1982 VOLVO 960 gearbox

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70019401960 Specifications
Section 0 General
General data
740
Section 0 General
Modell Designation
Chassis number Engine type Gearbox
year 744 745
1984 E 33720-819E,819ET, AW70, AW71,
81679" 823E,024 M46, M47,
ZF4HP22
1985 F
81680-1-6969 8200K,8200E, AW70, AW71,
215754 " 8200 ET, 8230 A, M46, M47,
8230E,8230F, ZF4H22
8230 K, 8230 ET,
8230 FT, 024, 024 T
1986 G
1-90199 6970-8200K,8200E, AW70, AW71,
62099 8200 ET, 8230 A, M46, M47,
8230E,8230F, ZF4HP22
8230 K, 8230 ET,
8230FT, 024, 024 T
-1987 H 90200-62100-8200K,8200E,
AW70, AW71,
190699 116099 8200 ET, 8230 E, M46, M47
8230 ET, 8230 F, ZF4HP22
8230 FT, 8230 K,
024,024 T, 024 TIC
1988 J 190700-116100-8200K,8200E, AW70, AW71,
294099 176799 8200 ET, 8230 E, M46, M47,
8230 ET, 8230 F, ZF4HP22
8230 FT, 8230 K,
024,024 T, 024 TIC
1989 K"" 294100-176800-8200 K, 8200 E, AW 70, AW 71, AW 72,
France: 396999 242699
8200ET, 8204 E, 8230E, M46, M47,
o (zero) 8230 ET, 8230 F
ZF4HP22
8230 FT, 8234 F, 8230 K
024, 024T, 024TIC
1990 L 397000- 242700-8200E, 8200F, 8204E, AW 70, AW 71, AW 72,
France: 499199
316299 8204GT, 8230E, 8230F, M46, M47,
o (zero) 8230 FT, 8230 GT, ZF4HP22
8234 F, 8230 K
024,024 T, 024 TIC
1991 M 499200- 316300-8200E,8200F, AW70, AW71,
France:
8200 FT, 8230 E, 8230 F ,
M46, M47,
o (zero) 8230 F8, 8230 FT, ZF4HP22
024,024 T, 024 TIC
* 744 and 764 models from 1984 and 1985 were grouped in same chassis number series. ** Sweden : K from chassis number 3422551208548.
2
Final drive
ratio
3.54:1, 3.73:1
3.91 :1
3.31 :1, 3.54:1
3.73 :
1, 3.91:1
3.31:1, 3.54:1
3.73:1,3.91 :1
4.10:1
3.31:1, 3.54:1
3.73:1, 3.91:1
4.10:1
3.31 :1, 3.54:1,
3.73:1, 3.91:1,
4.10:1
3.31:1, 3.54:1,
3 .73:1,
3.91:1,
4.10: 1
3.31 :1, 3.54:1 ,
3 .
73:1, 3 .91:1,
4 .10:1 (
3.31 :1, 3.54:1,
3 .73:1, 3.91:1,
4.10:1

70019401960 Specifications
760
Model Designation Chassis
number Engine type Gearbox
year 764 765
1982 C 1-3799 B28E AW71, M46
1983 D 3800-B28A, B28E, B28F, AW71, BW55
33719 D24T, B23ET M46
1984 E 33720-B28A, B28E, B28F, AW71, BW55,
81679" D24T, B23ET M 46 , ZF4HP22
1985 F
81680-1-999 B
28 A, B 28 E, B 28 F, AW71, M46,
215754" B 230 K, B 230 ET, M 47, ZF4HP22
B
230 FT, D 24 T
1986 G
1-16999 1000-B28A, B28E, B28F, AW71, M46,
8499 B
230 K, B 230 ET, M 47, ZF4HP22
B
230 FT, D 24 T
1987 H
17000-8500-B 230 K, B 230 ET, AW71, M46,
37399 16299 B
230 FT, B 280 E, M47,
ZF4HP22
B280F, D24T, D24TIC
1988 J 37400-16300-B 230 ET, B 230 FT, AW71, M46,
58499 23499
B280E, B280F, D24TIC M47,
ZF4HP22
1989
K"" 58500-23500-B 230 ET, B 230 FT, AW71, M46,
France: 76899
31119
B280E, B280F, D24TIC ZF4HP22
o (zero)
1990 L 76900-31200-B 230 FT, B 230 GT AW71, M46,
France:
B280E, B280F, D24TIC ZF4HP22
o (zero)
• 744 and 746 models from 1984 and 1985 were grouped in the same chassis number series . .. Sweden: K from chassis number 67303/27155.
780
Model Designation Chassis number Engine type Gearbox
year
1986
G 1-1199 D24TIC M46
1987 H 1200-3299 B 200 ET, B 280 E
M46, AW71
B280 F, D24 TIC
1988 J 3300-6499 B 200 ET, B 280 E, M46, AW71
B280F, D24TIC
1989 K" 6500-8999 B 230 FT, B 280 F, M46, AW71
France :
D24TIC
o (zero)
1990 L 9000-11299 B 230 FT, B 280 F, M46, AW71
France:
D24TIC
o (zero)
1991 M 11300-B 230 FT, B 280 F AW71
• Sweden: K from chassis number 7509.
Section 0 General
Final drive ratio
3.31 :1, 3.54:1
3.31 :1, 3.54 :1
3.31 :1, 3.54:1
3.73:1, 3.91:1
3.54:1 , 3.73:1
3 .
91 :1
3.54 :1, 3.73:1
3 .
91 :1
3.54 :1, 3.73:1
3.91 :1
3.54:1, 3.73:1,
3 .
91 :1
3.54:1, 3.73:1,
3.91 :1
3.54:1, 3.73:
1,
3.91 :1
Final drive
ratio
3.54:1
3.54 :
1, 3.73:1
3.91 :1
3.54:1, 3.73:1,
3.91 :1
3 .54:1, 3.73:1
3.54:1, 3.73:1
3.73 :1
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70019401960 Specifications
Section 0 General
940
Model Desig natio n C
hass is num ber Engine ty pe
Gearbox Fina l driv e
y ea r 944 945 r
a tio
1991 M 1- 1-B200E, B200F, M46, M47, AW70, 3.54 :1, 3.73 :1
France: B200FT, B204
E, B230E, AW 71, ZF4HP22
3.91:1,4.10 :1
o ( z ero) B
230 FB, B 230 FT,
B230GT, B234F, B234 G ,
D24, D24 T, D24 TIC
960
Mode l Designat io n Chass
is nu mbe r Engine type
Gearbox Final d riv e
y ear 964 965 ra tio
1991 M 1-1-
B 204 FT, B 230 GT, M46, AW71,
3.54:1, 3.73:1
France : B
230 FT, B 280 E, B 280 F, AW30-- 43 3.91 :1
o ( z ero) B
6304 F, D 24 TIC
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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 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
Itt liN
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70019401960 Specifications
Section 2 B 200, B 230 Engines
Section 2 B 200, B 230 Engines
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Group 21 Engine block ........................... 32
Group
22 Lubricating system ....................... 38
Group
23 Fuel system ......... ................ .. 39
Group
25 Intake and exhaust systems. . . . . . . . . . . .. 60
Group 26 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .. 62
Group
28 Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 63
..... 1/
j. Group 20 General
Performance , compression ratio, octane requirements
Engine Remarks Compres-
type slon ratio
B200K Europe, manual 10.0 automatic 10.0 Overseas
8.5
B200 E 10
.0
B200 F 1990 10.0 1991 10.0
B200ET 8.5
B204
E 9.7
B204FT / 8.2
B204GT 8.2
B230A Scandinavia 10 .3
B230K -1986 Europe 10.3 Overseas 9.0 1987-10.5
B230 E 10.3
B230ET 9
.0
B230 F USA, Canada 9
.8 Other markets 9.8
B230FB 9.3
B230 FT USA , Canada, Japan -1989 8.7 Other markets -1989 8 .7
USA, Canada 1990-8.7 Other markets 1990-8.7
B230GT 8.7
B234F USA, Canada 10.0
B234 F IG Other markets 10.0
LH-drive, man gearbox -1989 10.0
11 Unleaded fuel can also be used . 21 Unleaded fuel only. 91 octane unleaded fuel can be used. 31 Horse power. 41 Ft lb.
•
RON stands for Resea rch Octane Number, and is a measure of
the ability of a fuel to withstand knocking. MON stands for Motor Octane Number and is another way of
measuring the same property.
(R+M)/2,
also called AKI (Anti Knock Index) combines these two
m eas urem ents .
95
RON is equivalent to 91 (R+M)/2. 91 RON i s equivalent to 87 (R+M) /2.
Octane Output Max torque require-ment kWat hp at Nm at RON" rls
r/min rls
98 76/90
103/5400 165/45 98 78/90 106/5400 170/45 93 74/90 100/5400 165/45
95 1
.
71 89/95 121/5700 158/80
9521 80/98 110/5900 155/48 9521 82/95 11115700 158/57
98
118/92 160/5500 245/58
9511 102/100 139/6000 181/80
952
) 140/88 190/5300 280/49
9511 147188 200/5300 290/49
98 82/83 112/5000 192/42
98 84/87
114/5200 192/42 9311 80/87 109/5200 185/42 9511 86/87 117/5200 194/42
95 1
.
71 96/92 131/5500 190/55
98 134/97 182/5800 260/57
9521 85/90 11431/5400 183/4251
9521 85/90 116/5400 183/4251
9521 96/92 130/5500 185/49
9521 119/88 16031/5300 253/48 9521 115/80 156/4800 242/55 9521 121180 16231/4800 264/57 9521 121/80 165/4800 264/57
9511 125/80 170/4800 265/57
9521 114/95 15331/57 00
203/75
952
.81 114/95 155 /5700 203/75
9521 117/97 159/5800 210/74
51 With Regina-Re x I: 182/42 .
61 With Regina-Rex I: 134/2500 and 18.6/ 2500 . 71_1986: 98 octane .
81 B 234 G: Leaded fuel can be used .
~ ""
129750
kpm at r/min
16.8/2700
17.3/2700
16 .8/2700
16 .1/4800
15 .8/2900
16.1/2800
25 .0/3500
18.4/4800
28 .5/2950
29 .6/2950
19 .6 /2500
19.6/2500 18 .9 /2500 19 .8/2500
19.4/3300
26.5/3400 135
41/250061
18.7/250061
18 .9/2950
18rl/2900
24.7/3300
19541/3450 26 .9 /34 50
27.0/3450
150
41/ 4450
20 .7/4450 21.4/4450
35
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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
43
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General
024
Capacity: with manual
gearbox ......... litres (US qts) 9.5
(9.9)
with
aut.
gearbox ......... litres (US qts) 9.2
(9.7)
70019401960 Specifications
Section 2 024, 024 T, 024 TIC Engines
Group 26 Cooling system
128187
024T 024TIC
11.0 11.5
(11.6) (12
.
2)
10.0 11.5
(10.6) (12.2)
Coolant
Since aluminium 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.
• Never top-up the cooling system with water alone . Use
genuine
Volvo coolant diluted with clean water in propor­
tions of 50/50.
•
The coolant should be changed every 25,000 miles
(40,000
km) since the corrosion-protective additives in
the coolant lose their effect in time.
• Clean cooling system with solvent (P/N 1 161 328-8)
prior to
filling new coolant.
• If tropic type radiator is filled add 0.6 (0.6) to above.
Important: do not operate engine if cooling system is not topped-up. Failure to observe this may cause high local tem­peratures which could cause cylinder head to fracture .
Expansion tank /
Pressure valve in cap opens at:
overpressure, early type ............................ kPa (psi)
late type ............................. kPa (psi)
underpressure
............... ...................... kPa (psi)
Thermostat
Marking ..................................................... .
Starts to open
at ............................................ .
Fully open
at ............................................... .
Opening dimension, min ..................................... .
Drive belts Profile x length:
100 (14.2)
150 (21)
10(1.4)
87°C
87 °C
102°C
8 mm
A HC 38 x 1238
B HC 38 x 750
C HC
50 x 913
A HC 47 cog x 1 150
B HC 38 cog x 1 013
C
HC 50 cog x 913
--, / , I 5 I 1 I
--~_/
7401760 -1986 142814
Tightening torque
1 Crankshaft pulley 2 Alternator 3 Fan 4 Power pump
5 AC compressor
Nm
Fan.......................... ............................... 9
189°F
216 °F
0 .
31 in
780 1986 + 7401760 1987
ftlb
6.6
117
lit til' lit ,", ·111 11,1 ·111 1111 ,11'
--'