1982 VOLVO 960 lock

70019401960 Specifications
Section'-2" B 28 Engine
Group 21 Engine block
Cylinder head
Max warp:
Maxium warp is
0.05 mm (0.002 in) per
100 mm (4 in) length.
Note: Do not level a warped cylinder head,
replace it!
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)
..................................... .
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--0.23 mm
0.16-0.23 mm
6 grams
0.020-0.040 mm
90.970-90.980 mm
90.980-90.990 mm
90.990-91.000 mm
3.5826-3.5830 in
3.5830-3.5835 in
5.5835-5.5838 in
0.0055-0.0091 in
0.0063-0.0091 in
0.0007-0. 0015 in
3.5814-:3.5818 in
3.5818-3.5822 in
3.5822-3.5826 in
((0)) t
'" ~L-f
Piston diameter is measured at right-angles to gudgeon pin bore, S mm from bottom edge.
135676
Piston rings
/,
I 111111111 ~III
'--J 115085
Side clearance (measured with ring on piston) ............... mm
in
Ring gap when checked in 91 mm (3.5826 in) cylinder,
Ring gap measured 15 mm
(0.6 in) from lower edge of
cylinder
U 129520 pper
compression
ring
0.045-0.074
0.0017-0.0029
Lower Oil ring
compression
ring
0.025-0.054 0.009--0.233
0.0009--0.0212 0.0003-0.0091
(see fig) ................................................. mm 0.40-0.60 0.40-0.60 0.40-1.45
in 0.0157-0.0236 0.0157-0.0236 0.0157-0.0570 Gudgeon (piston) pins
Clearance in connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.041 mm
piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.010-0.016 mm
70 0.0007-0.0016
in
0.0003-0.0006 in

(
70019401960 Specifications
Section
2 B 28 Engine
V alve s yste m
Valve clearance
Inlet valves, cold engine ................................. .... .
warm engine ...
................................. :
Exhaust valves, cold engine ..... ................ ............. .
warm engine
................................. .
V alves (sizes in mm)
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
7,975-7,990 7,965-7,980
44
Valve seats
Seat for inlet
valve Inlet
valve
Venturi seat: 15° and 60° angles can be
used to reduce seat width.
Exhaust valve
,
I:i~~' 13 0021
Seat for exhaust valve
When replacing valve seats: the interference between the valve seat and its bore in' the cylinder head shall be 0 .070-0.134 mm (0.0028-0.0053 in), i.e. valve seat diameter must be 0.070-0.134 mm greater than the diameter of the bore in the cylinder head.
Valve seats are available in three oversizes .
Valve guide s
Inner diameter ................. ............................. .
Press -in measurement to cylinder head contact surface against
block:
inlet
............................................... ...... .
exhaust ..
............... ................................. .
Clearance in cylinder head ............. ...................... .
8 .000-8.022 mm
39.5-40.5 mm
36.9-37.9 mm
0.052-0.095 mm
0 .3149-0.3158 in
1.5551-1 .5944 in
1.4527-1.4921 in
0.0020-0. 0037 in
129851
71

70019401960 Specifications
Section
2 B 28 Engine
Distributor
Eng ine type Ignit ion system Distributor
Volvo P IN Bosch No
B28A, B28E TSZ-4 1269191 0237402013
B28F TSZ-4 1269380 0237402017
B28A, E B28F
Bosch number ............... ............................... . 0237402013 0237402017
Volv o PIN ................................................... . 1
269 191 1 269380
Direction of rotat ion ............................ ... .......... . Clockwise
Clockwise
Resistance of impulse sender coil, [2 .........•................. 540-660
540-660
Air gap, rotor -stator , min ............. ...................... . 0.3 mm 0.3 mm
Centrifugal governor
Advance, total, degrees (distributor) ........ ................... .
Advance
begi ns at distrib. rev/sees ............................ .
distrib. rev/min
............................. .
Data:
5 ° at distr ib. rev/sees .............................. _ ... .
'III 13±1
11±1 '" III 7.fr-9.6 8.fr-10 ttl
(450-575)
(500-600) :':':': 12.fr-15.4 12.4-15.3 I'NI
(distrib. rev/min) ................................. . (750-925)
(740-920)
10° at distrib. rev/sees .................................. . 23.3-32.5 30-50
(distrib. rev/min)
................................. . (1400-1950)
(1800-3000)
Advance max at distrib . rev/sees ... .......................... . 40 33 .3
(distrib. rev/min)
............ ................. . (2400)
(2000)
Vacuum governor
Control direction ............................................ . Positive
Positive
Contro l, total
degrees (distributor) ............................. . 7,5±1 10±1
Control
commences at mm Hg ............................... . 160-210 10fr-135
Data: 2° at mm Hg ......................................... . . 200-240 11 fr-145
max control at mm Hg .................................. . 300 210
Ignition advance
60-~O , I
I I
I I I I ,. I
I I
I , .tls 0 500 1000 1500 2000 2500 3000 3500 4000 r min
~ !=ttl-It ~~ 30' 15'
.,r~'
1 G~ 2,0. 3.0 , 4,0 , 5,0 I 6,0~~, 40~ 2Cf~ 50~ l~OO 1500 2000 2500 3000 3500 4000 rjmin
20' 10 + ~ IT , 1{,llrD ,I=±' -~ --+;r -IT ~I -' I=l=l-~ I 1-
f:=:t 17/ 1-,+-1 ~ -+
ffi rtt~ . -I-t--
Mo237 402 013 +r
0 ' cf'
- 10 ' -s
0' if
-10' -s 0237402017 -20' -10
0 10 20 30 40 50 60 kpa I I
I I I I I I I I I 0 100 200 300 400 mmHg o 10 20 30 40 50 60 kpa iii i I Iii a 100 200 JOD 400 mm Hg 135969 135356 B28A, B28E B28F
85

(
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
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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)

(
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 6304 Engine
Section 2 B 6304 Engine
Group 20 General.... . . . . . . . . . . . . . . . . . . . . . . . . .. 98
Group 21 Engine............................... 98
Group
22 Lubricating System. . . . . . . . . . . . . . . . . . .. 101
Group 23 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . .. 102
Group 26 Cooling system . . . . . . . . . . . . . . . . . . . . . .. 106
Group 28 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . 107
Group 20 General
Performance , compression ratios, octane requirements
Engine Notes Compres-Octane
Output
type sion
requirement
Ratio
RON· kWat hp at Nm at
rls rim
rls
B6304F 10,71
) 95 150/100 204/6000 267172
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 .
Other general data
Number of cylinders ......................................... .
Bore .
.................................................... .. .
Stroke .......................................... .......... . .
Displacement ......................... ................ ...... .
Firing order
............................................... .. .
Compression
(normal rating) 1) • ••••• ••••••••••••••••• •.••••••.•
Weight, approx ............................................. .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 rIm)
6
83.00 mm (3.268 in)
90 .00 mm (3.543 in)
2.922 dm3 (Iitres)
1-5 -3-6-2 -4
1 .3-1 .5 MPa (184-213 psi)
180 kg (397 Ib)
Group 21 Engine Block
Cylinder head
Max torque
kpm at
rim
27.214300
Height, new ............................... ........... mm (in) 129 .00±0.05
Max machining .............. ......................... mm (in) 0.3
(5.0787±0.0020)
(0.0012)
Max warp:
along ......... .... ................................. mm (in) 0.020
across .................................. ...... ..... mm (in) 0 .008
98

(
Cylinder block
Bore
Standard (marked C)
........................... ....... mm (in)
(marked
D) ........... ....................... mm (in)
(marked
E) .................................. mm (in)
(marked
G) ................... . .............. mm (in)
Rebore if wear exceeds 0.1 mm and oil consumption is abnormally high.
Pistons
Piston diameter
Diameter to be measured at right
angles to gudgeon pin and
16 mm from bottom of piston.
Standard (marked C)
.................................. mm (in)
(marked
D): ................................ . mm (in)
(marked
E) .. , ........................ ....... mm (in)
(marked
G) ............ ...................... mm (in)
Piston weight
.......................................... g (oz)
Max weight difference between pistons in same engine
......... g
Piston rings
Axial clearance in piston groove ............................ mm
in
Ring gap (measured in cylinder, bore 83.00 mm) ............. mm ? in
Gudgeon (P iston ) pins
Fit in connecting rod ......................................... .
in piston
................................................ .
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)
Valve Seats
Diameter standard .................................... mm (in)
oversize
.... ................................ mm (in)
Matching surface
angle .......................... ............ 0
Reduction angle, upper ...................................... 0
lower ................. ....... .............. 0
Width ...................................... ... ...... mm (in)
70019401960 Specifications
Section 2 B 6304 Engine
83.00-83.01
83.01-83 .02
83.02-83.03
83.04-83.05
82.98--82.99
82.99--83.00
83.00-83.01
83.02 -83.03
350
± 5
10
(3.2677-3 .2681 )
(3.2681-3.2685)
(3.2685-3 .2689)
(3.2693-3.2697)
(3.2669--3.26 7
3)
(3.2673-3.2677)
(3.2677-3.
2681 )
(3.2685-3.2689)
(12.5 ±
0.2)
(0.4)
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
ring s
0.02-0.055
0.0008 -0.0022
0.25-0.5
0.009--0 .020
Light thumb pressure (close running fit)
Thumb pressure (push fit)
104.05±0.18
103.30±0.18
45.5
1.5
1.2
0 .4 (4
.
096±0.007)
(4.067±0. 007)
(0.059)
(0.047)
(0.016)
inl et exhaust
32.61 (1.284) 28.61 (1.126)
33.11
(1.304) 29 .11 (1.146)
45.25 45.25
20.25 15.25
60.25 60.25
1.4-1.8 (0.055-0.071) 1.8--2.2 (0.071-0.087)
99
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