1982 VOLVO 960 check engine

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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70019401960 Specifications
Section
2 B 19, B 23 Engines
P iston rings
129521
Clearance In piston groove
Clearance in piston groove
819 E, 819 ET, 823 E .................................. mm
(in)
823ET, 823FT .............. .......................... mm
(in)
Ring gap (see above)
819E, 819ET, 823E .................................. mm
(in)
823ET, 823FT ................ .......... .............. mm
Gudgeon (Piston ) pins
Fit, in connecting rod. . . . . .. Light thumb pressure
(close running fit)
in piston. . . . . . . . . . . . . .. Thumb pressure (push fit)
Valves
Valve clearance
Inlet
and exhaust valves
(in)
cold engine ............................................ mm
(in) warm engine ........................................... mm
(in)
Adjusting shim, thickness .................................. mm
(in)
Valves
Upper
Camp.
rings
0.040-0 .072
(0. 0016-0.0028)
0.060-0 .092
(0.0024-0.0036)
0 .35-0.65
(0.0014 -0 .0026)
0.40-0 .
65
(0.0158-0.0256)
Checking
0.30-0.40
(0.012-0.Q16)
0.35-0.45
(0.014-0.018)
3 .
30-4.50
Ring gap 129 520
Lower Oil scraper
Camp.
rings rings
0.040-0.072 0.030-0.062
(0.0016 -0 .0028) (0.0012 -0.0024)
0.040-0.072 0.030-0.065
(0.0016-0.0028) (0.0018-0.0026)
0.35-0.55 0.25-0.60
(0.0014-0.0022) (0.0010-0.0024)
0.40-0.65 0.30-0.60
(0.0016-0.0256) (0.0118-0.0236)
'Adjusting
0.35-0.40
(0. 014-0 .016)
0.40-0.45
(0. 016-0.018)
(0.1300-0 .1773)
in increments of
0.05 (0.002)
IMPORTANT: Valves are stellite-flashed and must not be machined . They may only be ground in against seat. IMPORTANT! Scrapping valves. Exhaust valves in turbo en­gines are sodium filled and must not be mixed with ordinary
scrap iron without first removing the sodium.
Min: 7,935
Inlet valve
44,5°
44,5 °
Min: 7,945
144027
Exhaust valve turbo engines (8 19 ET, 823 ET/FT)
Exhaust valve E-engines (8 19 E, 823 E)
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70019401960 Specifications
Section 2 B 19, B 23 Engines
Timin g gears
Camshaft Letter stamped on
end ot camshaft
Engine type Camshaft
Check valves (cold engine)
Marking Max
lift height mm (in) Valve clearance
No.1 intake
valve mm (in)
B
19E A 10.5 (0.4137) 0.7 (0.0276)
B19ET T 9.9 (0.3901)
0.7 (0.0276)
B23E A 10.5 (0.4137) 0.7 (0.0276)
B23ET B 10.6 (0.4176) 0.7 (0.0276)
B23FT T 9.9 (0.3901)
0.7 (0.0276)
Radial clearance
............................................ 0.030-0 .071
max... . .... ... ............................... 0.15
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1-0.4
Int ermed iate shaft
Intake valve should
open at
13° B.T.D.C
4° B.T.D.C
13° B.TD.C
19° B.TD.C
4° B.iD.C
(0.0012-0 .0028)
(0.0012-0.0028)
(0.0344-0.0158)
Radial clearance.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.075 (0.0008-0.0030)
Axial clearance .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20-0.46 (0.0079-0.0181)
Crankshaft assembly
Crankshaft
Max out-ot-true .............................. mm (in)
Axial clearance, max ......................... mm (in)
Radial clearance (main bearings) .............. mm (in)
Connecting
rod bearings,
axial clearance ............................. mm (in)
radial clearance ............................ mm (in)
Main bearing journals
Out-oft-round, max ........................... mm (in)
Taper, max
.................................. mm (in)
Diameter, Standard .
.......................... mm (in)
undersize 1
........................ mm (in)
2 .
................ ....... mm (in)
Connecting rod bear ing journ als
Out-ot- round max ............................ mm (in)
Taper, max
.................................. mm (in)
Diameter, standard
........................... mm (in)
undersize 1
........................ mm (in)
2 ........................ mm (in)
Connecting rods
0.05 (0.0020)
0.25 (0.098)
0 :028-0.083 (0.0011-0.0033)
0.15-0.35 (0.0059-0.0138)
0 .024-0.070 (0.0009-0.0028)
0.07 (0.0028)
0.05 (0.0020)
63.451-63.464 (2.5000-2.5005)
63.197-63.210 (2.4900-2.4905)
62.943-62.956 (2.4800-2.4805)
0.05 (0.020)
0.05 (0.020)
53.987-54.000
(2.1271-2.1276)
53.733-53.746 (2.1171-2.1176)
53.479-53.492
(2.1071-2.1076)
Axial clearance
at crankshaft .................. mm (in) 0.15-0.35 (0.0059-0.0138)
Max weight deviation between connecting rods
in same engine 10 gms
Flywheel
Axial throw, max ............................. mm (in) 0.02 mm/100 mm
(0.0008/3.94 in diameter)
Taper
Out-of-round
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70019401960 Specifications
Section 2 B 19, B 23 Engines
Group 23 Fuel system
CO-content , idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or
idle speed
• CO should be checked/adjusted when engine 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
Engine Rem ar ks CO co ntent Id le spee d
type r/s (r/m in)
CO m ete r % Volv o
Adjusting Mono tes te r
(checking)
8 19E 1.0 (0.5-2.0) -15 .0 (900)
819ET 2.0 (1.0--3.0) -15.0 (900)
823E 1.0 (0.5-2.0) 1 -15 .0 (900)
823ET 1.5 (1.0--2 .5) -14.2 (850)
823FT USA + Canada 0.6 (0.4-0
.8f 20--70°3 12.5 (75W
Japan 0.6
(0.4-0.8)2 20--70°3 15.0 (900)
I) Pulsai r system disconnected and plugged. 2) Lambda-sond disconnected. 3) Lambda -sond connected . 4) AC switched off. Engine speed increases to 15.0 rls (900 r/min) when AC is reconnected.
Page CI system (819 ElE T, 823 E ). . . . . . . . . . . . . . . . . .. 22
Motronic
(823 ET) ... ......................... 25
LH -Jetronic
(823 FT) . . . . . . . . . . . . . . . . . . . . . . . . .. 28
. ~
135528
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70019401960 Specifications
Section 2 B 19, B 23 Engines
Group 25 Intake and Exhaust systems
Turbocharged engines
En gin e type ................................... B 19ET B23ET
C harge pressure, at full load .............. rlmin 3500
3500
checking ............ kPa (psi) 60-70 (8.5-10.0) 45-53 (6.4-7.5)
adjusting ............ kPa (psi) 64-70 (9. 1-10.0)
50 (7.1)
Charge air overpressure,
switch, opens at ...................... kPa (psi) 85-95 (12.1-13.5) 65-75 (9.2-10.7)
Charge air pressure, switch, closes at .. kPa (psi) -15-25 (2.1-3.6)
Tighten ing torque data
4)
1) Apply sealer (PIN 1161053-2). 2) Use new nuts.
3) Use sealer (PIN 1 161 035-9).
4) Use new bolts . (Old bolts can if absolutely necessary be reused if they
are smeared with sealer PIN 1161053·2).
Mounting bolts, turbocharg er - ex hau st m anifold
•
Measure length of bolt. Bolts can be reused if shorter
than
89 mm.
• Apply assembly paste PIN 1 161 078-9 to mating sur­
faces and threads
• Fit new locking plates
•
Tighten bolts in three stages according to below
Stage I = 1 Nm (0.7 ft Ib)
II = 45 Nm (32.5 ft Ib)
III = 45 ° in one movement without stopping
89mm
135780
sfJ
Nm
45Nm 45·
B23FT
3000
46-54 (615-717)
48-54 (6.8-7.7)
85-95 (12.1-13.5)
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Piston rings
129521
Axial clearance
Side clearance measured with ring on piston 8200 ........... mm
(in)
8204 ........... mm
(in)
8230/234 ....... mm (in)
Ring gap (checked
in 88.9, 96.0 mm bore) 8200/204 ........ mm (in) 8230/234 ........ mm
Gudgeon (Piston) pins
Fit, in connecting rod. . . . . .. Light thumb pressure
(close running fit) (in)
in piston.
. . . . . . . . . . . . .. Thumb pressure (push fit)
Cylinder head-
Height, new ............................... mm
(in)
after machining
..................... mm
(in)
• Max machining 0.3 mm
B204/234
103.5
(4.078)
102.7*
(4.078)
Max warp .......................................... .
NOTE: If warp is greater than 1.0 mm (0.0394 in) length­
wise or 0.5 mm (0.0197 in) crosswise, cylinder head must
be replaced.
Valve clearance
B200/230
Inlet and exhaust valves
cold
engine ............................................ mm
(in)
warm engine
........................................... mm
(in)
70019401960 Specifications
Section 2 B 200, B 230 Engines
Upp er Compo rings 0.060-0.092
(0.0024-0.0036)
0.040-0.072 (0.0016-0.0028)
0.060-0.092 (0.0024-0.0036)
0.30-0.50
(0.0118--0.0236)
0.30-0.55
(0.0118--0.0217)
B200/230
146.1
(5.756)
145.6
(5.737)
Checking
0.30-0.40 (0.012-0.Q16)
0.35--0.45 (0.014-0.018)
Lower Compo rings 0.030-0.062 (0.0012-0.0024)
0.030-0.062 (0.012-0.0024)
0.040-0.072 (0.0016-0.0028)
0 .30-0.55
(0.0118--0.0217)
0.30-0.55
(0.0118--0.0217)
Adjusting
0.35--0.40
(0.014-0.016)
0.40-0.45 (0.016-0.018)
Ring gap 129520 Oil scraper rings 0.020-0.055
(0.0008--0.0022)
0.020-0.050 (0.008--0.0019)
0.030-0.065 (0.0012-0.0026)
0.20-0.50 (0.0098--0.0197)
0.30-0.65 (0.0118--0.0256)
max o 25mm
129 826
Adjusting shim, thickness .............................. mm (in) 3.30-4.50 (0.1300-0.1773)
in increments of 0.05 (0.002)
Valve stem, B 204/234
Valve stem height . . . . . . . . . . . . . . . . . . .. 49.4±0.04 mm
(measured with gauge 5222) . . . . . . . . .. 1.946±0.002 in
Note: Valve stem height must be as specified. Otherwise
tappets will not function properly.
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70019401960 Specifications
Section 2 B 200, B 230 Engines
Camshaft belt, sp ring s, B 204/234
144B!Hi
Balanc e shaf ts , B 204 /234
Length
75.6 mm (2.979 in)
65.0 mm (2.561 in)
52.0 mm (2.049 in)
Axial clearance. . . . .. 0.06-0.19 mm (0.0024-0.0075 in)
Belt tension, B 204/ 234
Camshaft belt
Coolant
Checking limits ' Used belt New belt
temp.
20°C < 2 .5 or > 3.5 3.2±0.3 3.8±0.3
40°C < 3.2 or > 4.2 3.9±0.3 4.4±0.3
8rC < 4.6 or > 5.3 5
.1 ±0.2 5 .5±0.2
• Carry out at 10,000 km (6,000 miles) after belt replacement.
< = less than
> = more than
Crankshaft assembly ,/
Cranksh aft
Max out-at -true .................................. ..... mm (in)
Axial clearance, max .................................. mm (in)
Radial clearance (main bearings) early type ............. mm (in)
late type ............... mm (in)
Connecting rod bearings, radial clearance ............... mm (in)
Main bearing journals
Out-at-round , max ................................ .... mm (in)
Taper, max
........................................... mm (in)
Early type
Diameter , standard ............. mm (in) 55 (2.1574)
54.75 (2.1572)
54.50 (2. 1473)
undersize
1
.......... mm (in)
2 .......... mm (in)
Connecting rod bearing journa ls
Out-at-round max ..................................... mm (in)
Taper, max .
.......................................... mm (in)
Diameter, standard .
............ , ...................... mm (in)
mm (in)
40
undersize 1 ................................. mm (in)
mm (in)
2 ................. ................ mm (in)
mm (in)
Load
o
153 N
340 N
Balance shaft belt
Used belt New belt
3.4±0.2 3.8±0.2
4.0±0.2 4.3±0.2
4.7±0.2 4.9±0.2
0 .040 (0.0016)
0.080-0 .270 (0.0032-0.0106)
0 .
024-0.072 (0.0009--0 .0028)
0.024-0.064 (0.0009--0.0025)
0.023-0.067
(0. 0009--0.0026)
0.006 (0.0002)
0.006 (0.0002)
Late type
63 (62.987-63 .000) mm
62.75 (62.737-62.750) mm
62.50 (62.487-62.500) mm
t
Taper
0.025(0.0010) f ~
0.025 (0.0010) ) 49.00 (1.9306)
48.984-49.005
(1.9300-1.9308)
48.75 (1.9207)
8.734-48.755 (1.9208-1.9209)
115 089
48.50 (1.9109) Out-ot-round
48.484-48.505 (1.9103-1.9111)

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70019401960 SpecHications
Section
2 B 200, B 230 Engines
Group 23 Fuel system
Petrol/gasoline engines . CO content, idle speed
• Selector lever must be in position P (and handbrake applied) when checking/adjusting CO or id-
le.speed
•
CO should be checked/adjusted when engine 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
Engine Remarks
type Co-meter % Setting
B200K 1
.5
B200E 1.0
B200F not adjustable -
B200ET 1.5
B204E 0 .8
B204FT not adjustable -
B204GT not adjustable (1990) -
B230A 2.0
B230K Switzerland -1986 1 .5 Other markets -1986 1.0 1987-1.0
B230 E 1
.0
B230ET Scandinavia , Switzerland, I Australia 1.54
)
Other markets 1.0
B230F Japan -1988 0.6
Other markets -1988 0 .6 1989-not adjustable -
B230FB not adjustable -
B230FT Japan -1988 0.6
Other markets -1989 0 .6 1990-not adjustable -
B230GT (1990 not
adjustable) 1.0
B234F not adjustable -
B234G 0.8
I) Pulsair system disconnected and plugged, as applicable 2) Connected Lambdasond . Measured in front of catalytic con­verter . 3) Disconnected Lambdasond . Measured in front of catalytic con-
verter 4) 1988-only for 760 with manual gearbox . 5) 1990, connected Lambdasond. 6) AC switched off. Idle speed should rise to 15.0 r ls (900 rpm) when AC is switched on again
CO leveP
Idle speed
Volvo rls (r/min)
Checking Mono Tester
Manual Automatic
1.0-2
.5 15.0 (900)
0 .5-2.0
15.0 (900)
0.4-0.8
2 ) 12.9 (775)
1.0-2.5 15.0 (900)
0.6-1.0 15.0 (900)
0.4-0 .8
2
) 13.3 (800)
0.4-0.8
5 ) 13.3 (800)
1.5-3 .0 15.0 (900)
1 .
0-2.5 13.3 (800) 15. 0 (900)
0 .5-2.0 13.3 (800) 15. 0 (900)
0.5-1 .5 13.3 (800) 15. 0 (900)
0.5-2.0 15.0
(900)
1.0-2.54
) 15.0 (900)
0 .5-2.0 15.0 (900)
0 .4-0.8
3
) 20-7004
) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0 .82
) 12.9 (775)
0.4-0 .82
) 12.9 (775)
0.4-0.83
) 20-7004 ) 15.0 (900)
0 .4-0.83
) 20-7004 ) 12.5 (750)6) 0.4-0.82
) 12.5 (750)
0 .
5-2.05
) 12.5 (750)
0
.4-0.82 ) 14.2 (850)
0 .5-1.1
14.2 (850)
Page
Carburetted engines
(8200 K, 8230 NK) .. ....... 44
CI-system (8200/230 E) ........................ 48
Motronic (8200/2 30 ET) ...... ... .. .. .......... . 51
Constant idle speed system (8200/230 ET) ....... 54
LH-Jetronic (8200/230 F/FT/GT) ................. 55
Regina (8230 F USA) .......................... 58
LH-Jetronic 2.4
(8204 E, 8204 GT, 8204 FT, B 234 F/G) .. ........ 61
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