1982 VOLVO 940 Service Repair Manual

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70019401960 Specifications
Section
2 B 280 Engine
Group 21 Engine block
Cylinder head
Max warp:
Maximum warp is 0.05 mm (0.002 in) per
100 mm (4 in) length.
I
[
Note: Do not level a warped cylinder head,
replace it!
n~Ql;J 129860
Cylinder liners
Bore liners marked 1 (A-marked piston) ........................ .
2 (B-marked piston) ....................... .
3 (C-marked piston) ....................... .
Liner height above
block face ................................. .
Shims for adjustment of liner height:
thickness, orange paint marking
............................ .
white paint marking
.............................. .
blue paint marking ............................... .
Pistons
Max weight difference between pistons in same engine .......... .
Piston
float ..................................... ............ .
Piston diameter, A-marked pistons
........ .
B-marked pistons .
....... .
C-marked pistons
........ .
91.00-91.01 mm
91.01-91.02 mm
91.02-91.03 mm
0.14-0.21 mm
0 .098-0.134 mm
0.118-0.154 mm
0.138-0.194 mm
6 grams
0.070-0.090 mm
90.920-90.930 mm
90.930-90.940 mm
90 .940-90.950 mm
(3.5826-3 .5830 in)
(3.5830-3.5835 in)
(3.5835-3.5838 in)
(0.0055-0.0083 in)
(0.0039-0.0053 in)
(0. 0046-0.0061 in)
(0.0054-0.0076 in)
(0.0028-0 .0035 in)
(3.5822-3.5826 in)
(3.5826-3.5830 in)
(3.5830-3.5834 in)
((0)) t
~ ~~ Piston diameter is measured at right-angles to gudgeon pin bore, 13 mm (0.512 in) from bottom edge.
135676
Piston rings
Side clearance (measured with ring on piston) .. ............ . mm
Ring gap measured 13 mm (0.51 in)
from
lower edge of cylinder
Upp er Lower Oil ring
com pres-compres-
sion ring sion ring
0.045-0.
074
0.025-0.054 0.009-0.233
in
Ring gap when checked in 91 mm (3.5826 in)
. 0.0017-0.0029
0.0009-0.0212 0.0003-0.0091
(cylinder,
see fig) ..................................... .... mm
Gudgeon (piston ) pins in
0.40-0.60 0.40-0.60 0.40-1.45
0.0157-0.0236 0.0157-0.0236 0.0157-0.0570
Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007-0.017 mm (0.0003-0.0007 in)
87
"' lit ill lit ·,11 tit ill, til Itil

70019401960 Specifications
Section 2 B 280 Engine
Valve system
Valve clearance
Inlet valves, cold engine ..................................... .
warm engine
................................... . .
Exhaust valves, cold engine
.................................. .
warm engine
................................. .
Valves (sizes in mm)
44,5°
0.10-0.15 mm
0.15-0.20 mm
0.25-0.30 mm
0.30-0.35 mm
(0.004-0.006 in)
(0.006-0.008 in)
(0.010-0.012 in)
(0.012-0.014 in)
7,973-7,995
7,965-7,980
45,3
129851
Inlet valves Exhaust valves
Valve guides
18-22mm 20-24mm
'·Il'I====JI, '·':1 ~:J' 141 RClfj 130021
Seat for Inlet valve
Seat for exhaust valve
When replacing valve seats: the interference between the valve seat and its bore in the cylinder head shall be 0.136-0.200 mm (0.0054-0.0079 in), i.e. valve seat diameter must be 0.136-0.200 mm greater than the diameter of the bore in the cylinder head .
Valve seats are available in three oversizes .
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
46-47 mm
36.9-37.9 mm
0.053-0.098 mm
(0.3149-0.3158 in)
(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 .
129865
Valve springs
Standard
Oversize 1
Oversize 2
Oversize 3
115083
Rocker arm mechanism
Marking
No groove
1 groove
2 grooves
3 grooves Reamer
5166
5167
5168
Spr ings marked green
Length
mm in
47.1 1.85
40.0 1.57
30.0 1.18
N
o
230-266
613-689
The rocker arm tips are surface hardened and must not be ground
Load
Ibs.
o
52-60
137-154
Clearance, shaft-rocker arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012-0.054 mm
Timing gears
Camshaft
(0.0005-0.0021 in)
~
--~
Engine type ............................. B280E B280F
Left
Right Left
Right
Marking
........................... ...... R R S S
Colour
code ...... ... .................... White
White Green Green
Part number (last three digits)
.............. ... 957 ... 959 . .. 958 . .. 960
1
32608
B280E B280 F
Max lobe lifting height . left and right. inlet
...................... .
exhaust
........... ' " ... .. . 6.08
mm (0.
2396 in) 5 .96 mm (0.2348 in)
5.85 mm (0.2305 in) 5.43 mm (0.2139 in)
Checking camshaft settings (cold engine) :
adjust valve clearance
on 1 st and 6th inlet valves to .......... .
The inlet valves should then open
at:
1st ...... .................... .......................... .
6th . ................................................... .
Journal clearance
............................... ............ . 0.7
mm (0.0275 in) 0.7 mm (0.
0275 in)
4.50 B.T.D.C. 5 0 B.T.D.C .
4.50 B.T.D.C. 5
0 B.T.D.C.
0 .035-0.085
mm
(0.0013-0.0033 in)
89
III .. III .. III ... III ·11 III

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

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

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

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

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