Volvo 960 repair manual

Article PrintVolvo 960 specifications

1994 ENGINE PERFORMANCE

Volvo Service & Adjustment Specifications

Volvo; 850, 940, 960

INTRODUCTION

Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This is a quick-reference article to use when you are familiar with an adjustment procedure and only need a specification.

CAPACITIES

BATTERY SPECIFICATIONS

Application Cold Cranking Amp. Rating 850 ………………………………. 440 or 520

940 …………………………………….. 520

960 …………………………………….. 600

FLUID CAPACITIES

Application Qts. (L)

Crankcase (Includes Filter)

850 (1) ………………………….. 5.6 (5.3)

940 (2) ………………………….. 4.0 (3.8)

960 ……………………………… 5.9 (5.7)

Cooling System (Includes Heater) 850

Non-Turbo ………………………. 7.6 (7.2)

Turbo ………………………….. 7.4 (7.0)

940 …………………………….. 10.0 (9.5)

960 ……………………………… 10.5 (10)

Manual Transaxle (Volvo Synthetic Gearbox Oil (97308)) 850 (M56L) ……………………….. 2.2 (2.1)

Automatic Transmission/Transaxle

850 (AW 50) (3) …………………… 8.0 (7.6)

940 (AW 71) (4) …………………… 7.9 (7.5)

960 (AW 30/40) (4) ………………… 7.9 (7.5)

Differential (SAE 80-90W/API GL-5)

940 ……………………………… 1.7 (1.6)

960

Sedan ………………………….. 1.4 (1.3)

Wagon ………………………….. 1.7 (1.6)

1. – On turbo models, add .95 qt. (.9L) if oil cooler has been drained.

2. – On turbo models, add .70 qt. (.6L) if oil cooler has been drained.

3. – Use ATF Dexron IIE or Mercon fluid.

4. – Use ATF Dexron IID or Dexron IIE fluid.

QUICK-SERVICE

SERVICE INTERVALS & SPECIFICATIONS

REPLACEMENT INTERVALS

Component Miles

Air Filter ……………………………. 30,000

A/T Fluid (1) (940) ……………………. 20,000

Timing Belt

850 ………………………………… 70,000

940 & 960 …………………………… 50,000

Coolant …………………………………. ( 2) EGR

850 & 960

Inspect …………………………… 60,000

Clean (3) ………………………… 100,000

940

Inspect …………………………… 60,000

Clean (4) …………………………. 20,000

Fuel Filter …………………………… 60,000

Oil & Filter ………………………………..

Normal Service ………………………. 10,000

Severe Service ………………………… 5000

PCV (Inspect & Clean) ………………….. 60,000

Spark Plugs …………………………… 30,000

1. – Transmission fluid replacement for 850 and 960 is not recommended by manufacturer.

2. – Coolant replacement interval is no longer recommended by manufacturer.

3. – After 100,000 mile EGR service, clean every 20,000 miles.

4. – After 60,000 mile inspection, clean every 20,000 miles.

VALVE ADJUSTMENT INTERVALS (1)

Application Miles

940 ………………………………….. 30,000

(1) – 850 and 960 are equipped with hydraulic lifters.

BELT ADJUSTMENT

Application Deflection – In. (mm) Accessory Drive Belt

850 & 960 ……………………………… ( 1)

940 (2) ……………………….. .2-.4 (5-10)

Timing Belt

850 & 960 ……………………………… ( 1)

940 …………………………………… ( 3)

1. – No adjustment is necessary, vehicles are equipped with a self-tensioner.

2. – Deflection is measured with moderate thumb pressure applied midway on longest belt run.

3. – See D – ADJUSTMENTS article in the ENGINE PERFORMANCE section.

MECHANICAL CHECKS

ENGINE COMPRESSION

COMPRESSION SPECIFICATIONS

Application Specification

Compression Ratio 850

Non-Turbo 10.5:1

Turbo 8.5:1

940

Non-Turbo 9.8:1

Turbo 8.7:1

960 ………………………………… 10.7:1

VALVE CLEARANCE

VALVE CLEARANCE	SPECIFICATIONS – 940	In. (mm)
Application
Cold When Checking	……………. .010-.018	(.25-.45)
When Setting	…………….. .014-.016	(.35-.40)
When Checking	……………. .012-.020	(.30-.50)
When Setting	…………….. .016-.018	(.40-.45)

NOTE: 850 and 960 models are equipped with hydraulic lifters.

Warm

IGNITION SYSTEM

IGNITION COIL

IGNITION COIL RESISTANCE – Ohms @ 68 F (20 C)

Application Primary Secondary 850

Non-Turbo ………… .5 …………….. 8400

Turbo ………….. .5-1.5 ………. 8000-9000

940

EZ 116K (Bosch) ….. .6-.9 ………. 7000-8500

REX-I (Bendix) …… .5-.6 ………. 5000-7000

960 ……………….. .5 ……………… N/A

SPARK PLUGS

SPARK PLUG TYPE
Application	Bosch	Champion
850
Non-Turbo …………	FR6DC	…………. RC9YC

Turbo ……………. ….. ………… RC7GYC

940 ……………….. WR7DC …………… N/A

960

Normal Driving ……. FR7DC …………. RC9YC

High-Speed Driving … FR6DC …………. RC7YC

SPARK PLUG SPECIFICATIONS

	Gap	Torque
Application	In. (mm)	Ft. Lbs. (N.m)

All Models … .028-.032 (.70-.80) ……. 18 (25)

FIRING ORDER

Refer to appropriate illustration for firing order and distributor rotation. See Fig. 1, 2 or 3.

Fig. 1: Firing Order & Distributor Rotation – 850

Fig. 2: Firing Order & Distributor Rotation – 940

Fig. 3: Firing Order – 960

IGNITION TIMING

IGNITION TIMING (Degrees BTDC @ RPM)

Application (1) Timing

850

Non-Turbo ……………………. 8-12 @ 750-850

Turbo ………………………… 4-8 @ 750-850

940

Non-Turbo

EZ 116K (Bosch) ………………. 12 @ 725-825

REX-I (Bendix) ……………….. 10 @ 725-825

Turbo …………………………….. 12 @ 750

960 …………………………………. 5 @ 750

(1) – Ignition timing is computer-controlled and is not adjustable.

FUEL SYSTEM

FUEL PUMP

FUEL PUMP PERFORMANCE (1)

Pressure Volume In 30 Sec. Application psi (kg/cm ) Pts. (L)

All Models …… 43.5 (3.06) ………. 1.1 (.52)

(1) – At 12 volts, 68 F (20 C), with engine off and fuel pump relay by-passed.

IDLE SPEED & MIXTURE

IDLE SPEED & CO LEVEL (1)

Application Idle RPM (2) CO Level 850 …………….. (3) 850 ……… (3) .2-.8%

940

Non-Turbo ……….. 775 …………… .4-.8%

Turbo …………… 750 …………… .4-.8%

960 ………………. 750 …………… .4-.8%

1. – Idle speed and CO level can only be checked, not adjusted.

2. – Measured upstream of catalytic converter with oxygen sensor connected.

3. – With cooling fan off.

FAST IDLE

NOTE: All idle speeds are controlled by electronic control unit.

Specifications on fast idle are not available from manufacturer.

THROTTLE SWITCH

See D – ADJUSTMENTS article for switch adjustments.

 

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