Service Manual Section 2, D1-D7. 1991
Contents
1. facing downwards towards the tappet 8 Check adjust the valve clearance for the other cylinders Check adjust the valves in the following sequence 1 5 3 6 2 4 Important Do not forget to rotate the crankshaft a further approx 1 4 revolution before valve clearance is adjusted 9 Recheck valve clearance for all the cylinders Turn the engine a few revolutions prior to checking 10 Fit the valve cover Use new gaskets if necessary D4 Fill engine oil Oil quality _Enginetype Acc to APl Service Acc to Oil change interval Petrol turbo engines Other petrol engines min class SG min class G4 15 000 km Diesel engines min class CD min classD4 7500km 1 Oils with designation SG CD meet this requirement 2 Oils with designation SF CD and SG CD meet this requi rement 3 On all D 24 variants and D 19 T engine oil shall be chan ged every 7 500 km Engine oil and oil filter every 15 000 km 2007700 900 800 400 o Engine Litres_ Modelyear_ Engine Litres_ B 200 230 385 1992 an 5 3 B 204 234 400 19983 jan 5 0 B5202 5252 5 30 1994 B16 B18 46 5 30 JB2 57 B 280 600 D19T 50 B amp 244 6254 6304 5 75 Chassis no 401000 440 460 amp 585000 480 4 6 litres D5 Automatic gearbox fill oil AW 70 71 72 Undo the rear connection for the oil cooler pipe Connect a transparent plastic hose to2. opposite the 0 mar king on the timing plate Both the rocker arms for cylinder 1 should have adequate play Note There are two marks on the pulley 1 TDC cyl 1 and 2 TDC cyl 6 Check adjust valve clearance In the set position the following valves are checked Inlet cylinders 1 2 and 4 Exhaust cylinders 1 3 and 6 Valve clearance mm Inlet valve cold engine 0 10 0 15 hot engine 0 15 0 20 Exhaust valve cold engine 0 25 0 30 hot engine 0 30 0 35 3 Rotate the crankshaft one revolution to gas ex change cylinder 1 Marking 1 should be opposite the 0 mark The rocker arms for cylinder 1 should balance Check adjust valve clearance At the set position the following valves should be checked Inlet cylinders 3 5 and 6 Exhaust cylinders 2 4 and 5 Clean the sealing surfaces of the valve covers and cylinder heads Fit new gaskets and valve covers Use new gaskets Fix the gaskets with sealing agent P N 1 161 026 8 applied at a few points Tighten 10 15 Nm 1 0 1 5 kpm T joint between the valve cover cylinder block and timing gear casing To ensure that the joint is entirely sealed apply a thin string of silicon P N 11 61 231 4 above the joint Note Do not apply too much silicon because of the risk that silicon may enter the lubrication system and clog the oil ducts Refit the other parts which were disassembled Use a new O ring gasket for the vacuum pump if fitted Ensure
3. that the pump shaft is at the upper side of the camshaft B 16 B 18 B 20 D 19 T Special tool 5989 Note The valves can only be checked tightened when the engine is cold Remove the valve cover B18 K KP U B 20 Remove the air cleaner B 16 F B18 EP FP FT B 20 F Remove the inlet manifold bolts and the screw at the front of the cylinder head Remove the manifold and valve cover Set cylinder no 1 at TDC Note Cylinder no 1 is closest to the flywheel Always use the crankshaft centre bolt to rotate the crankshaft Both the cams on cylinder 1 should point offset up wards 3 Check valve clearance for cylinder no 1 Inlet valve 0 15 0 25 mm Exhaust valve 0 35 0 45 mm Exhaust valve turbo 0 45 0 55 mm inlet valve A exhaust valve lf adjustment is necessary steps 4 9 4 Rotate the crankshaft another 1 4 revolution The piston should not be at TDC when valve clearance is adjusted since the valves may otherwise strike the pistons when the tappets are pressed downwards Lf a Press the tappets downwards with tool 999 5989 and remove the shims Turn the tappets to the correct position the grooves run slightly inwards Press on the tappets with tool 5989 Remove the shims Calculate the thickness of the shim to be used Adjustment B 16 B18 without turbo B 20 Inlet valve 0 20 0 25 mm Exhaust valve 0 40 0 45 mm Turbo engine Inlet valve 0 20 0 25 mm Exhaust
4. D1 Air filter replace Remove the cover from the air filter housing Remove the air filter If necessary clean the bottom of the filter housing Insert the new filter and refit the cover 850 Replace the filter for the control unit box Undo the quick release fasteners and remove the air duct from the anchorage on the front member Replace the filter and refit the air duct If the car is driven in adverse conditions e g frequently on abnormally sandy or unpaved roads the filter should be replaced more often D2 Spark plugs replace Tightening torques for spark plugs Nm kpm B 16 18 20 25 2 5 B200 230 25 2 5 B204 234 25 2 5 B 280 12 1 2 B 5204 5254 B 5202 5252 25 2 5 B 5204 5234 T 25 2 5 B 6254 6304 25 2 5 Electrode gap spark plugs 400 0 8 0 9 mm Others 0 7 0 8 mm D3 Valves check adiust Special tool 999 5022 5026 1 Undo the valve cover and remove it Set the camshaft to TDC combustion for cyl 1 The cams for cyl 1 should be offset upwards and the pulley ignition marking should be at 0 Note Always rotate the crankshaft s centre bolt d TOR Ofr a st J L 7 7 1 Measure and note the valve clearance for cyl 1 Clearance at inspection Cold engine 0 30 0 40 mm Hot engine 0 35 0 45 mm Clearance at adjustment Cold engine 0 35 mm Hot engine 0 40 mm Same clearance for inlet and exhaust For wrong clearance 3 6 Turn the en
5. der no 1 The following values are permitted at inspection Cold engine Inlet 0 15 0 35 mm Exhaust 0 35 0 45 mm Hot engine Inlet 0 20 0 30 mm Exhaust 0 40 0 50 mm inlet valves A exhaust valves LO A If clearance is incorrect steps 3 8 3 Rotate the engine another approx 1 4 revolution When adjusting the clearance the piston should not be at TDC otherwise the valves may strike the pistons when the tappets are pressed downwards Press the tappets Turn the tappets to the correct position the grooves should point somewhat inwards Press the tappets downwards with tool 999 5196 The grooves in the tappets should be over the edge so that the washer is accessible with a pair of pliers Lift off the washer User pliers 999 5195 Calculate the thickness of the washer which gi ves the correct clearance The following data applies for setting Cold engine mm Inlet 0 20 Exhaust 0 40 Hot engine Inlet 0 25 Exhaust 0 45 Measure the thickness of the old washer with a micro meter Calculate the thickness of the washer which is to be used Examples if the valve clearance is 0 20 mm and the required valve clearance is 0 25 mm the existing washer should be replaced with one which is 0 05 mm thinner Use only new washers They are available in thicknes ses from 3 00 4 25 mm in increments of 0 05 mm Fit the new washer and remove the tools The washer should be lubricated and placed with the marking
6. gine about another 1 4 revolution Piston should NOT be at TDC when adjusting valves otherwise valves may strike the piston when the tappets are pressed down Turn the tappet The grooves should be at right angles to the camshaft s longitudinal direction Press the tappet down with tool 999 5022 Re move the washer with 999 5026 The groove in the tappet should be located above the edge so that the washer is accessible with a pair of pliers 5 Measure the washer s thickness with a micro meter Calculate the thickness of the washer to be used Example Measured play 0 25 mm Correct play 0 40 mm Difference in play 0 15 mm Measured thickness of existing washer 3 80 mm Correct thickness of new washer 3 80 0 15 3 65 mm Use only new washers Available in thicknesses 3 30 4 50 mm in increments of 0 05 mm Lubricate and fit the new washer Note The washer should be fitted with the marking facing down Remove press tool 999 5022 Check and if necessary adjust valve clearance for the other cylinders in sequence 3 4 2 Turn the engine over a few revolutions with the starter motor Then check the clearance again Adjust if necessary 9 Fit the valve cover Use a new gasket Fit new hoses and ignition cables Refit all other parts which were removed Remove the valve covers Rotate the crankshaft to ignition position for cy linder 1 36 mm socket Marking 1 on the pulley should be
7. h means that a hasty level check may be incorrect Note The engine must run at idling speed with the gear selector lever is P before the correct oil level can be read off If engine speed is increased while the level is too low the oil will be whipped up into a foam and the wrong level will be registered The oil level on CVT cars should be measured when the gearbox has attained normal operating temperature Oil capacity CVT 3 8 I ZF 3 3 1 Move the gear lever back and forth between the various gear positions and keep it in each position for at least 2 or 3 seconds Select P and wait 2 minutes Check the oil level Check the oil level Wipe the dipstick with a nylon rag chamois leather or a rag which does not fluff Insert the dipstick correctly i e with the side marked warm cold facing the gearbox The ZF unit has two measurement ranges A cold oil B hot oil Pull up the dipstick after 4 seconds and read the level The difference between max and min is ZF 0 3 CVT 0 6 Top up if necessary with Volvo oil ZF P N 33 44 208 8 CVT P N 33 44 959 6 D6 Fluid levels engine compartment check adjust cooling system top up if necessary with Genuine Vol vo coolant mixed with clean water 50 50 brake fluid reservoir Quality DOT 4 reservoir for power steering oil If necessary top up with ATF oil type F or G washer fluid reservoir Check the fluid levels in the The illus
8. the pipe Fill about 2 litres of oil 1 Start the engine and let it run at idle speed 2 Switch off the engine when air bubbles appear in the hose 3 Fill about 2 litres of oil Repeat steps 1 and 2 once Reattach the pipe to the gearbox Fill about 2 litres of oil Start the engine and let it run at idle speed Move the gear selector lever between the diffe rent settings Move the gear selector lever to P wait 2 minu tes then check the oil level Top up if necessary Remove the lower return pipe from the oil coo ler on the gearbox Connect a transparent plastic hose to the re turn pipe Fill about 2 5 litres of oil Dexron II D 1 Start the engine and let it run at idling speed 2 Switch off the engine when air bubbles appear in the hose 3 Fill 2 5 litres of oil Repeat steps 1 and 2 once and step 3 once Connect the return pipe to the gearbox Fill about 2 5 litres of oil Start the engine and let it run at idling speed Move the gear selector lever between the vario us settings Check the oil level with the selector lever in P Top up if necessary ZF 4 HP 14 Q and CVT Warning Top up oil with considerable care Fill oil Fill slowly through the dipstick tube If too much oil is filled the excess may be pressed out resulting in leakage Do not check the oil level immediately after filling The oil in the pipe must have sufficient time to flow down into the sump whic
9. tration shows the 850 engine compartment D7 Battery check level anchorage Check that there is sufficient battery acid in all the battery cells Top up if necessary with distilled water Check that the battery is properly anchored and con nected Clean the battery terminals do not disconnect the cables and apply vaseline to them
10. valve 0 50 0 55 mm Measure shim thickness with a micrometer and calcu late the thickness of the shim which is required Carburettor engines Remove the fuel pump for adjustment of cylinder no 4 Fit a new shim and remove tool 999 5989 Lubricate the shim and check that the assembly mark faces downwards towards the tappet Note Always use new shims Available in thicknesses from 3 25 mm to 4 25 mm in increments of 0 05 mm and in thicknesses 4 30 4 40 and 4 50 mm Rotate the crankshaft 1 3 4 revolution and check valve clearance again Check adjust valve clearance for the remaining cylinders Check valve clearance in the following sequence 1 3 4 2 Important Do not forget to rotate the crankshaft a further 1 4 revolution before valve adjustment Refit the valve cover Fit new gaskets Apply sealing agent at the four corners Volvo P N 11 61 231 4 B18 K KP U Fit the fuel pump and air cleaner B 16 F B18 EP FP FT B 20 F Fit the manifold Tight ening torque 12 Nm Special tool 999 5188 5195 5196 Set cylinder no 1 at TDC injection Remove the valve cover Always turn the vibration damper s centre screw 27 mm socket tool 999 5188 if necessary Both cams on the camshaft for cylinder 1 should point offset upwards rerrcee rire eg al ILA a 2 Check the valve clearance for cylin
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