1982 VOLVO 940 Service Repair Manual

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Carburettor
Fuel pump
Clutch
Alternator ,­
Steering box
SU
Pierburg
Solex Pierburg
Bosch
AC- oelco
Sofabex
Fichtel & Sachs
Verto/Valeo
Bosch
Cam Gear
Zahnrad Fabrik (ZF)
~
'?' .'" ... .
.
---
" .. u.·.. ,
2
3
5
2
3
4
5
2
3
1
2
3
6 . Fina l drive ratio , part and seria l numbers
Located on rear axle .
7. Gearbox type des ig nation, part numbe r and
serial num ber
A. Manual : On bottom of gearbox .
B. Automatic:
BW 55,
AW 55/70171 /72: On LH side of gearbox.
AW3Q-43:
On RH side of gearbox.
8 . Body number pla te
Located above left head lamp.
780
70019401960 Specifications
Section
0 General
3
6
8
7 B 143980
9. Engine type des ig nation, serial number an d
part number
A. 024, o24T, o24TIC
Stamped on cylinder block, beneath vacuum pump.
B. B28
Located on plate in front of oil filter . On B 28 ElF en­
gines: a
decal on the right rear side of cylinder head
shows
last three digits of part number.
B280
Stamped on cylinder block. (Some models: decal)
Early
type : between cylinder banks, to rear.
Late type: front right side, between
inlet manifold and
water pump.
__ -G.-819, B 23
I
Stamped on left side of engine, behind distributor. Last
three digits of part number are shown
on transmission
gearcase.
O. B 200, B 230
Located on timing gearcase . Also stamped in left side of
cylinder block.
E. B6403
Decal
on timing gearcase. Also stamped in right side of
cylinder block, above water pump housing , between
timing gearcase and
manifold.
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70019401960 Specifications
Section 0 General
Product plate
1982-1 989
A Type approval *
B Vehicle identification
number (type designation) **
C
1 Gross vehicle weight
C
2 Max train weight Ca Max axle load: front C
4 Max axle
load: rear
D Special vehicle
numbers
E Market code
F
Colour code
G Interior code
H Country of manufacture
147941 * Certain countries.
199 0 -W 944
II '. 1.'DE Irl ~========:~===;:=:::;::;W::::,::::EW'::;:::::=r== ;==============ill, , , ,I, ,1'1 II' , , I I EEl ~===========;II 3 3 + El EEl
;==============ill 6 7 71 7 7 1 I II a a a al a al I ~===================; 11999919911
1 99 0 W 945-
199 1-
[ '.11'10E III S I.'/ FD E"I
148098
,I, ,1,1,1,1,1
EEl ~I ======== I
,I, ,I 21 21 I 31
41441414 1 I IEEl
515 161616161
71 7 7 1 71 71 71 I
Iiaia alai I 191
14 8099
The chass is code~has seven positions :
pos 1-2 Front spring, shock absorber, brake disc and caliper
pas 3 Front anti -roll bar
pas 4 Rear shock absorber
pas 5 Rear spring
pas 6 Rear anti -roll bar
pas 7 Bump rubber
the ch ass is code sh ould be inte rp reted as follow s: ~
9X27A24
E
8
Bump rubber:
Rear
anti -roll bar:
Rear spring:
Rear shock absorber:
Front
anti -roll bar:
front spring:
shock absorber:
brake disc:
brake
caliper:
** T ype designation codes, see next spread.
A-C4 As before
1 = Version
2 = Chassis type
3 = Market code
4 = Emission
5 = Steering gear
6 = Brakes
7 = Interior fittings code
8 = Colour code
9 = Special variant (if applicable)
A-C4 As before
1 = Version
2 = Market code
3 = Brakes
4
= Chassis code (see below) 5 = Emission
6 = Interior fittings code
7 = Colour code
8 = Special variant (if applicable) 9 = Steering gear
1330853 -1
3516572 -9
1273977-7
1329507 -6
1330218 -7
1329822-9 I
2 74040 -5
1359906 -3
1359557-4, 1359558- 2
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Volvo PIN for each code
Pos Front Shock Brake Brake Pos
1,2 spring absorber,
disc caliper 1,2
front
31 1329822-9 274040-5 1359906-3 1329640-5 EG
1329641-3
42 1329822-9 1329648- 8
1359908-9 1329642-1 EN
1329643-9
44 1329824-5 3530274-
4 1359908-9 1329642-1 ER
1329643-9
54 1329822-9 274040-5
1359906-3 1329866-6
ET
1329867-4
( 5L 1329824-5
271105-9 1359906-3 1329866-6
1329867 -4
5M 1293449-3 271105-9 1359906-3 1329866-6
1329867-4
Pos
5P 1329823-7 271105-9 1359906-3 1329866-6 3
1329867-4
1
5Y
1329822- 9 274040
-5
1359906-3 1329866-6
2
1329867-4
3
9A 1329822-9 274040-5 1359906-3 1359557-4
1359558-2 4
9F
1329823- 7 271105-9
1359906-3 1359557-4 5
1359558-2 6
9X
1329822- 9 274040-5
1359906-3 1359557-4
1359558-2 7
A2 1329822-9
1329648-8 3516567-9 3516565-3 8
3516566-
1 A
A3 1329823-7 3530274-4 3516567-9 3516565-3 B
3516566-1
A4 1329824-5 3530274-4 3516567-9 3516565-3
3516566-1
A5 1387678-4 3530274-4 3516567-9 3516565-3
3516566-1
A9 1387677-6 3530274-4 3516567-9 3516565-3
3516566-1
03 1329824-5 271105-9
1359908-9 3516517-4 Pos
3516518-2 6
07 1329823-7 271105-9
1359908-9 3516517-4 1
3516518-2 2
DC 1329823-7 3530274-4 1359908-9 3516517-
4
3
3516518-2
E2 1329823-7 3530273-6 1359908-9
3516513-2
3516514-1
EE 1329824-5 271105-9 1359908-9
3516513-2
3516514-1
EJ 1293449-3 271105-9 1359908-9 3516513-2
3516514-1
Spring,
front
1329822- 9
1329823-7
1387677-6
1387678-4
Anti-roll
bar, front
1330220-3
1330218- 7
1330221-1
1330219-5
1359808-1
1359807-3
3530276-9
3530277- 7
3516447-4
3516446-6
Anti-roll
bar, rear
3516573-7
3516572-9
3530751-1
70019401960 Specifications
Section
0 General
Shock Brake Brake
absorber, disc
caliper
front
271105-9 1359908-9
3516513-2
3516514
-1
271 105 -9 1359908-9 3516513-2
3516514-1
271 105-9
1359908-9 3516513-2
3516514-1
271105-9 1359908-9 3516513-2
3516514-1
Pos Shock ab-Pos Spring,
4 sorber,
rear 5 rear
1 1329501-9
4 1273759-9
5 1329505-0
7 1273977-7
7 1329507-6 A 1273977-7
9
1329504- 3 C 1359710-9
C 1329500-1 E 3530199-3
F 1330332-6
9 1387836-8
G 1330702-0
H 3516668-5
J 3530200-9
N 3542466-2
M 3530283-5
Pos Bump
7 rubber
4 1330853-1
5 1359653-1
6 1387181-9
9
Itl tit
til til
Itl - til til -til
til

70019401960 Specifications
Section
0 General
Identification number, other markets (not USA/CAN )
l~ L
YV1 74468 2 C 1 001234
TTL----
Vehicle identification number, USA & Canada
YV1DH6923C1001234
11"--------
10
Manufacturer's code
Vehicle type
Engine type
Chassis number
Assembly plant
Model
year
designation
Transmission
Mc; mufacturer's code
-1985: D = 70 with 3 poi nt seat belts
1986-1990: F = 740 G = 760 H = 780
1991-: F = 740 H = 780 J = 940 K = 960
-1985: Vacant
1986-: A = SRS (Air bag) and front 3-point
seat
belts
X = 3 -point seat belts
Engine type
Body version 2
= 2 door
4
= 4 door
5 = 5 door
Chassis number
Assembly plant
Model
year
designation
Check number
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Engin e typ e Asse mbly plant
21 = B200 FT 77 = 024 o = Sweden (VKAV)
23 = B200K 81 = B230A, B234G 1 = Sweden (VTV)
24 = B19E,
B200E 82 = B230GT 2 = Belgium (VEC)
25 = B204FT 83 = B230K 3 = Canada (VCl)
26 = B 19 ET, B 200 ET 84 = B23E, B230E 4 = Thailand (TSA)
27 = B200F 85 = B230FB 5 = Malaysia (SMA)
28 = B204GT 86 = B 23 ET, B 230 ET 6 = Australia
29 = B204E 87 = B230FT 7 = Indonesia
f 62 = B28A 88 = B230F (ISMAC)
·
68 = B28E, B280· E 89 = B234F A = Sweden
69 = B 28 F, B 280 F 95
= B6304F (Uddevalla)
75 = 024TIC o = Italy, Bertone
76 = D24T

Model year
d es ignation
C = 1982
0= 1983
E = 1984
F = 1985
G = 1986
H = 1987
J = 1988
K = 1989
l =
1990
M = 1991
70019401960 Specifications
Section
0 General
Transmission
2 = M46
3 = M47
5 = ZF4HP22,
AW 71 l -87
6 = AW70l, AW71l,
AW 72l, AW 30-43
7 = AW:70, AW 71
8 = BW55
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1111 'III 1111 III 1111 'II' 1111 ,III 1111

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70019401960 Specifications
Section 1 Service and maintenance
Section 1 Service and maintenance
Group 16 Lubrication
MAX
M'N
Petrol (gaso line ) eng ines
U
SA,Can ada,Japa n
011 quality According to API. ................. min SG "
• Oils with designations SG/CC and SG/CD fulfill this requirement.
Viscos ity (stable ambient temperatures)
• -3,0 -20 -10 0 10 20 30 40°C -I ! ! ! ! ! ! !
-22 -4 14 32 5 0 6 8 8
1
6 104 of
S A E 5W/30 ~ I
«iprttWn: WSAE 10W/30¥ti'i'iW,iJl>
I < S AE 15W/4 0
141375
Ot he r marke ts
Oil quality According to API .... .............. min SG "
According to CCMC ........... class G4/GS "
• Oils with designations SG/CC and SG/CD fulfill this requirement.
Viscos ity (stable ambient temperatures)
-30 -2 0 -10 0 10 20 30 40°C • I I ! ! ! I ! I -22 -4 14 32 50 68 86 104 of I I I SAE 5W/30 I
1<:::SAE1Q~Jii •
::I:i:1SD:flQWZ401t ::::It:I:,
< SA E 15W /40
SA E 20W/40
k" SAE 30
k SAE40
13 7 642
D iese l eng ines
USA, Can ada,Japa n
MAX
MIN
135901
Oil quality According to API Service .......... min CD"
• Oils with designations SE/CD and SF/CD fulfill this requirement.
Viscosity (stable ambient temperatures)
-22 -4 14 32 50 68 86 10 4 of 1----~SA~E~5~W~V=3~0--~--L-~)
14138 1
Other marke ts
Oil q uality According to API ...... ............ min CD "
According to CCMC .......... class 02lP01"
• Oils with designations SE/CD and SF /CD fulfill this requirement.
Viscos ity (stable ambient temperatures) I
• -3 P -2 p -1,0 Q W 2 p 3 p ~O °C
- 2
12 -4 14 32 50 68 8 6 104 of
S A E 5W/30
···t.:.::':·::ISil\E(1S:WZ4l·::: :ttit
SA E 20W/40
I<-.. SA E 30
I< SAE40
142444
Synthetic or semisynthetic oils may be used if their specifications comply with the oil quality re­
quirements.
12
V olvo does not re comme n d additio nal o il additives, as they ca n ad ve rsely affect the
e n g
ine.
Note ! SA E 1SW/40 and SA E 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.
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70019401960 Specifications
Section 1 Service and maintenance
Engine oil, capacity, litres (US qts )
Difference
Excl. oil Incl. oil in volum e filter
filter max.-min.
819,823,8200,8230· .................. ................... .
3.35 (3.6)
3.85 (4.1) 1.0(1.1)
8204,8234 ............................ .................... . 3.5 (3.7) 4.0 (4.2) 1.0 (1.1) 86304 ............................................. ........ . 5.0 (5.2) 5.75 (6.1) 1.0 (1.1)
828 ....................................................... . 6 .0 (6 .3) 6.5 (6.9) 1.0 (1.1)
8280 .......................... ............................ . 5.5 (5.8) 6.0 (6.3) 1,0(1.1)
024,024 T, 024 TiC·· ....................... ............... . 5 .0 (5.2) 6 .0 (6.3) 1.0(1.1)
• Turbo: Add extra 0.6 litres if oil cooler is drained . .. Turbo Intercooler : Add extra 0.7 litres (air oil cooler) .
Carburettor
Oil for damper cylinder , 828 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-40 (or SAE 10W-50) Engine oil
8230A................................ ATF
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 ............................. .
• Volvo Thermo Oil (PIN 1 161 243-9) is recommended for vehicles driven in areas where ambient temperature seldom drops below -10°C (+14°F) , or
high mileage vehicles such as taxis . NOTE! Do not mix oil types .
Automat ic transmission
132414
Lubricating oil AW/8W55, AW70/AW71 -1983 ................. .
AW70/AW 71/AW721AW
30-43/ZF4HP22 ......... .
Oil change quantity (drained only) AW 70, AW 71 lAW 72 ......... .
AW30-43 ................... .
8W55 ............ .......... .
ZF4HP22 ................... . 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)
Do not use ATF Oexron as
vibration damper and overdrive
may
slip.
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
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70019401960 Specifications
Section 1 Service and maintenance
Rear axle
134142
Lubricating oil ............................................... .
grade , without limited-slip differential or with
automatic differential lock (Eaton)
............ .
I with limited-slip differential (Dana) .................. .
viscosity , above
- 10 °C (+14°F) ............ ........ .
below
- 10 °C (+14°F) ............ ........ ..
Oil change quantity, 1030 .................................... .
1031, -1990 ............................. .
1031, 1991-.... ......................... .
1035 .................................... .
1041, -1990 .... ......... " .............. .
I
1041, 1991-............................. .
1045 .................................... .
Steering gear
134143
.Lubricant. .................................................. .
quantity
..................... ........ .. ............ .
Power steering fluid .
....................... ................. .
quantity,
828 ................................. .
819,823 ...................... ...... .
8200,8230 .... ...................... .
8280 ................................ .
I 86304 .......... ....... .............. .
D 24, D 24 T
-1986 .................... .
D24,
D24 T, D24 TIC 1987-. .......... .
* Volvo power steering fluid (PIN 1161 317-1 is recommended if temperature
is below -20°C (-4°F).
14 Final
drive oil
API-GL-5(6) or MIL-L-21 05 8(C)
Low -friction oil Volvo
PIN 1161 329-6 0 .5 litrelUS qt
API-GL-5(6) or MIL-L-2105 8(C)
with additive Volvo
PIN 1161129-00.5 litre/US qt
SAE
90
SAE 80
1.3 litres (1.4 US qts)
1.6 litres (1.7 US qts)
1 .75
litres (1.85 US qts)
1.4 litres (1.5 US qts)
1.45 litres (1.55
US qts)
1.6 litres (1.7 US qts)
1 .3 litres (1.4
US qts)
Grease, Volvo
PIN 1161 001-1
approx 100 grams (3.5 ozs)
ATF type
A, F or G*
litres
1.0
0 .8
0.8
0.8
0.8
0.8
0.5
(US qts)
(1.1 )
(0.9)
(0.9)
(0.9)
(0.9)
(0.9)
(0.5)