1982 VOLVO 960 engine

148680
( 150599
150432
70019401960 Specifications
Section 2 B
6304 Engine
Main relay
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 323592-4
Relay , fuel pump
Volvo part number . . . . . . . . . . . . . . . . . . . . . .. 1 362 914-2
Relay , e lectric cooling fan
Volvo part number. . . . . . . . . . . . . . . . . . . . . . . 1 523872-4
105
III II III
iii ,II lit ,II lit

70019401960 Specifications
Section 2 B
6304 Engine
General
Group 26 Cooling System
128187
General
Coolant-com position-warranty
Since aluminum is used in the engines, active corrosion
protection
is necessary in the coolant to help prevent corro­
sion damage ,
Use genuine
Volvo coolant, type C (blue-green) diluted
with clean water in proportions of 50/50, This mixture helps
to prevent corrosion and frost damage 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.
Capacity, , , , , , , , . , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , , , . , , . , , approx 10,7 litres (11,3 US qt)
Expansion tank
Pressure valve in cap opens at:
overpressure , , , , , , , , , , , , , , , , , , , , . , , , , , , , , , . , , . , , . , , . , , , , , , , ,
underpressure , , , . , , , , ,
.. , , . , , . , , . , , , . , , . , , . , , . , , , , , . , , , , , , , ,
Thermostat
Marking , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,
starts opening
at, , , , , , , , , , , , , . , , , . , , , , , , , , . , , , , , , , , , , , , , , , , , ,
fully open at, , , , , , , , . , , , , , . , , . , , , . , , . , , . , , . , , , , , , , , , , , . , , . , , ,
106 150
kPa
7 kPa
(21 psi)
(1 psi)

(
70019401960 Specifications
Section
2 B 6304 Engine
Group 28 Ignition System
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motronic 1.8
Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Ignition timing at 12.5 rls (750 rim). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 °
Made in Germany @
150365
150431
148680
COMPONENTS
Power stage
Bosch number. . . . . . . . . . . . . . . . . . . . . . . .. 0 227 100 203
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 367 776-0
Ign ition 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
Designation, Bosch ......................... FR 6 DC
Champion. . . . . . . . . . . . . . . . . . .
.. RC 7 YC
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 517629-6
kit number .......................... 271 427-7
Electrode gap. . . . . . . . . . . . . . . . . . . . . . . . . . 0.7-0.8 mm
(0.0276-0.0315 in)
Tightening torque,
unoiled threads . . . . . . . . . . . . . 25 Nm
(18 ft Ib)
Relay, ignition
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 3 323 592-4
Knock senso r
Bosch number ........................ 0261 231 006
Volvo part number . . . . . . . . . . . . . . . . . . . . . .. 1 367644-0
107
III 'IIt III II' III 'III III ,III III

70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Section 2 D 24, D 24 T, D 24 TIC Engines
Group 20 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 108
Group 21 Engine..... ...................... .... 109
Group 22 Lubricating system . . . . . . . . . . . . . . . . . . . . 114
Group 23
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Group 25
Intake and exhaust systems. . . . . . . . . . .. 116
Group 26
Cooling system .. . . . . . . . . . . . . . . . . . . . .. 117
Group 20 Genera l
Performance , co mpress io n r atios
Engine Market Compre
s-Output, DIN
type sion
ra tio
kWat hp at
r/s r/min
024 23:1 60/78 8214700
024T USA+Canada, Austria 1987-23:1 79/80 108/4800
106'/4800
Other
markets 23:1 80/80 109/4800
024TIC 740/760 23:1 90/80 12214800
780
23:1 95/78 129/4650
1) Horsepower 2) Ft Ib
Ge ne ra l da ta
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
6
76.5 mm
86.4 mm
2.383 dm
3 (Iitres)
1-5-3-6-2 -4
3.2
MPa (455 psi)
2.4
MPa (341 psi)
0.8 MPa (114 psi)
200 kg (440 lb.)
210
kg (463 lb .)
,/1-'"
It
t1 '
'29750
Max torque, DIN
Nm at
r/s
145/33
190/40
205/42
235/40
250/40
3.0118
in
3.4015 in
kpm at
r/min
14.8/2000
19.4/2400
140
2/2400
20.9/2500
24 .0/2400
25 .5/2400

(
70019401960 Specifications
Sect ion
2 024, 024 T, 024 TIC Engines
Cylinder head
Max. warp .......................... , ... .
Cylinder head may not be machined.
It must be replaced if warp exceeds
maximum .
Cylinder head gasket
Group 21
129146
Three different gaskets are used depending on height of piston above cylinder block.
Notches
Height of piston above
cylinder block
mm
0.67-0.80
0.81-0.90
0.91-1.02
in
0.026-0.031
0.032-0.35
0.036-0.040
@.2 mrp = 0.008 in
!:, :' 1 ' . , • t ~I
129147
Gasket
number of thickness
notches mm
in
1 * 1.4 0.055
2 1.5 0.059
3 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
Cy lind er block
Bore Marking
(honing group)
Standard .
....... , . .. , ...... , .. .... , .. , ................. 651
652
653
Oversi ze 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
Max wear (compared with specified diameter) .... , ............. .
Pistons
Max . weight deviation between pistons in
same engine .............................. , .. .
Piston float, new .......... , ...... , .. , ........ . .
max
.................. ....... , .. , .. .
Piston diameter, see cylinder bore table
Max wear (compared with specified diameter) .....
Piston diameter is measured at right-angles to gudgeon
piston
lower edge .
12 grams
0.03-0.05 mm
0.13 mm
0.04 mm
Piston diameter
mm in
76.48 3.0110
76.49 3.0114
76.50 3.0118
76.73 3.0209
76.74 3.0213
76.75 3.0216
76.98 3.0307
76.99 3 .0311
77.00 3.0315
77.48 3.0504
77.49 3.0508
77.50 3.0512
0.04
mm (0.0016 in)
0.0012 -0.0019 in
0.0051 in
0.0016 in
Cylinder bore
mm in
76.51 3.0122
76.52 3.0125
76.53 3.0130
76 .76 3.0220
76.77 3.0224
76.78 3.0228
77.01 3.0318
77. 02 3.0322
77.03 3.0326
77.51 3.0515
77.52 3.0519
77
.53 3.0523
~ 0 • + .... I
t 129835
109
,III
.' .... 1
"' ·111
'" ·111
'" ·111

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engine
Pistons rings
~~ ~L---,-C--., -L-J
• ""~,
129521
Side cleara n ce
P iston rings R in g gap
Side clearanc e
(measured with ring
Uppe r comp ress ion
mm in Lo
wer comp ress io n O il sc rape r
mm in
mm
in
on piston) new ........ .
max
....... .
0.11-0 .14
0 .2 0
.0043 -0.0055 0.07-0.10
0.008 0.2 0.0028-0
.0039 0.03-0.0 7
0.008 0.
15
0.0012-0 .0028
0 .006
Ring gap (measured
in cylinder, see
illustration) new. . . . . . . . 0 .3-0.5
max........ 1.0 0.012
-0.020
0 .040 0.3-0.5
1.0 0.012
-0.020
0.040 0.25-0
.50
1.0 0
.010-0.0197
0.040
Gudgeon (piston ) pins
Fit, in connecting rod ........................................ .
Ligh t thumb pressure (close running fit)
T humb pressure (push
fit) in piston .............................. ............. ..... .
Valv e system
Valve clea ra nces
128157
Cold engine = engine at room temperature
= intake valves
A = exhaust valves
Check/adjust valves in this order : 1-5 -3 -6-2- 4
Va lv e cleara n ces
C heck ing
Settin g
m m in
mm
Intake valve, warm engine ..... ............................... . 0 .20-0.30 0.008 -0.012
0.25
cold
engine ................ ..................... . 0.15-0 .25 0.006-0 .010 0.2 0
E xhaust valve, warm engine ............. ..................... . 0.40-0 .50 0.016-0.020 0.45
cold
engine ................ . " ................. . 0 .35-0.45 0.014-0.018
0.40
Shims, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.00 to 4.25 at intervals of 0.05 mm
(0.012 to 0.16 7 at intervals of 0.002 in)
Valves (dimensions in mm)
7,97
~r-i4--Min. 0 ,5
Int ake va lv e
130061
44 ,5 °
7,95
Exh au st valve
in
0 .010
0 .008
0 .018
0.016
129836
Note : Exhaust valves are stellite plated. Only the valve face may be ground.
110

(
70019401960 Specifications
Section 2
024, 024 T, 024 TIC Engines
Valve seats (measured in mm)
I!+ (O'O~rIOS)
I max 1,5
129843
Intak e valve sea t
Exhaust valv e seat
When
replacing valve seats: the interference between the valve seat and its bore in the cylinder head shall be 0.074-
0.105 mm (0.0029-0 .0041 in) i.e. valve seat diameter must be 0.074-0.105 mm greater than the diameter of the bore in the cylinder head .
Valve guides
Inner diameter ............... ................. .
Height above cylinder head
lower sur1ace ........ .
8.000-8.015 mm 0 .3149-0.3155 in
40.1-40.5 mm 1 .5787-1.5944 in Clearance valve stem -guide (see illustration),
new........................................ 0.3 mm
max.. ...................................... 1.3 mm
Clearance is measured with new valve and with valve
stem flush with valve guide.
/
Valve springs
Inner va lv e spring s
Length Load
33.9 mm 0 0.0118
in
0.0511 in
Outer
valve springs
Length Load
40.2 mm 0
1,3mm '-.~
115083
28.6 mm 67-77 N (15-17 .5 Ib)
18.3 mm 209-231 N (47-52.2 Ib)
32.6 mm 167-185 N (38-42 Ib)
22.3 mm 433-479N (98-108.3 Ib)
S him s (for valve clearance)
Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.00-4.25 at intervals of 0.05 mm
(0.012-0 .167 at intervals of 0 .002 in)
Timing gears
Toothed belts
Belt tension (measured with tool 5197)
Check
value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Setting
... . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Camshaft
Max. lift height , intake ....................................... .
exhaust
...................................... .
Bearing clearance, new .
..................................... .
End clearance , max. . ....................................... .
Camshaft setting
is checked by using gauge 5190
8.5 mm
9.0 mm
0.05-0.10 mm
0 .15 mm
133536
0.334 in
0.354 in
0.0019-0.0039 in
0.006 in
111
·111 1111 ·111 1111 ·111 1111 11 .... 1 III

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Crankshaft
Max1
) 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
............... .
l)Measured with two outer main bearings in V·blocks.
Main bearing journal s
Out of round, max ........................................... .
Taper, max
................................................. .
Diameter, standard .
.................................... ..... .
undersize 1 .
...................................... .
2 ....................................... .
3 ......................... .............. .
Con necting rod bearing journ als
Out of round, max ........................................... .
Taper, max
................................................. .
Diameter, standard
.......................................... .
undersize 1
....................................... .
2
....................................... .
Con necting rods
Only to be replaced in sets.
0.06 mm 0.0023 in
0.04 mm
0.07-0.18 mm
0.25 mm
0.016-0.075 mm
0.16 mm
0.0015 in
0.0027-0.0071 in
0 .0098 in
0.0006-0.0029 in
0.0062 in
0.4 mm 0.0157 in
0.12 mm
0.015-0.062 mm
0.0047 in
0 .0005-0.0024 in
0.03 mm 0.0012 in If ~ 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 t
2.2637 (2.2620-2.2627) in 57.25 (57.205-57.225) mm Out of round 115089
2.2539 (2.2521-2.2529) in
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 Taper
Side clearance on crankshaft, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm 0.0157 in Max. weight deviation between connecting rods in same engine. . . 6 grams
Flywheel
Warp, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm at 150 mm diameter
0.0019 in at 5.90 in. diameter
112