ... .... . not adjustable
..
~mm
clutches w!th return spring. (A) ...... .. ... .. .. , .... .. . .... 1:3 mm (0.04-0.12 !n) (to fro!:),t)
.~ .
clutches without return sprlng ........... .. . . ..... .. . ... .. 1 3 mm (0.04-0.12 In) (to rear) -~"
Clutch pedal travel . . ... .. .. . .. .. ..... . .. ................. 160 mm (6.23 in)
IllJ
ru~'
-if.
I@
B ..
\ \
' "
W7 ' \.
Group 43 Gearbox
\\
' ..,, ~
/ _\
136763
Manual gearbox
Reduction ratios:
1st gear ....... ...... .. .... . .. . ... . . ... . . ... . .............. , .
2nd gear . ... . .. .... . . .. . .. .. .... . ...... . . . . ... . .. . .. . .. ... . .
3rd gear .. ..... ....... . .. . ........ .. .. ..... ...... . ..... . . .. .
4th gear .. . .. .. .. .... . . . ... .. .. . . . .. . .... . .. .. ... . .. . ..... . .
Overdrive (M 47 : 5th gear) . . ... .... . .. . ..... . . .. . ............ .
Reverse . . .. .... .. .. . ..... . ..................... . .. . . . .. .... .
M46
M47/M47 II
4.03:1'
2.16:1
1.37:1
1 :1
0.79:1
3.68 :1
4.03 :1
2.16:1
1.37:1
1: 1
0.83:1 (M 47 II : 0.82:1)
3.68:1
0.1-1 .0
(0.004-0.040)
0.01-0.20
(0.0004-0.0079)
0.03 (0.0012) to
preload of 0.05
(0.0019)
0.01-0.20
(0.0004-0.0079)
0.1-1.0
(0.004-0.098)
0.01-0.20
(0.0004-0.0079)
0.01-0.10
Clearances
Clearance: reverse gear to gear selector .......... .. . .. . mm (in)
Axial clearance : input shaft ............ .... .. ... . . ..... mm (in)
countershaft. ... ....... . . .. . ....... . ... mm (in)
(0.0004-0.0004)
0.01-0.20
(0.0004-0.0079)
0.01 - 0.20
(0.0004-0.0079) (M 47)
70019401960 Specifications
Overdrive engaged
Type J
.
.
.
.
2.8--3.1
2.8--3.1
3.9-4.2
3.7-4.0
MPa
MPa
MPa
MPa
(400-440
(400-440
(555-600
(525-570
psi)
psi)
psi)
psi)
Type P
Nm
ft Ib
35-50 (25-35)
40 (30)
15-25 (10-20)
35-45 (25-30)
70-90 (50-65)
90-110 (65-80)
165-180 (120-130)
12-18 (9-13)
120 (87)
27-40 (20-29)
Lubricant
/
.
.
.
.
.
Litres US qts
ATF* type F or G
2.3 (2.4)
2.6 (2.7)
1.3 (1.4)
1.6 (1.7)
On complaints about gearbox noise, Volvo Thermo oil (PIN 1161 243-9)
can be used.
Volvo Thermo oil is only recommended for vehicles driven in areas where
ambient temperature seldom drops below -10C (+14F), or high mileage
vehicles such as taxis.
NOTE: Do not mix oil types.
.til
I!
II
I!
II
I!
1,
I!
139
70019401960 Specifications
Section 4 Power Transmission
Automatic transmission BW 55
1 :1
2.21 :1
1-approx 2:1
ATF, type G (or F)*
6.9 litres = 7.2 US qts (inc!. approx 2.5 litres = 2.6
US qts in torque converter)
Engine type
B28A
Normal
stall speed*
rls (r/min)
Type
designation
38.3 (2300)
029
* At sea level.
Stall speed drops 2
.~
Type plate
colour
.......
55
WAOIIHUH
SERIAl~
Light brown
131755
0.25-1 .0 mm
51 +1.6 mm
-0.6
(0.001-0.040 in)
(2 +0.63 in)
(-0.024Ih)
0.07-0.30 mm
0.11-0.50 mm
0.02-0.10 mm
(0.0027-0.118 in)
(0.004-0.019 in)
(0.0008-0.004 in)
0.3-1 .2 mm
0.20-0.55 mm
0.20-0.55 mm
(0.0118-0.0472 in)
(0.0078-0.0216 in)
(0.0078-0.0216 in)
Clearances
Oil pump: pump body - outer cog wheel .... . .................. .
arc segment - large cog wheel .. .. .... ............ . . .
axial clearance .... ... ............ . .. .... ... .... .. . .
Clutch C2, brakes B1 and B2 :
clearance between clutch assembly pressure plate and
locking .... . ... ...... . . .. ....... .... ........................ .
Input shaft, clutch C1 axial clearance .. ..... .... .... ... ... . ... . .
Output shaft, axial clearance . .. .... ... .. . .. .. . .... ... .. ...... .
Line pressure
Idling D . ........ ....... . .......... .. . ....... ...... . . ..... . . .
R ... . .. .. . .. ... ..... . . . . .. .. . ... . ..... . . ..... . ...... . .
Stall speed, D .. .. ..... . .... . . .. .. . . ........ . . . ... .. .. .. ... . .
140
0.53-0.63
0.74-0.91
1.12- 1.37
1.54-1.96
MPa
MPa
MPa
MPa
(75-90 psi)
(105-129 psi)
(159-195 psi)
(219-279 psi)
70019401960 Specifications
Section 4 Power Transmission
0.10-0.13 MPa
0.14-0.18 MPa
0.30-0.36 MPa
(14-18 psi)
(20-26 psi)
(43-51 psi)
71 (44)
128 (80)
117 (73)
approx. 60 (38)
2.1 mm
(0.083 in)
Nm
ftlb
41-50
35-50
55-90
(30-37)
(26-37)
(41-66)
24-28
6-9
22- 28
6-9
(18-21 )
(4-6)
(16-21)
(4-6)
Nm
ftlb
26-40
47- 60
26-40
8-12
6-9
5-6
5-6
6-9
6-10
8-12
40-50
9-12
(19-29)
(35-44)
(19-29)
(7-9)
(4-6)
(3-4)
(4-6)
(3-4)
(4-8)
(7-9)
(29-37)
(6-9)
'",
""
'",
11"
""
11.
""
1111
,11'
141
70019401960 Specifications
Section 4 Power Transmission
13B 733
Plate
colour
AW70
AW71
AW71
36.7 (2200)
35.0 (2100)
41.7 (2500)2)
1208314
1208300
1208334
Silver
Orange
Pink
B28A
B28E
B28F
AW71
AW71
AW71
35.0 (2100)
35.0 (2100)
33.0 (2000)
1208360
1208310
1208248
Yellow
Black
Blue
B200K
B200E
B200F
AW70
AW70
AW70
38.0 (2300)
35.0 (2100)
37.0 (2200)
1208332
1208415
1208659
Red
Green
Pink
B230A
B230K
AW71
AW71
AW71
35.0 (2100)
42.0 (2500)
42.0 (2500)
1208304
1208371
1208417
Black
Pink
Blue
B230F
AW70
1208563
Dark brown
1208604
Pink
Type
B19E
B23E
B23FT
-1986
1987-
AW70
USNCDN
5-door, Japan,
33.0 (2000)
Australia 1988
USNCDN Japanl 33.0 (2000)
Australia
33.0 (2000)
Others
1208652
Red
B230FB
AW71
33.0 (2000)
1208682
White
B234 FIG
AW72
30.0
41 .0
30.0
41.0
1208637
1208666
1208638
12086673)
White
Orange
Black
Green
45.0 (2700)2)
45.0 (2700)2)
1208334
1208661
Pink
Yellow
USNCDN/Japanl
42.0 (2500)2)
Australia 1990
42,0 (250W)
Others 1990
1208642
1208643
AW70
Stall speed 1
rls (rpm)
Volvo PIN
Engine
USNCDN
Europe
B230FT
B280E
B280F
1)
2)
3)
AW71
AW71
AW71
AW71
AW71
Scandinavia
Others
35
35
35
35
(1800)
(2450)
(1 800)
(2450)
12085333)
1208534
1208532
12085333)
(2100)
(2100)
(2100)
(2100)
Green
Orange
Purple
Green
At sea level. Stall speed drops 2 rls (120 rpm) for each 1000 m increase in altitude.
Start-stop.
With kick-down inhibitor.
142
AW70/71
AW72
2.45:1
1.45:1
1:1
0.69 :1
2.21 :1
2.83:1
1.49:1
1:1
0.73 :1
2.70:1
1-2:1 approx
see page 13
x Converter
ratios
70019401960 Specifications
Section 4 Power Transmission
Throttle cable setting
025 - 10mm
Solenoid valve
Resistan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 0
Clearances
(in)
(in)
(in)
0.07-0.15
0.11-0.14
0.02-0.05
(0.003- 0.006)
(0.0043--0.0055)
(0.0008-0.0019)
(in)
0.35-1.60
(0.0138-0.0629)
(in)
(in)
(in)
0.3--1.2
0.3--0.9
0.3--0.9
(0.0118-0.0472)
(0.0118-0.0354)
(0.0118-0.0354)
2.1 mm
(0.083)
Line pressure
Engine
Transmission
Pressure, 0
MPa (psi)
Pressure, R
MPa (psi)
0.50--0.64 (71-91)
"
B 19/200 ElF
B23E
B230K -1986
AW70
AW71
AW71
0.35-0.44 (50--63)
"
B200K, B230F
B23/230FT
B 230 A, B 230 FB
B230K 1987B28A, E, F
AW70
AW71
AW71
AW71
AW71
0.46-0.54 (65-77)
B234 FIG
AW72
0.44-0.52 (63--74)
0.64-0.76 (91-109)
B280
AW71
0.51 (73)
0.77 (110)
Pressure, 0
MPa (psi)
Pressure, R
MPa (psi)
1.37-1.70 (195-242)
"
"
"
"
"
"
0.70--0.82 (106-117)
"
"
"
"
Transmission
B 19/200 E
B23E
B230K - 1986
AW70
AW71
AW 71
B 200 K, B 230 F
B23/230 FT
B 230 A, B 230 FB
B230K 1987B28A, E, F
AW70
AW 71
AW 71
AW71
AW71
B234 FIG
AW72
1.55-1.95 (220--277)
B280
AW71
1.15 (164)
1.74 (247)
"
"
"
"
"
"
"
"
"
"
"
I
143
70019401960 Specifications
Section 4 Power Transmission
Governor pressure
Rear axle reduction ratio
4.10:1
3.91:1
3.73:1
3.54:1
Speed
Pressure
Speed
Pressure
Speed
Pressure
Speed
Pressure
35 km/h
(22 mph)
30 km/h
(19 mph)
29 km/h
(18 mph)
0.09-0.15 MPa
(12.8-21.3)
27 km/h
(17 mph)
25 km/h*
(16 mph)
55 km/h
(34 mph)
0.17-0.23 MPa
(24.2-32.7)
55 km/h
(34 mph)
0.16-0.22 MPa
(22.8-31 .3 psi)
53 km/h
(33 mph)
0.16-0.22 MPa
(22.8-31.3 psi)
50 km/h
(31 mph)
45 km/h*
(28 mph)
0.16- 0. 22 MPa
(22.8- 31 .3 psi)
110 km/h
(69 mph)
108 km/h
(67 mph)
0.41-0.53 MPa
(58.3-8.4 psi)
103 km/h
(64 mph)
0.41-0.53 MPa
(58.3-8.4 psi)
98 km/h
(61 mph)
95 km/h*
(59 mph)
0.41-0.53 MPa
(58.3-8.4 psi)
1-2
3-2
2-1
2-3
3-4
4-3
62 (39)
63 (39)
63 (39)
103 (64)
105 (66)
105 (66)
109 (68)
135 (84)
111 (69)
38 (24)
39 (24)
39 (24)
97 (61)
99 (62)
99 (62)
49 (31)
50 (31)
50 (31)
3.54:1
3.54 :1
3.54 :1
73 (46)
67 (42)
67 (42)
123 (77)
112 (70)
112 (70)
123 (77)
119 (74)
119 (74)
28 (24)
29 (24)
29 (24)
115 (72)
106 (66)
106 (66)
58 (36)
53 (33)
53 (33)
AW70
AW70
AW70
4.10:1
3.91 :1
3.91 :1
57 (36)
67 (42)
67 (42)
101 (63)
113 (71)
113 (71)
110 (69)
114 (71)
114 (71)
37 (23)
40 (25)
40 (25)
94 (59)
107 (67)
107 (67)
46 (29)
55 (34)
55 (34)
B230 A
B230 K - 1986
B230 K 1987-
AW71
AW71
AW71
3.73:1
3.91 :1
3.91 :1
71 (44)
66 (41)
55 (34)
119 (74)
111 (69)
98 (61)
118 (74)
112 (70)
107 (67)
27 (17)
35 (22)
35 (22)
111 (69)
105 (66)
91 (57)
56 (35)
55 (34)
44 (28)
B230 F2)
B 230 F 1989-3)
B230 FT
AW70
AW70
AW71
4.10:1
4.10:1
3.73:1
63 (39)
57 (36)
63 (39)
106 (66)
99 (62)
105 (66)
108 (67)
110 (69)
111 (69)
37 (23)
36 (23)
39 (24)
100 (62)
93 (58)
99 (62)
52 (32t
45 (28)
50 (31)
3.73 :1
4.10:1
3.91 :1
65 (41)
56 (35)
60 (38)
112 (70)
102 (64)
105 (66)
130 (81)
116 (73)
116 (73)
27 (17)
33 (21)
44 (28)
106 (66)
93 (58)
99 (62)
54 (34)
41 (26)
49 (31)
AW71
3.73:1
63 (39)
110 (69)
121 (76)
46 (29)
104 (65)
51 (32)
Engine
Type
Rear axle
ratio
B 19 E
B23E
B23FT
AW70
AW71
AW71
3.91 :1
3.73 :1
3.73:1
B28A
B28E
B28F
AW71
AW71
AW 71
B200 F
B200 E
B200 K
B280 F
100 1)
100 1)
100 1)
Mechanical lock-up
B230 K
B230F
B230F*
19899230 FB
B234F
B230 FT""
Engages at ... . ... ......... . .... ... . . .. .. . .... ... . km/h (mph)
Disengages at .... . . .. . . .... ... .. . .. . .. .. ..... . . .. km/h (mph)
85 (53)
83 (52)
78 (49)
76 (47)
86 (54)
84 (53)
95 (59)
90 (56)
1)
2)
3)
1001)
75
Kick-down .
USA/Canada estate cars - 1988, 1989-: other markets.
USA/Canada/Japan!Australia 1989-.
144
70019401960 Specifications
Section 4 Power Transmission
Tightening torques
Nm
ftlb
35-50
55-90
41-50
(25-36)
(40-65)
(30-36)
24-28
6-9
22-28
6-9
(17-20)
(4-6)
(16-20)
(4-6)
27-42
48-68
27-47
6-9
5-6
5-6
6-9
8-12
4-5
40-50
5-9
20-30
4-6
65-70
10-16
18-23
(20-30)
(35-49)
(20-34)
(4-6)
(3 .5-4)
(3 .5-4)
(4-6)
(6-9)
(3-3 .5)
(30-36)
(3 .5-6)
(14-22)
(3-4)
(47-51)
(7-12)
(13-17)
II
.,
II"
..
II
'
..
145
70019401960 Specifications
Section 4 Power Transmission
1)
Engine
Type
Notes
B6304 F
AW3Q-43
Volvo PIN
Decal
colour
35 (2100)
1208657
Black
At sea level. Stall speed drops 2 rls (120 r/min) for each 1 000 m (3300 feet) increase in altitude.
Reduction ratios, 1st gear . .... . . ..... ..... . .... . ... . ... . . . . .. .
2nd gear . .. . ..... . ........... '.............. .
3rd gear .... . .... ... . .. . ... .. . .. ... ......... .
4th gear . .... .. . . . .. .. ... . .. ...... ..... ..... .
Reverse ..... .... .... ........ .. . .. ..... ... . . .
Torque converter, K-factor ............. . ........... ...... . . . .. .
diameter ......... .. . . ... .. ... . ............. .
reduction ratio . ...... .. . . .... . . . . . . ..... . .. . .
Lubricant, fluid capacity .... .. ........ . .. . .. . .. . .. . .. . ........ .
type ...... .. .. ... ... .. . . . ... .. . ..... . .... . . . . ..... .
2.80 :1
1.53:1
1 :1
0.75:1
2.39:1
177
254 mm (10 in)
1:1-2.1:1
approx 7.7 litre (8 .1 US qt)
ATF-fluid Dexron II 0
Line Pressure
Engine
Transmission
Idling, position D
Pressure MPa (psi)
Idling, position R
Pressure MPa (psi)
B6304F
AW3Q-43
0.41-0.45 (58-64)
0.61-0.67 (87-95)
Eng ine
Transmission
Idling, position D
Pressure MPa (psi)
Idling, position R
Pressure MPa (psi)
B6304 F
AW3Q-43
1.24-1.34 (176-191)
1.44-1.74 (205-248)
146
7001940/.960 Specifications
Section 4 Power Transmission
Type
B6304F AW30--43
Final drive
ratio
1-2
2- 3
3-4
3-4
4-3
3-2
2-1
(100+KD)
(100+KD)
(75)
(100+KD)
(100+KD)
(100 + KD)
(100+KD)
3.73:1
58
114
157
180
175
105
45
Mode selector in position SPORT (S). Shift selector in position D. Throttle open ing in %
Engine
Type
B6304 F AW3D-43
Final drive
ratio
1-2
2-3
3-4
3-4
4-3
3-2
2-1
(100+KD)
(100+KD)
(75)
(100+KD)
(100+KD)
(100+ KD)
(100+KD)
3.73:1
58
114
177
180
175
105
45
Mode selector in position WINTER (W). Sh ift selector in position D. Throttle opening in %
Engine
Type
B6304F AW3D-43
Final drive
ratio
1-2*
2- 3*
3-4
3-4
4-3
3-2*
2- 1*
(100+KD)
(100+KD)
(0-100)
(100+KD)
(0-100)
(100+KD)
(100+KD)
3.73:1
50
100
50
170
40
70
20
Mechanical lock-up (LOCK-UP), km/h (mph). Sh ift selector in position D. Throttle open ing in %
ECONOMY (E)
Engine
Type
B6304 F AW3D-43
Final drive
ratio
3.73:1
WINTER
(W)
SPORT (S)
(100+KD)
in
out
(100+KD)
in
out
(100+KD)
in
out
(100+KD)
in
out
(100 + KD)
in
out
(100+KD)
in
out
(15-98)
out
in
85 1 77
130 1123
180 1175
85 1 77
130 1123
180 1175
50 1 40
III
'II
III
II
II I
,II
W
II I
147
700/940/960 Specifications
Section 4 Power Transmission
Components
Control unit
- Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3515646
Sh iH position sensor
- Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3515639
9903740153
Mode selector
- Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3515640
Solenoids:
ShiH solenoid 1 (51) and 2 (52)
- Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance at +25C (7rF). . . . . . . . . . ... . . . . . . . . . . . . . . .. . . . . . .
3515643
9903740040
1320
3515644
9903740041
1320
3515645
9903457389
1320
Speed sensor
- Volvo part number .....-: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3515641
9903740151
3515642
9903740154
20.72.90
2067396 0
>20670
Tightening torques
Converter casing - engine, starter motor (2 pcs) ................ .
others .... . .. .. . . ... ... .. .. .. . .. . .. .
Drive plate - torque converter . ....... ... .... . .... . .... .... . .. .
Coupling flange to output shaft ................ . .............. .
Plug, oil pan ............ .. . . . ............ . ... . .. . .... ....... .
148
Nm
(ft Ib)
40.0
48.0
30.0
50.0
20.0
30
35
22
36
14
70019401960 Specifications
Section 4 Power Transmission
Automatic transmission ZF
4HP-22 Q
NO.
NO.
Saarbrilcken
ZF 4HP 22
Other engines
2.73 :1
1.56:1
1:1
0.73:1
2.09:1
2.48:1
1.48:1
1:1
0.73:1
2.09:1
024
Other engines
IF Gelriebe GmbH
x converterratio
218K
195K
1- approx 2.57
1- approx 2.3
260 mm
ATF oil type Dexron II D'
7.5 litres incl oil cooler and tubes (2.5 litres
qts approx in torque converter)
2.6 US
,/
Stall speed 1
rls (rpm)
Volvo P/N
B23E, B230E
1208375
1208391
1208502
1208662
36.0 (2150)
B230ET
1208376
1208480
1208503
1208609
33.3-41 .0 (2000-2450)2
1208518
1208601
B 230 F Others
(not estates 1987)
1208301
1208501
B230FB
1208686
1208517
1208610
D24
1208407
1208505
1208594
36.0 (2150)
D24 T Europe
1208317
1208389
1208506
1208595
1208664
31 .7-39.0 (1900-2350)2
D 24 T USNCanada
Austria 1987-
1208365
1208390
1208507
1208596
1208665
30.0-33.3 (1 800-200W
D24 TIC
1208397
1208663
0)
I)
2)
1208680
III
til'
'IIt
til '
,lit
lit
,lit
35.0 (2100)
35.0 (2100)
til
,III
33.0 (2000)
31 .7-40.8 (1900-2450)2
149
70019401960 Specifications
Section 4 Power Transmission
0.25-1 .0 mm
51 +1 .6 mm
- 0.6
0.001 - 0.040 in
2 +0.063 in
- 0.024
MPa
(85-108)
(156-199)
Position R
Position 0
MPa
psi
MPa
psi
B23E
B230E
B230 F/FB
0.83-1 .03
0.83-1 .03
0.95-1.15
118-147
118-147
135-164
1.51-1 .72
1.51 - 1.72
1.61-1 .81
215-245
215-245
229--257
B230ET
024
0.95-1.15
0.86-1.06
135-164
122-151
1.61-1 .81
1.57-1.76
229--257
223-250
D24T
Austria 1987USA/Canada
Others
0.81-1 .01
115-144
1.48-1 .67
211-238
0.99-1 .10
141 - 156
1.61 - 1.82
229--259
D24TIC
0.96-1 .06
137-236
1.57-1.76
223-250
Ratio
1-2
2-3
3-4
4-3
3-2
2-1
Mechanical lock-up
Engages"
Disengages"
B23E
B230E
B230 F
USA/Canada
3.73 :1
3.73:1
3.91 :1
98 (61)
98 (61)
93 (58)
52 (33) 96 (60)
52 (33) 85 (53)
50 (31) 78 (49)
94 (59)
83 (52)
76 (48)
B230F
Europe 1987B230 FB
B230 ET
3.91 :1
93 (58)
50 (31) 85 (53)
83 (52)
3.91 :1
3.91 :1
3.73:1
102 (64)
93 (58)
98 (61)
54 (34) 85 (53)
50 (31) 92 (58)
52 (33) 97 (61)
83 (52)
90 (56)
95 (59)
B230FT
Europe 1987-
3.73 :1
98 (61)
52 (33) 97 (60)
95 (59)
024
D24T
Austria 1987USA/Canada
Others
3.91 :1
3.91 :1
46 (29) 83 (52)
46 (29) 83 (52)
98 (61)
98 (61)
34 (21)
34 (21)
79 (49)
79 (49)
39 (24) 76 (48)
39 (24) 73 (46)
74 (46)
71 (44)
3.73 :1
48 (30) 87 (54)
82 (51)
41 (26) 87 (54)
85 (53)
D24TIC
3.73 :1
48 (30) 87 (54)
82 (51)
41 (26) 87 (54)
85 (53)
150
100*
100*
85
100*
100*
70019401960 Specifications
Section 4 Power Transmission
Tightening torques
Nm
ftlb
17-27
41-50
35--50
55--90
7-9
9--11
20-26
7- 9
9--11
9--11
9--11
34-46
43- 57
40-52
7-9
85--115
13-17
85--115
12-20
30-36
25--36
40-65
5--6.5
6.5--8.0
14-19
5--6.5
6.5--8.0
6.5--8.0
6.5--8.0
25--33
31-41
29-38
5--6.5
61-83
9--12
61-83
ikd@
139 137
/'
30 Nm (22 ft Ibs)
50 Nm (36 ft Ibs)
80 Nm (58 ft Ibs)
angle-tighten 60*
1....1
III
11 1
III
111
III
111
151
70019401960 Specifications
Section 4 Power Transmission
Tightening torques
Pinion drive flange, pinion with spacer .... . ... . . . . .. .. . . . .. .... .
pinion with compression sleeve' .. ......... . .
Differential bearing caps . .. .. ..... .. ... .. ... . . ....... . . ... . . . .
Crown wheel" . . . ..... ..... ...... . . ... ..... . . .. . .... . . . ... . . .
Wheel nuts .. . . . . . .. .... ...... ... .. .... . .. .. .. . . . . . .. . .... .. .
Lock nut - speedometer sensor . .. . ... ......... ... . .. ... . .. .. .
Nm
ttlb
200-250
180-280
45-60
90-110
85
25-40
147-185
130-207
33-44
66-81
63
18-29
Tightening torques
='..
152
Nm
ftlb
180-280
35
85
8-12
20-28
40-56
40-56
20-28
27-40
27-40
30
140
(133-207)
(26)
(63)
(6-9)
(14--20)
(29-40)
(29-40)
(14--20)
(20-29)
(20-29)
(22)
(103)
70019401960 Specifications
Section 5 Brakes
Section 5 Brakes
fJy
~~
132426
Brake fluid
Grade ... . ... .. .. .. . .. ............ . .. . . .. .. . . . . . . ..... .. . . ..
DOT 4
(
Brake disc, outer diameter, . . . .... . . .. .. . . .. . .. . . . . . ... mm
thickness new .. .. .... ... . .. . .. . ... . . . .. . . . mm
change at .. .. . . .. .. . . ..... .. .. . . ....... ... mm
run-out -1987 .. . . .... .. .. .. .... . .. . .. ... . . mm
1988- . ... ......... ... . . . .. .. . ..... mm
Brake pad thickness, new . .. .. . ......... ..... . . . . ..... mm
min ... . . ... . ..... .. .. ... . . .. . . . .. mm
(in)
(in)
(in)
(in)
(in)
(in)
(in)
Alt I
Alt III
Alt IV
Alt"
nonventilated ventilated ventilated
ventilated
('Jumbo')
280 (11.0) 287 (11 .3) 262 (10 .3) 280 (11 .0)
14 (0.55)
22 (0 .87)
22 (0.87)
26 (1 .02)
11 .0 (0.43) 20.0 (0 .79) 20.0 (0 .79) 23.0 (0.91)
max 0.08 (0.003)
max 0.06 (0.0024)
11 .5 (0.453)
('Jumbo' 12.0 (0.472)
3 (0 .12)
I
I
(in)
(in)
(in)
(in)
(in)
(in)
Standard
Multi-link
281 (11.06)
9.6 (0.378)
min 8.4 (0.330)
max 0.10 (0.0039)
10 (0 .393)
2 (0 .078)
Nm
ftlbs
100
58
48
24
40
34
85
30
5
4.5
14
17
17
(74)
(43)
(35)
(18)
(29)
(25)
(63)
(22)
(4)
(3 .3)
(10)
(12)
(12)
Tightening torques
Attaching , bolts , front brake calipers ... . ..... .. .. .. .. ....... . .. .
rear brake calipers .......... . .. ... .. ....... ... .
caliper bracket ... . . . ... . .. .. ... ... .. . . .. . . . . . .
front dust shield ... . .. .... .. . .. . .. . . . .. (approx.)
rear dust shield . ...... ... . ... . . . .... .. (approx.)
brake caliper, slide pin .. ........ . .... .... .... . .
Wheel nuts ...... . .. . . .... . .. ... .... .. . ... ..... . ..... . . .. . .. .
Attaching nuts, master cylinder . . . .. .. ...... . ... . .... .. (approx.)
Bleeder screws, front . . .. ... ...... . .... . .. . .. . . . .. . .. . (approx.)
rear .... . . . . . .. . . ... ... .. . . . . .. . .... . (approx.)
Brake pipe unions ... . . . . . .. . .. . . . . . ... .... .. . . .... ......... . .
Brake hoses to nipple ... .. ... .. .. .. ........... . . ...... .... .. .
Nipple to caliper .... . . .. . . .. .. . ... . .. ... . .. ..... . ... . ...... . .
"I
II
II
II
II
II
II
11
II
153
70019401960 Specifications
Section 5 Brakes
Parking brake
123427
max 0.15 mm
max 0.2 mm
3-5 notches
max 11 notches
max 0.0059 in
max 0.0078 in
-r
154
70019401960 Specifications
Section 6 Suspension and steering
4.5-5.5
- 0.2 - +0.8
o.r.
Toe-in
All variants*
8-b
C-c
Angle (2 (X)
A-a
18'8'
.-
All measurements to be carried out on an empty vehicle. Dimensions are noted at hub height in the form of an angular
measurement a or as the difference in mm between the front and rear edges of the wheels at points A, B or C (the tire tread,
shoulder and wheel rim edge respectively) .
Ball joints
Max axial play with normally loaded front end, 3 mm
(0.12 in)
Max radial play, 0.5 mm (0.02 in).
Camber
'leg all. um b ..
113'
l
~
r;; ~
+a
+a
P- - I
ii
-1.0
-0.
-0.6
I-
-0
I-i
. IT - ' .
ltl
-0.
'It
. - .1-
-4 -
'.-3
"';-2
+i
+2
f-L
_ .
?.4
1-
-\-;h-
+4
H-
i-J:-L
11.L
1"'-- .
_ 1_ i-'-
_J .I,. :. I. :
. ill
LLLu ....L 1
I~)
"!
143721
tI " "
i
H 1-1 I I I I I I ~ t
I I I I Im
Positive Camber
,I.
It '
-~~
ltl
III
ltl
It .
ltl
III
143 720
155
70019401960 Specifications
Section 6 Suspension and steering
A
Toe-in
Measured as angle
Toe-in (<X) ang le = 2'3' per wheel.
- --- - - - -.-.--..---
Specification
Toe-in measurement (B-A) should be is 0.50.8 mm, measured at C, see left.
Note: Camber must always be adjusted before Toe-in.
Toe-in tolerance
Measure Toe-in of unladen vehicle, according to above.
143 724
-c
143723
143 722
Tightening torque
.'"
95 Nm
(70 ft Ib)
135 398
156
Nm
ft Ib
60
30
60
40
150
70
95
85
44
22
44
29
111
50
70
63
100
74
70019401960 Specifications
Section 6 Suspension and steering
Group 64 Steering
Steeri ng gear
132429
Cam gear
3.5
16.9:1
0.0~.12
mm
0.6-1.7 Nm
0.0019-0.0047 in
5.3 in. lb.
1.2 MPa
3.5-4.5 Nm
171 psi
31-40 in. lb.
1 Nm
9 in. lb.
Grease, Volvo PIN 1161001-1
100 grams
See page 14
ZF
Numbers of turns, lock to lock ............ ..... .. . .. . . ........
Steering ratio ... ..... . .. ... . ... . .. .... .. .... . .. . .... . ... ....
Clearance between pre-tensioning piston and cover . ..... . ......
Frictional torque, measured on input shafl. .. . ..................
Checking servo balance:
pump pressure when measuring steering wheel torque .... ....
torque un steering wheel .. .. ... . ..... ....... . . .. . ....... . ..
max deviation between right and left locks ..... ... ... . ..... ..
Lubrication, type ..... ............. .... ... ...... ... . ...... ...
quantity ...... ......... . .... . .. . .. . . . . .... .......
Hydraulic fluid ........ ...... ... . ... .. . .... ............... . ..
.
.
.
.
3.5
16.9:1
0.025-0.05 mm
0.6-2.1 Nm
.
.
.
.
.
.
1.2 MPa
3.4-4.5 Nm
1 Nm
0.0010-0.0020
0.4-1.5 ft Ib
171 psi
31-40 in lb.
0.7 ft Ib
Grease Volvo PIN 1 161 001 -1
100 grams
See page 14
Servo pump
136 000
132 430
Max pressure, early type (A, B,C) ....... . ..... .. .. . . .... .... . . .
late type of "C" ... ... . . . .. .. . .. . ..... . . . ..... .. .
type "0" ... .. . ...... .. . ... . . . .. 0- ' . . . . .
C
7.6-8.3 MPa
9.3-10.0 MPa
10.0-11.0 MPa
9.3-10.0 MPa
D
1081-1180
1323-1422
1422-1564
1323-1422
psi
psi
psi
psi
I
157
70019401960 Specificatidns
Section 6 Rear wheel suspension
Tightening torques
Steering
Steering
Steering
Steering
Steering
Steering
Nm
ftlb
24
34
24
44
70
60
17
25
17
32
52
44
158
Nm
ft Ib
50
50
70
70
48
125
60
115
37
37
51
51
35
91
44
83
70
85
85
70
70
70
160
160
24
56
85
140
24
24
60
51
61
61
51
51
51
116
116
17
41
61
102
17
17
43
700194019fiO Specifications
Section 7 Springs, dampers and wheels
Aluminium
Steel
Max. 0.8 mm
(0.032 in)
Max. 0.6 mm
(0.024 in)
1.0 mm
(0.039 in)
0.8 mm
(0.032 in)
~tttt*.
-e-US
,
I
1-3 occupants
Tire size/model
132428
Full load
Front
Rear
Front
Rear
190
190
210
200
190
210
190
190
210
210
230
210
230
280
230
260
7401760
4-door
Estate
780 - 1987
7601780 1988-
(28)
(28)
(31)
(29)
(289)
(31)
(28)
(28)
(31)
(31)
(33)
(31)
(33)
(40)
(33)
(37)
940/960
4-door
Estate
190 (1.9)/940
200 (2.0)/960
190 (1.9)
190 (1.9)
210 (2.1)
260 (2.6)
210 (2.1)
210 (2.1)
280 (2.8)
350 (50)
280 (40)
350 (50)
280 (40)
350 (50)
280 (40)
350 (50)
280 (40)
Sustained high speed driving (more than an hour at above 120 kmlh = 72 mph) : air
pressure of cold tires should be increased by 30 kPa (4 psi). Note: This does not apply to
the "Special Spare".
For USA/Canada: refer to sticker on front right door.
Tightening torques
Trailing arm bracket ................................. .. ... . .. .
Springs rear, upper mount. . . . . . . . . . . . . . . . . . . . . . . . . .. (approx.)
Attaching bolts, front brake calipers ....... . . .. .. .. .......... . . .
Attaching bolts, rear brake calipers ........ .. .. ... ............. .
Wheels .................................................... .
Nm
ttlb
45
48
100
58
85
33
35
74
43
63
..
III
III
II
III
..
III
11
III
159
700/940/960 Specifications
Section 8 Body and interior
Delco R4
Freon 12 (dichlorodifluoromethane)
1.2 kg (2.6 Ib)
1.1 kg (2.4lb)
Sanden
Sankyo
S0510
York A210
Kiki YA 15 Sanden
OKS 15BHI S0709
CH
100 rls
(6000 rIm)
100 rls
(6000 rIm)
115 rls
(7000 rIm)
100 rls
(6000 rIm)
300 ml
3.1 MPa
(441 psi)
200 ml
3.2 MPa
(455 psi)
240 ml
3.2 MPa
(455 psi)
Tightening torques
1
2
3, 4
5
6
7
8
9
10
11
12, 13
160
Nm
ftlb
27
39
45
10
27
12
3.5
20
24
18
16
20
29
33
7.5
20
9
2.5
15
18
13.5
12
70019401960 Specifications
Section 8 Body and interior
Delco R4 Compressor
Compressor, coupling plate ..... ... ................. . . . .......
14-34
10-25
22
15
22
11
16
11
16
Kiki Compressor
Front cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive plate centre bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil drain/filler plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
York Compressor
30
25-30
20
20
20-30
20-30
22
3.5
18-22
14
14
14-22
14-22
10
38
15
27
11
Sankyo Compressor
Oil drain plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley/clutch centre bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure sensor
(Only fitted to vehicles with D 24, D 24 T and tropic type radiator)
Electric cooling fan engaged at pressure ............ . ....... . .. .
disengaged at pressure ......... .. .... . .. .. .
Performance test
Test conditions
Bonnet . . . . . . . . . . .. closed
Doors . . . . . . . . . . . .. closed
Engine speed. . . . .. 33 r/s (2000 r/min)
+ AC
Control settings
CU
3
COOL
MAX
ACC
ECC
5
Max cool
Auto Hi
Max cool
Vent
143 985
In
In
5-8C
(41-46F)
5-8C
(41-46F)
8-12C
(46-54F)
11
11
lit
11
lit
11
lit
III
II
161
'-
AS:
CERTIFIED.
15384
Service literature
Your
most important
special tool