1982 VOLVO 960 lock

(
Connecting rod bearing caps (stage 1) ................ Nm (ft Ib)
(stage 2) angle-tightening ......... 0
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
Camshaft wheel. .................................... Nm (ft Ib)
Tensi oning pulley, camshaft timing belt ................ Nm (ft Ib)
Damper unit, camshaft timing belt ..................... Nm (ft Ib)
Angle pulley, camshaft timing belt ..................... Nm (ft Ib)
Water pump ........................................ Nm (ft Ib)
Pin bolts, exhaust manifold (in cylinder head) ........... Nm (ft Ib)
(to front pipe) .............. Nm (ft Ib)
Oil sump pan ....................................... Nm (ft Ib)
Plug, oil sump ...................................... Nm (ft Ib)
Oil suction line ...................................... Nm (ft Ib)
Oil cooler, connector block ........................... Nm (ft Ib)
Oil trap ............................................ Nm (ft Ib)
Nipple, oil·filter ...................................... Nm (ft Ib)
Oil pressure switch .................................. Nrn (ft Ib)
Impulse sensor ..................................... ~~m (ft Ib)
Knock sensor ....................................... Nm (ft Ib)
Temperature sensor, rear edge of top cover ............ Nm (ft Ib)
Temperature sensor, thermostat ............... ....... Nm (ft Ib)
Plug, O-adjustment tool .............................. Nm (ft Ib)
Spark plugs ... ..................................... Nm (ft Ib)
20
90
300±30
35
60 45
50
20±2
39±5
24±4
24±6
17±3
20±3
35±5
17±3
38±5
17±3
17±3
15±2.5
40±2
40±5
8±2
20±2
20±2
10±2.5
38±6
25
Group 22 Lubricating System
Genera l
Oil fill volume and type, see p. 12.
Oil pressure with warm engine and new oil filter :
at 12,5 rls (750 rim), at least ....... ................ Mpa (psi) 0.1
at
50 rls (3 000 rim), at least ....................... Mpa (psi) 0.3
max
...................... ....................... Mpa (psi) 0.5
Lubricat ing oil pump
Relief valve spring, length under various loads
unloaded
.................... ....... mm (in)
loaded to 52±4 N (5.2 kp) ....... .... mm (in)
loaded to 85±8 N (8.5 kp) ........... mm (in)
82.13
56.1
39.9
70019401960 Specifications
Section 2 B 6304 Engine
(15)
(221 ±22)
(26)
(33)
(15±1.5)
(29±4)
(18±3)
(18±4)
(13±2)
(15±2)
(26±4)
(13±2)
(28±4)
(13±2)
(13±2)
(11 ±2)
(29±1.5)
(29±4)
(6±1.5)
(15±1.5)
(15±1.5)
(7±2)
(28±4)
(18)
(14)
(43)
(71 )
(3.233) (2.21)
(1.57)
101
I ..... ' '.','
"' ,III III ill u,1

(
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 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

(
70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Tig ht enin g to rqu es
Tightening torques apply to oiled bolts and nuts. Oegreased (washed) parts should be oiled prior to assembly .
I' ~ ~ 0 8 CD 0 (IJ
#' ~ G e Q e Q GJ
128149
Tighten
sequence for cylinder head bolts
Note: Loosen the bolts in the reverse order when removing the cylinder head.
R etorquing of cylinder head bolts
Retorque after 1 000-2000 km (600-1200 miles). The en­
gine
should be cold or almost cold.
Tighten each bolt separately in correct sequence (see
above
illustration).
Tighten bolt 90°. Note: This should be done in one move ­
ment without stopping.
Bolts should not be slacken ed
first.
Crankshaft
pulley (vibration damper) Ti
g
hten cylinde r h ea d bolts in stages
Remove oil and dirt from bolt holes. Oil left in holes will
reduce the pressure on the cylinder head gasket.
Bolt threads and washers must however be oiled, other-
wise
frictional forces will be too large.
Use new bolts .
Tighten in six stages in sequence shown above
Stage 1 = 40 Nm (30 ft Ib)
2 = 60 Nm (44 ft. Ib)
3 = 75 Nm (55 ft. Ib)
4 = tighten 180°. Note: This should be done in
one movement without stopping .
5
= run engine until oil temperature is at least
+50°C (112°F).
6 = tighten 90°. Note: This should be done in one
movement without stopping
Nm
ft lb.
center bolt1) ............................... ............... . 350 258
Allen bolts ..... :: ......................................... . 20 15
Flywheel (use new bolts and locking fluid,
Volvo PIN
277 961-9) ............................... .
75
55
Camshaft gear, front
......................................... .
45
33
rear
....................................... .. . 100 74
Camshaft bearing caps .................................... .. . 20 15
Main bearing caps .......................................... .
65 48
Connecting rod bearing caps (use new nuts)
................... .
45
33
1) Tightening torque 350 Nm (258 ft. lb.) applies when using special tool 5188.
5187
G lo w plugs
Threads and bolt head contact surface to be smeared with lock­ing compound (Volvo PIN 277961-9).
If a torque wrench is used directly on the centre bolt (without 5188), the bolt must be tightened to 450 Nm (332 ft. lb.) .
PIN.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 257889-4
Tightening
torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft Ib)
113
'il IN 11 '11 11
·11 III

70019401960 Specifications
Section
2 024, 024 T, 024 TIC Engines
Group 25 Intake and exhaust systems
Turbocharger
Charge pressure
D 24 T, at 3000 rlmin (full load) ............................... .
Pressure sensor
Cut-out point, approx
.................................... .. .
D 24
TIC, at 2400 rlmin (full load) ............................. .
Overpressure safety valve, opens ........................... .
Tightening torques
Use sealing paste (PIN 1 161 035-9) on bolts below.
Mount ing 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
70-77 kPa
80-85 kPa
90-100
kPa
110-130 kPa
Nm
25
20
20
18
20
25
6
6
60
10-11 psi
11-12 psi
13-14 psi
13-18 psi
ftlb
18
15
15
13
15
18
4
4 45

(
70019401960 Specifications
Section
3 Electrical system
Group 32 Alternator
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 ................................. .
Test values
Resistance, rotor winding .................................... .
stator
..... ...................................... .
Amperage
at 14 V (min value) ................................ .
, A low range ohm meIer should be used.
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 ................................. .
Test values
Resistance, rotor winding .................................... .
stator
......................................... .. .
Amperage
at 14 V (min value) ................................ .
, A low range ohm meter should be used.
132417
55A
770W
225 rls (13500 r/min)
Clockwise
28 mm
26.8
mm
0.03 mm
0.05 mm
3-4N
5 mm
4 Nm
40 Nm
3.4-3.70
0.14-0.15 0 phase'
1.102 in
1.055 in
0.0012 in
0.0019 in
0.6-0.9Ib
0.2 in
3 ft Ib
30 ft Ib
36 A at 33.3 rls (2000 rpm)
47 A at 50 rls (3000 rpm)
52A at 66.7 rls (4000 rpm)
70A
980W
225 rls (13500 r/min)
Clockwise
28 mm
27 mm
0.03 mm
0.05 mm
3-4N
5 mm
4 Nm
35-45 Nm
3.4-3.70
approx 0.1 0 phase'
1.102 in
1.063 in
0.0012 in
0.0019 in
0.6-0.9Ib
0.2 in
3 ft Ib
30 ft Ib
46 A at 33.3 rls (2000 rpm)
58 A at 50 rls (3000 rpm)
64A at 66.7 rls (4000 rpm)
119
HI Itli til III ·111 III ·tli III ,til

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 ................................. .
Test values
Resistance rotor winding ..................................... .
stator
........................................... .
Amperage
at 14 V (min value) ................................ .
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 .................................. .
Test values
Resistance , rotor winding .................................... .
stator
........................................... .
Amperage
at 14 V (min value) ................................ .
* A low range ohm meter should be used.
120
80A
1120W
250 rls (15000 r/min)
Clockwise
28 mm
26.8
mm
0.03 mm
0.05 mm
3-4N
5 mm
4 Nm
45-55 Nm
2.9 Q
approx. 0.09 Q phase
1.102 in
1.056 in
0 .0012 in
0 .0019 in
0.6--0 .9Ib
0.2 in
3 ft Ib
33-40 ft Ib
31 A at 25 rls (1 500 rpm)
80 A at 100 rls (6000 rpm)
90A
1260W
225 rls (13500 rpm)
Clockwise
28 mm
27 mm
0.03 mm
0.05 mm
3-4N
5 mm
4 Nm
35-45 Nm
2.8-3.1
Q
0.07 -0 .08 Q*
1.102 in
1 .063 in
0.0012 in
0 .0019 in
0 .6--0.9Ib
0 .2
in
3 ft Ib
30 ft Ib
34 A at 25 rls (1 500 rpm)
60 A at 33.3 rls (2000 rpm)
90 A at 100 rls (6000 rpm)

Bosch N1 14 V 31/100 A
Max amperage ........................... .................. .
Max output ............................................. 00 •••
Max speed ........................... 0 •••••••••••••••• 0 •••••
Direction of rotation ................ ............ 0 •••••••••••••
Diameter, slip rings, new ..................................... .
min (after machining) .
................ 0 •••• •
Max permissible run-out, slip rings ........................ 0 • 0 ••
rotor body .... o •••••••••••••••••• 0 ••••
Carbon brush spring force ............................. 0 • • 0 •• •
Min length, carbon brushes .................................. .
Tightening torque, attaching screws .
.......................... .
pulley nut .......... o ••••••••••••••••• o •••••
Test values
Resistance, rotor winding .................................... .
( stator ................. 0 ••••••••••••••••••••••• • ••
Amperage at 14 V (min value) ..................... ........ .. 0 •
• A low range ohm meter should be used .
Bosch NC 14 V 60 /120 A
Volvo PiN ............ ................... 0 •••••• ••• ••••••••••
Bosch number ........................... 0 •••••••••• 0 ••••••••
Max amperage ............................................ . .
Max output
................................ 0 •••••••••••••••••
Max speed ......................................... 0" 0 •••••
Direction of rotation ................................ 0 ••• ••••••
Diameter , slip rings, new ........ . 0 ••••••••••••••••••\
••••• •••••
min (after machining) ...................... .
Max permissible run-out,
slip rings ................. 0 •••••••••••
rotor body ........................... .
Carbon brush spring force ...
........................... ..... .
Min length, carbon brushes ... 0 • •••••••••• 0 ••••••• 0' 00.00 •••••
Tightening torque, attaching screws ................. 0 ••••• 0 ••••
pulley nut ........... 0 ••••••••••• 0 •• 0 0 • 0 ••••
Test va lues
Resistance, rotor winding ................... .... 0 •• •••••••••••
stator ..................................... ...... .
Amperage
at 14 V (min value) .................. 0 ••••••••• 0 ••••
Nippon Denso 80 A
Volvo PiN ............. ..................................... .
Nippon Denso number .
................ 0 •••••• 0 ••••• 0 •••••••• •
Max amperage .............. ............................... .
Max output .................... ............................. .
Max speed ............................... 0 ••• ••••••• •••• ••••
Direction of rotation ..... 0 •••••• 0 •••••••••••••••••• 0 ••••••••••
70019401960 Specifications
Section
3 E lectrical system
100A
1400W
250 rls (15000 rpm)
Clockwise
28 mm
27 mm
0.03 mm
0.05 mm
3-4N
5 mm
4 Nm
45-55 Nm
2 .6
n
ca 0.05 n
1 .063 in
0.0012 in
0.0019 in
0 .6-0.9Ib
0.2 in
3 ft Ib
33-40 ft Ib
31 A at 25 rls (1 500 rpm)
100 A at 100 rls (6000 rpm)
3523420
0120465 006
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)
2,6 n
0,02 n
60 Avid 30 rls (1 800 r/min)
120 Avid 100 rls (6000 r/min)
1398327
100211-8370
80A
1120W
300 rls (18000 r/min)
Clockwise
121
I
III II III II III -II III oil III
j