Service IVlanual Section 2 (2!

>-29)

Engines 8 17, 819,

821 , 823
Repairs
and mainbanance
240 197!>-1985
 B 17, B 19, B 21, B 23 engines

B21 A

What do the designations mean"7 This manual covers the following

enginetypes :

1t -
B 21 E T
Engine type Model year
Tu,bo 817A 1979-1984
B 19 A 1977- 1984
B 19 K 1984
A = carburel or engine, B 19 E 1977- 1984
K "" carburetor engine B 19 ET 1982-1984
E ... fuel injection engine B 21 A 1975-1984
F ,., tuel injection engine - USA version B 21 E 197 5-1983
B 21 ET 1981 - 1984
21 - cylinder capacity B 21 F-S' 1976-19843
B 21 F-8 2 1982
B 21 F-9 4 1981 - 1982
B :: petroi (gasoli ne) B 21 FP 1981- 1985
B 23 A 1981 - 1984
B 21 = basic engine B 23 E 1979-1984
823 = a B 21 with larger bore and higher compression B 23 F (lH-Jetronic) 1983-1984
ratia
B 19 = a B 21 with smatler bore Aem arkl
B 17 = a B 19 with shorter streke , B 21 F-S _ CI system with Bosch ignition system.
1 B 21 F-S _ LH Jetronic injection system with Chrysler igni-
tion system
3 Oiscontinued 1982 in USA & Canada.

Superseded by B 21 F-8.
Volvos are sold in versions adapted for different
• B 21 F- 9 - CI system with Chrysler ingition.
markets. These adaptations depend on many faetors
5 1ntercoolef introduced as a runnin g chenge on 1984 models
including legal, taxation and marke! req u irements.
during the spring of 1984.
This manua l may th ersfare show illustrations and
text which do not apply to ca rs in your country.
 Con tents

Contents

Page
Important . 2
Specifications 2
Special too Is ... 6
Group 25 Intake and exhaust systems ... 7
Group 26 Cooling system ........ . 78
Group 27 Engine controls ....... . 92

Index page 102

Order No.: TP 30163/2

•
This book supersedes the following service
man uals :
Section 2 (25-29): Order No. TP 30163/1
Section 2 (25): Order No. TP 30296/1

TP 30163/2
6000.2.85
Printed in U.S.A.

Cl 198S, Volvo 01 America Corporation

We reserve the right to make modifications w ithout prior notification

Importanr information - specification

Important information

Torques
There are two types of torques specified in this book :
I. Tightening torque 40 Nm (30ft Ibl '" given for parts
Nm which must be tighetened with a torque wrench.
II. Torque 40 Nm (30 ft Ibl "" nominal value, the parts
need not necessarily be tightened with a torque
wrench.
The specifications section includes torque on ly for
those parts which must be tightened with a torque
wrench.

Specifications
GroulP 20 General •
Engine type designation, serial number,
and part number
You will lind this engraved on a plate on the left-hand
side 01 the engine.
1977 models - : additional plate on timing gear cover,
showing last three digits of part number.

•
TURBO ENGINES
Group 25 Intake and exhaust systems
•
Charge pressure
B 19121 ET Checklng Setting
At 3,500 rpm full Ioad . . .. kPa 60-70 64-70
(lblifl2) (8.5-9.9) (9 .1-9.9)

B 21 FT without Intercooler

At 4,000 rpm fullload .... ...... kPa 40-48 42-48

(Ib/inl) (5.7-6.8) (6.0-6.8)

B 21 FT with intercooler

At 3,000 rpm lullload .....• ... . .... . .. . . •. ....... kPa 50-58 55

(In[on') (7.1-8.2) (7.8)
2
 Specifications

Fuel enrichment
B 19/21 ET
Contrei pressure (warm engine) at zero charge pressure (idling) 345-375 kPa
(49-53 Iblin 2)
at charge pressure 45 kPa (6.4lb1in 2) 265-295 kPa
(38-42 Iblin 2 )

B 21 FT
Pressure contac! blocks the Lambda-sClnd system at a charge
prassure of . .... . ............. . .................. . ....... . 20.3 kPa
(2.9 I b/in')

Pressure sensor
B 19/2 1 ET
Cut-out pressure, approx. 85-95 kPa
(12.1-13.5IbJin 2 )

B 21 FT
Cut-oul pressure, approx. 65-75 kPa
(9.2-'0.7 1b1in 2 )
B 21 Fl with intercooler
Cut-out pressure, approx. 100-110 kPa
114.2-15.6)

Ignition retardation
B 19/21 ET
Atcharge pressure 30 kPa (4.3Ib/in 2) . 3-7"
B 21 FT

• Al charge pressure 36 kPa (S.1Ib/in 2 ) ..•••........• • .

LAMBDA-SOND SYSTEM
Controi unit

Different conlral units are used depending on the year

and engine tvpa. These are idenlified by the number on
the cover (tast three figurasJ.

3
SpecificBrions

Engroe design ... .. . ......... B 212F B 21 FT

Mode! year .. . . . . ... . ........ 1971-79 19sa 1981 1982-8' 1981 1982-85
ConIroI unil,
Volvo number ... ......... . ... 1219143-3 1276721-6' 1276879-2 1306411 -8 1276896-6 1306412-6
Bosch No. (last 3 ligures) .. ..... ... 004 ... 021 ... 033 ... 053 . .. 034 .. . 052
Frequencies,
disconnecled lambdasond .. .... 51-57° 51_57° 51-Sr 51_57° 42-48° 42-48°
Thermal switch connecled
lo ground ' ........ ..... . . ..
.. 54" 64-70°
Pressure differential switch
connected to grounc9 ..... . ... 82"
Pressure switch, connecled
lo grouOO1 • • • • • • ........... 64-70° 64_70°

Note,:
1 Thermal switch introduced 1982

2 Pressure differential switch only on B 21 Fl 1984-1985

, Pressure sWitch only on turbo engines
.. Replaced bV 1276879-2 as spare part

TORQUES
Nm tUb
lambda-sond 55 41
ApplV " Never·Seez" {detail No. 1161 035-91 on all the threaded parts of
the sond

Retaining nuts, Iront exhaust pipa to turbo' . 25 18

Retaining boIts, turbine housing' ....... . 20 15
compressor houslng" .... . 18 13
Rear housing (with wastegate)' ............... . 20 15

• Use anti-seize compound (part No. 1161035-9) on the bolts and nuts
•• Use new bolts. In an emergencv. the old bolts may be used if thevare

•
l ..
smeared with thread sealer (part No. 1161053-2).

Retaining nuts. lurboeharger 10 manifoid:

- Measure the length of the bolt, replace bolts if neees- "'
sarv·
The bolts may be used as long as thevare no longer
than 89 mm (3.50 in) and 105 mm (4. 13 in) respee-
•
tivelv·
- lubricate the threads and eontact surlaees of the
balts with instaning paste 1161078-9.
Install e new securing plate.
I
- Tighten the balts in Ihree Slages aeeording t o t he O
illustration.
Stage I

"
. 1 Nm(9 in Ib)
- 45 Nm (33 ft Ib)
III _ 45°
;;13-
•• ' UM",

t!>
a!
®~
m • T
F,

4
 Specifications

Group 26 Cooling system

GENERAL

Since aluminurn is used in the engines, active corrosion

protection is necessary in the coolan! to help p!'event corro-
sion damage.
Use genuine Vo/vo cooIanl typa C (blus-green) diluted
with clean water in proportions of 50/50. This mixture helps
to pre...en! CQfrosion and frost damage .

• • Never top.up the COOIing system with water alone. Usa

genuine Volvo COOlan! diluted with claan water in propor-
tions of 50/50 .
• The cooIanl should be changed regular1y since the corro-
sion-pmtective additives in the coolan! Iose thelr effec-

•
tiveness In time.

,.,or

Capacity, manual geatao)!; .. 9.5l itras (10 US qts)

with aulomalic transmission 9.3 rilres (9.8 US qls)

EXPANSION TANK
The pressure valve in the cap apens at:
excess pressure .. 65-85 kPa /9.2- 12.1 Iblin 2 )
partiSI vacuum

•
7 kPa (1.0 Ib/in 2 )

THERMOSTAT
Model1 Model2 Model3
Marking ............................ . .. .. ..... 82 87 97
Starts to open at 8 1-83"C 86-S8"C 91-93"C
Fully open at .. 92°C 97°C 101"C

FAN BELTS
Designaiian
modell HC 38x925
modeI2 ... HC 38x913

TIGHTENING TORQUE
Fan balt, self-Iocking forfixed fan .................... . 9 Nm (7 fUb)

5
Special rools

Special tools

...
2901 -0
Oescription
Tongs: for pinching hose
5011·5 Pressure gaug e: for measuring controi pressure
5015·6 Allen Key : for adjusting CO
5151 ·9 Connection : checking CO (Lambda-son d system)
I 5170·9 Test relay : checking the Lambda·sond system
5228-5 Nippre : fo r connecting Sal l
5229-3 Nipple: for connecting Sal l
5230· ' Pressure gauge : for measuring chargo pressu re etc
5250-9 Key : removing/instarling Lambda-sond.

I,+-..L.- '

5228, 5229
9724 I
(
\
For trouble-shooti ng of the lambda-sond system the (
following items are also needed : F
l
- rev counter and dwell meler, for example Volvo
l
M ono-Tester 999 9921 -1
- Ohmmeter, for example Volvo ohmdiode meter 999
9724·0
- Test ramp and voltmeter, for examp re vorvo Vol t·
Amp meter 999 6450·4. t
6450

6
 Group 25 {ntake and exhaust systems
Contents

Group 25 Intake and exhaust systems

Operation Page
Intake manifold
AemovlngJinstalling Al - 9 8
Exhaust manifold 81 -3 12

• Turbocharger
Important information ....... .
Trouble-shooting .... ........ ... ............ . .
Routing offuellines
Cl-4
Dl
El
13
14
15

•
Charge pressure, checking/adjusting Fl -g 16
Pressure actuator, replacement Gl-4 18
Contral system forcharge pressure ....... . Hl-lO 19
Ignilion retardation, full-road enrichment and pressure sensor
B 19/21 ET 11-8 22
B21 Fr Jl-7 24
Wastegate, replacing Kl-9 26
Modifications . U--6 28
Quick check . Ml 30
Removing, cleaningfchecking, installing Nl-40 30
Clips, pressure hoses .. . ............. . 01 - 2 40
Installing mounting bracketon earlier models Pl- 12 41
Exhaust pipe and muffler Q1- 2 44
Crankcase ventilation . Rl-9 45
Catalytic converter 51-3 48
Airpump T1 - 6 49

•
Pulsair system ................ .. ... ................... . Ul -7 51
Exhaust gas recirculation (EGR)
Onloffsystem Vl - 11 53
Stapless system , A engines X1-3 56
F engines modell Yl-14 57
ElFengines, models 2 & 3 . Zl - 11 61
Cleaning (all systems) AAl 64
Reseuing warning lam p IF engines) AB l 65

Lambda-sond system
Positioning ofcomponents . ACl 66
Connection of vacuum hoses AC2 67
Wiring diagram AC3 67
General AC4-5 6B
Fauh symptoms . AC6 69
Trouble-shooting Ichecking the system) AC7-42 69
lambda-sond. checkingJreplacing ADl-3 77

7
Group 25 Intake and exhaust systems
Intake manifold

A. Intake manifold

Removal

Drain the coolant

The level must be below the inlet pipe.
Al

•
A2
Remove the inlet pipe

A engines

•
K engines E/ F engines
I

ET/ FT engines F engines with LH jetronic tuel system

•
8
 Group 25 Intake and exhaust systems
Intake manifold

A3
Installing
Use new gaskets. NOTE! Early- and lale-production
types. The earty production version is not reversible
and must be fitted wilh the OUT marking facing out·
wards (see illustration). On the lale production cylinder
head (1979-) ont y a tate production gasket can be used.

NOTEI
New intet pipes of latest models have some unthreaded
holes. Use self·tapping bolts in Ihese holes.

Installing the inlet pipe

Operation
Aengines.see .. A4
K engines, see ... AS
ElF engines, see .. AG
ET/FT engines, see ... A7
F engines with lH-jetronic fuet system AB

A9
Fil! with coola nt
Close the cock on the lefthand side of the engine. Fill the
expansion tank up to max. with genuine Volvo coolant,
diluted with clean water. Mixing proportion : SOlSO.
Aun the engine untll warm. check for leakage and. if neces-
sary. top up with COOlanl.

A4
A engines

9
Group 25 Intake and exhaust systems
Intake manifold

AS
I< engines

•
t

ElF engines A6

,o
 Group 25 fntake and exhaust systems
Intake manifold

ET1FT engines A7

•
•
F engines with LH jetronic fuel system AB

11
Group 25 Intske and exhaust systems
Exhaust manifold

B. Exhllust manifold

Removing
81 •
• Aemove the exhaust pipe from the manifoid.
• Aemove the manifold from the cylinder head.

82
Installing
• Use new gaskets when insta11ing . The outside of the
UT gaskets are marked "ur".
• lnstall the manifold on the cylinder head .
• lnst811 the exhaust pipe on the exhaust manifoid.

83
Turbo engines
See pages 30 and 36 for information concerning remov -
ing/installing exhaust manifoid.

12
 Group 25 Intake and exhaust systems
Turbo, important information

c. Turbo, important information

el
Never race an engine directly after start
1~ Allow il to idle for a while to ensure the turbocharger is
lubricated.

" e2
Allow the engine to idle before switching off
If the engine is switched off at high revs the turbochar-
ger will rotale for a long time without lubrication.ldling
for a short time befors switching off 81so helps to reduce
turbocharger temperaturs.

J
e3
Ensure oU and filter changes are carried out at the
correct service intervals
The oi l supply (qua lity and purity) is essentiai to the
working and service life of the turbocharger. The COf-
reet grade of oil must always be used and precautions
taken to prevent the ingress of dirt etc. into the oilways

~)
during servicing operations.

,,, ...

e4
Do not usa sealers when repairing the engine
If a sealant is used it may enter the lubrication system
and block the oilways to the turbocharger.

'.-
13
Group 25 Intake and exhaust systems
Turbo, trouble·shooting

D. Turbo, trouble-shooting

Fault
Symptom
Reason Check/remedy •
Charge pressure too low Air cleaner clogged Replace air cleaner insert
Throttle controi incorrectly adjusted Adjust
Lowoutput Engine fault (low compression, in- Check and remedy as required
Boost pressure gauge correct valve clearance, poor fuel
reading low supply)
Leakage between compressor hous- Replace damaged gaskets, con-
ing and cylinder head or belween nections etc. Tighten screws,
cylinder head and turbine housing nuts, clamps
Wastegate valve stuck in open posi- Replace valve with housing, see
tion (fully or partly) page 26
Exhaust system partly blocked Replace
Charge pressure incorrectly adjusted Checkladjust charge pressure,
see page 16
Turbocharger faulty Aeplace completely or partially
as necessary.
Charge pressure too high leakage in hose belween compress- Change hose and damps
I
The engine knocks at
high output
or housin g and pressure actuator
Pressure actualor (diaphragm) dam-
aged
Aeplace pressure actuator,
page 18
...
Boost pressure gauge pointer Wastegatevalve stuck i n closed posi - Replace relief valve with housing,
moves inta red secror tion see page 26
Pressure sensor cuts out Charge pressu re incorrectly adjusted Checkladjust charge pressure,
(engine stops) see page 16
Engine knacks Fuel not suitable, (octane too low) Change fuel
Ignition settinglretardation incorrect CheckJadjust ignilion setting &
retardation .
B19/21 ET, see page 22
B 21 FT, see page 24
Charge pressure too high CheckJadjust charge pressure,
see page 16
Metallic noise from Preheating plates loose or cracked Replace, tighten
wastegate valve

Housing for waslegate or exhaust Tighten

pipe loose
Waslega t e valve loose in guide Aeplace valve with housing, see
page 26

Continued on next page

14
 Group 25 Imake and exhaust systems
Turbo, trouble-shooting

Fault Reason Check/ remedv

Symptom
Noise or vibrations from Preheating plates loose or eraeked Aeplace, tighten
turbocharger
Leakag6 in intake or exhauSI system Tighten loose connections, ,e-
place gaskats, seals etc.
Poar lubrication of turbocharger Check oil pressure and oil flow to
turbo. If fault ramains af ter reme·
diat measures, re place turbo
Imbalance 00 "'bo shalt, turbine Replace turbo
wheel or compressor wheel because
of damage

Oil leakage at turbo Air cleaner daggad (oil leakage on Replace air cleaner insert
shaft seals inlet side gives white smeke)
Di! smoke in exhaust Exhaust system loose or faak ing Tighten or replace system
gases
Excessive pressure in crankease Clean crankcase ventilation, see
page 45
Check the crankcase ventilation
hose, see page 46
Return oil pipe clogged Clean the return oil pipe
Turbo shaft seels damaged Replace turbocharger

E. Turbo, routing of fuel lines EJ

Pluggad 3 2

roO"'~, Clean the connections carefully before

laosening the lines. Make sure that the
lines do not rub against anything .

•
Conlrol-pressure Cold slan
Inlet Return lecto

2 3 4
late design

•
,e Z-..(! Coldst'rt ~ ~~~:Ji InJector
Coldst' ,
3

bJt
", .
d InJector
Controi ': :.
~~
J:: pressure
Contral
o. pressure
I regulator
L!'--___c" c:.guI3tor
15
Group 25 Intake and exhaust system
Turbo, charg e pressure checking/adjusting

F. Turbo, charge pmssure, checking/adjusting

Special tool: 5230

Important! Excessively high charge pressure can

•
cause serious damage t o engine.

Fl
Disconnect the solenoid valve
(Applies only to B 21 FT with intercooler)
Separate the connec tor.

F2
Connect test equipment
Connect pressure gauge 5230 between charge air over-
pressure switch hose and nipple on intake manifoid.
Place pressure gauge on dashboard.

F3
Run engine until warm
{Test drivel.
B 21 Fl
with inlereooler F4

•
Measure charge pressure
Drive in third gear (second gear with aut omatic trans-
mission) at approximately 1,500 rpm .
3 Accelerate to fullthrottle by dep ressing the accelerator

,
pedal to floor.
~.
Notel Automatie transmission
Do nol depress the accelerator so quiekly that kick-down is
engaged.

Apply brakes at :
819/2 1 ET 3,500rpm
821 FT . ... 4,OOOrpm
821 FTwith intercooler . 3 ,OOOrpm
keeping the accelerator pedal fully down to obta in full
load.
Read the charge pressure on the pressu re gauge.

2 IMPQRTANTI To prevenl damage 10 brakes, do not apply

brakes for more than 5 seconds

Charge pressure must be:

819121 ET 60-70kPa
(8.5-9.9Ib/in 2 )
821 FT . ........ 40-48kPa
(5.7-6.8 Ib/in 2 )
821 FTwith intercoolar . ................. 50-58kPa
(7.1-8.2Ib/in 2 )
When charge pressure is correct, rem ove measuring
equipment and connect the hosa to the intake manifoid.

16
 Group 25 Intake and exhaust systems
Turbo, adjusting charge pressure

Adjusting charge pressure

Operation F 5-9

Not.] Wastegate actuator of early design cannol be ad-

Justed. Jt is sealad by riveling the adjusting sleeve lo the hnk
rOO. If faulty, Ihe 8ctuator must be replaced; see page 18.

F5
Adjust charge pressure
Aemove the seal and the circiip. Adjusl pressure by
turning the sleeve on the link rad.

IMPORTANTI Do not turn the fink rad as this may damage

the diaphragm in the actualar.

One turn of the sleeve gives a pressure change of

approx. 2 kPa (0.3 Iblin 2 ).
If the sleeve is turned :
- in, the charge pressure increases
- out, the charge pressure decreases.
B 19/21 ET ... ........... 64-10kPa
(9. 1-9.9Ib1in 2 )
B21 Fr . .... 42-48kPa
(6.0-6.8 Jblin 2 )
B 21 Frwith inlercooler ......•. 55kPa
(7.81b1in 2 )

F6
Check basic position of link rod

lin k rad travel must be between 2-6 mm (0.08-0.24 inf lo

obtain correct operaling function .

To aajust :
Disconnect rad sleeve from lever.
Mark position of rad at wastegate actuator.
Aeeonnect sleeve to lever.
Measure distance between mark and wastegate
actuator.
Distance .. 2-6 mm (0.08-0.24 in).
If incorreet, replace wastegate actuator, see instruct ions
on next page.

Fl
Install new circlip
FB
Check charge pressure
See page 16. F9
Seal wastegate actuator
II is important to wind wire tightlyaround the sleeve as
shown. Otherwise seal will loosen due to vibrations.
Volvo anli-tamper seal tongs, part No. 9986408-4 have
"Volvo" stampad on grips.
"'III'

17
Group 25 Intake and exhaust systems
Turbo, replacemen t of wastegate actuator

G. Turbo, replacernent of wastegate actuator

Special tool: 5230

Gl
Replace wastegate actuator
Check the pressure hose for damage and replace if
necessary.
Use new nut s.
Do not fi t the hose damp, and do not connect the hose
at Ihis stage.

G2
5230 VI
Adjust wastegate actuator (charge pressure)
Cannact p ressure gauge 5230 and pressure tester to
w astegate actuator.
Pump up l O a pressu re o f :
8 19/2 1
B 21 FT .
55 kPa (7.8 Ib/in 2 )
41 kPa (5.8 Ib/in 2)
,
B 21 FTwith intercooler . . .. 57 kPa (8.1 Ib1in 2 )
Push the arm of the wast egate forward h'alve closed ).
Adjust link rod to fit precisely to the pin on the lever.
Install a new circlip and lighten the lock nul.
Remove the pressure gauge and pressure tester. Con -
nect the pressu re hose (hose damp).

G3
Check charge pressure
See page 16.

TI
G4 •
Sea I wastegate actuator !ink rod
See page 17.

18
 Group 25 Intake and exhaust systems
Tu rbo, contral system for charge pressure

H. Controi system for charge pressure

Only B 21 FT with intercooler
Special tool; 5230
Posilioning 01 componenls (Iaclory-installed inlercooler) Hl

Charge air pressure switch

Rpm relay
ff
fleetri!;: coolin9 fan
Sol.nold valv.
Ralay (diKonnection of rel ay
AC c:ompressor)
•

See next page for checking the syslem's function.

NOTElOn cars equipped with intercooler kils the elec-

i2 Wiring diagram trical connections and placing of the components are
different, see page 21.

-k~~
;0
I
" H2

'I

... .., ,:o- , ", .. .J~ ..

'I 1 2
'I
I.
.,. •
.. 3

,.
7JlJ
.~
" / Bl-R
I I
" .. N~

N-'
'or
•' 4 •
BL- R
10
L..... G~
GN
8
" 7
,j)J :' .tJll@
GN

~-
;3 $ Bl-T
" GN nu
.L ' - - - '
'-N/
..~ J!b
6
frti 11.•-
9..31
The picture.hows the cp.rating position at engine speeds ellceeding 3,700 rpm and charge pressur. exceeding 20 kPa (2.8Ib/in2)

1 Rpm relay 4 19nilion coil 7 FUSB No. 13 10 Low pressure SWitch

2 Electric cooling fan relay 5 Charge air pressure 8 Ignition (in dryed
3 Relay (disconnection of
AC compressod , switch
Solenoid valve
9 AC compressor 11 Switch Icircuit cl osed)

"
Group 25 Intake and exhaust systems
Turbo. controi system for charge pressure

Checking system function

Operations H3-9

•
H3
Checking h oses
Check. that hoses are correctly conneeted, clamped and
undamaged.
Itls Important that the T-piece IS posltioned as shown in •
the illustration.

H4
I ~ Check so lenoid valve
Check funClion of valve by blowing through it.
Normally the valve should be closed.
Connect 12 V to the valve. The valve should then open.
If faulty, check the wiring.

r
I
12V I
)
H5
Check ch arge air pressure sw itch
Connect pressure gauge 5230 and a pressure pump 10
the switch.
Connect a test lamp between switch and 12 V. Pump up
pressure 10 20.3 k Pa ~2.8 Ib/in 2).
The switch should then elose '" test lamp light up.
Remove testlamp and connect electrical wire. Leave Ihe
pressure gauge and pressure tester in position.

20
 Group 25 Imake and exhaust systems
Turbo, controi system for charge pressure

H6
Co nnect test light
Connect a light at the solenoid valve, between the con-
tact piece and trame.
Connect another light at AC compressor, between wire
and trame.

/
...·w H7
Start engine
Switch AC on to give max cooling

H8
Check rpm relay and AC relay
Check that charge air overpressure switch is closed;
pump up the pressure if necessarv.
Rev the engine. The rpm relav should be activated at
approximatelv 3,700 rpm. The test light at the solenoid
valve should light up and the AC compressor should be
disconnected at the same time (the test light should go
out).
Iffaulty, check electrical wires, see wiring diagram page
19. If the wires are in order, check wi th a new re lav.

H9
Restore to original condition
Remove the instrument.
Connec! electrical wire, hose.

H'O
Intercooler kit; installation of components

5
•
'1c~/ ,\ '
"r:' ,
H .
1
.~'.J' ~.,r:' I
, '<'\
,
ON ON

.. 4 ..
", 3 +

Components ,.

,,
1 Rpm relav 6 AC compressor
19",tion cOl i 1 Charge alf prassure switch

4
SolenOld valve
Fl,lse No. 12
•
9
low preSSl,lre SWitch lin dryerl
Switch (circuit brasker)
5 Relay Idisconnection of 10 Intercooler
AC compressorl

21
Group 25 Imake and exhaust systems
Turbo, ignition retardation, full load enrichment, charge air overpressure switch

I. B 19/B 21 ET retardation, full load enrichment and

charge air overpressure switch, checking
Special too/s: 290?, 5011, 5015, 5228, 5229, 5230

11
Connect pressure gauge 5011
Connecl belween fuel distribulor and controi pressure
regula t or.
Clean the hose connections before disconnecting the
hoses.
Connect pressure gauge 5011, using nipples 5228 and
5229.
Set the tap to position 2 (righ t angle to hases ).

/2
Connect CO meter and Volvo Mona-Tester
(A stroboscopic timing light can be used instead of a
Mono·Tester.)

/3
Start engine

/4
Check ignition timing retardation
Connect pressure gauge 5230 and a pressure pump to
the distributor.
Read ignition sening.
Pump up to a pressure of 30 kPa (4.3 Ib/in 2).
Ignition retardation should be 3-7°.
Remove pressure gauge and pressure pump. Recon·
nect hose from th e distributor to the inlet manifoid.

Ignltion setting : 15" B.T.D.C!l1 11.7- 13.3 rps 1700-800 rpml.

hose dlsconnected.

22
 Group 25 Intake and exhaust systems
Turbo, ignition retardation, full/oad enrichment, charge air Qverpressure switch

2901 5230 15
Check fuel enrichment
The engine must be running.
Pinch the hose belween the conlrel pressure regulator
and the nlpple on the Inside of the inlet pipe. Usa langs
2901 .
Remove the hose from the nipple on the Qutside of th e
throttle housing . Connec! pressure 9auge 5230 and
pressure pump.
Check that the contrei pressure regulator is warm bV
reading off pressure gauge 5011. The contrei pressure
should be 345-375 kPa (49-53 Ib/in 2 ).
,,' ... Pump the pressure up to 45 kPa (6.4 Ib/in 2). The contrei
5011 pressure should then drop lo 265-295 kPa (38-42
1 Ib/in 2 ),
Remove the pressure pump, pressure 9auge 5230 and

• tongs 2901. Reconnect the hose to the throttle hosing .

, Fuel enrichment IS necessary to ensure the internai coolmg

01 the engme II the luel-air mixture is too lean, this will
, r81se the co mbushon chamber temperature with fisk of
overheatmg.

'2 16
Checkladjust ca content
, Use key 5015 for the adjustment.
Check value:
B 21 ET, 1983 Nordic countries
and Switzerland . 2.5-3.5 %
'3
Other markets 1.0-3.0 %
Adjustment value:
B 21 ET 1983 Nordic countries and Switzerland 3.0%
Ol hermarkets 2.0%
Idling speed 15.0 rps (900 rpm)

14 17
Check pressure sensor
lO Connect pressure gauge 5230 and pressure pump to the
hose which goes to the charge air overpressure switch.
/The switch is placed on the mside of the dashboard
above the pedal carrie r).
Pump up the pressure until the engine stops (t he switch
,. cuts ou t the ground connection for the pump relay).

IMPORTANTi Do not exceed 120 kPa (17 Ib/in 2). This

J cou ld damage the dashboard boosl pressure gauge.

23
Group 25 Intake and exhaust systems
Turbo, ignition retardation, fullload and enrichment, charge air overpressure switch

The engine must stall at a pressure of 8> 95 kPa (12.1-

13.5Ib1in 2). At the same time the pointer on the boost
pressure gauge must be in the red sector and the lamp
on the dashboard should be on (this lamp deleted on
later models).
18
Resetting
Switch off the ignition.
Aemove the pressure gauge 5230 and the pressure
pump. Aeconnect the hose to the inlet manifoid.
,,'. Aemove pressure gauge 5011. Reconnect thefuellineto
the fuel distributor.

J . B 21 FT ignition retardation, full load and enrichment and

charge air overpressure switch, checking
Special tool: 5230, 5015

J7
Connect CO m et er and Volvo Mona-Tester
A stroboscopic timing light and a dwell meter may be
used instead of the Volvo Mono·Tester.
Connect Mono·Tester to the Lambda·sond service
outte!. )
Connect CO meter to the outlet in the exhaust pipe in
front of t he catalytic converter.

J2 )
Start engine

J3
Check ignition timing retardation
Connect pressure gauge 5230 and a pressure pump to
the distributor.
Read off ignilion setting.
Pump up to a pressure of 36 kPa (5.1 Ib/in 2 ).
Ignilion retardation should be 60 _10°.
Remove the pressure gauge and pressure pump. Re·
connec! the hose from the distributor to the inlet
manifoid. )
Ignill0n sening: 12" B.T.D.C. at 1S r ps (900 rpml. hose
disconnecled .

24
 Group 25 Intake and exhaust systems
Turbo, ignition retarda tion, full foad enrichment, charge air Qverpressure switch

J4
Check fuel enrichment
Connec! pressure gauge 5230 and pressure pump to the
hose from the inlet pipe.
Engine must be runnlng.
Pump up pressure to 20.3 kPa (2.8 Iblin 2 ). The dwell
meter should then read 640 _70" (overpressure switch
cuts out theground pin for l ambda·sond's contral unit).

,..
J5
Check charge air overpressure switch
Engine running.
Pump up the pressure unlil the engine stops (pressure
sensor cuts out).

IMPORTA NTI Do not exceed 120 kPa C17 Iblin 1 ) or dash·

board pressure gauge may be damaged.

The engine should statl at a pressure of:

B 21 Fl ........ . . 65-75 kPa
(9.2-10.7Ibfn"')
B 21 FT with intercooler ............ 100-110 ttPa
{1 4.2-1S.6 IbIi~
1
At the same time the pointer in the car's charge press-
ure gauge must be in the red sector and the lamp in the
instrument should be on (on later models this lamp has
been deleted).
, ~\\'I'/M
, ; [ Turbo ~ J6
/71/1'\\'\::"- Switch off engin e. Remove pressure ga uge 5230
and pressure pump

I _. Connect the pipe to the inlet manifoid.

3 I
J7
l~'
Checkl adju st CO content
, Usa key 5015 for adjustmenl.
ca, check value . 0.7- 1.3 %
adjustment value 1.0 0/.
Idling speed . 15.0 rps (900 rpm)

,.
"
]
25
Group 25 Intake and exhaust systems
Turbo, wastegate with housing, replacement

K. Turbo, wastegate, with housing, replacement

Special tool: 5230

Kl
Detach exhaust pipe from turbocharger
Remove the nuts at the turbocharger and the bolt at the
gearbox mounting.
Move the p ipe aside.

K2
Remove :
- circlip lor !ink rod
- wastegate and housing

K3
Check turbine housing
Check that the contact surface is smooth and that the
"seat" is not burnt.
)
..-
K4
Install :
- wastegate and hou sing . Smear the bolts with anti·
seize compound.· Tighten to a torque 01 20 Nm (1 4 fl
Ibs).
- tne exhaust pipe. Smear the studs with anti·seize
compound.· Tighten to a torque of 25 Nm PS ftlbs) .
- gearbOx front mounting bolt

• Part No. 1116035·9,

26
 Group 25 Intake and exhauSl systems
Turbo, wastegate replacement

K5
Adjust wastegate actuator
Notel Wastegate aCluator of previous design can not be
adjusted . II is sealed by riveting the adjusting sleeve to
5230 the link rcd. If faullY, the acluator must be replaced, see
page 18.
Connec! pressure 9auge 5230 and pressure pumpto the
actuator,
Pump up to a pressure of:
B 19/21 ET . 55kPa
(7.8Ib/in 2 )
821 FT ................... . 41 kPa
(5.8 Ib/in 2)
B 21 FTwith intereooler 57kPa
(8.1 Ib/in 2)
Push th e arm of the was tegate forward (closad valve).

, 'lO'" Adjust the rcd so that il fil s e){actly to the pin on the
lever.

IMPORTANT! 00 not tum the rod as this may damage the

diaphrsgm in the actuator.

Remove the pressure 9auge and pressure pump. Con·

nect the pressure hose (hose cli p).

K6
2 Check position of link rod

Link rod travel must be belween 2-{) mm 10 obtain eorreel

operating funelion .

To adju st:
Diseonnect rad sleeve from lever.
3 Mark position o f rod at wastegate aetuator.
Aeconnect sleeve to lever.
, Measure distance between mark and wastega te
aetuator.
Disl ance = 2-6 mm (0.08-0.24 in)
If ineorreet, replace wastegate aetuator, see instructions
on page 18.
K7
·4 Install new circlip.

,. KB
, Check charge pressure

., See page 16 .

I. K9
Sea I wastegate aetuator
It is important to wind wire tightlyaround the sleeve as
shown. Otherwise seal willlOosen dua to vibrations.
Volvo anti-tamper seal tongs. Part No. 9986408-4 have
E.rly model
... " Volvo" stamped on grips.

27
Group 25 Intake and exhaust systems
Turbocharger, mocificarions

,
L. Turbocharger, production modifications

L1
Fixing of pressure pipe
The pressure pipe may be fixed in three different ways:
M odel1 Hose clips only (1981-82).
Model2 Hose clips and a bracke! between the pressure
)
pipe and the cylinder head (1982).
Model 3 Hose clips and hosehoider (1984-).
Fixing by means of holder and haseclips replaces pre·
vious designs and mayaiso be refitted 10 earlier
modeis. See page 40.
Model l Modet 2 Model 3

L2
Turboc harger centre ho using
The form of the centre housing was ehanged on models
from 1982 on. This was done in order lo obtain a more
even heat distribution and to reduee temperatu res at
the turbine bearing.
Earliar Lat er
mod el model

)
L3
Adjustment sleev e. wBst egat e actuator
On earlier models Ihe adjustment sleeve is riveted to
the rad.
On later models (1982- modeis) the sleeve is loeked by
means of a lock nut and a seal. This al lows adjustment
of the charge pressure without replaeing aetuator.

•
Eedier
Adjustment of wastegate aetualor, see page 16.
model

28
 Group 25 Imake and exhaust systems
Turbocharger, modifications

L4
Turbocharger support braeket
Earlier models are equipped wi th a ring brackel and a
support brackat which is connecled between the tur-
bocharger and inlet manifoJd.

r'u5~~~r::;~=-- Ring
A new type of support brackel was introduced on 1983
bracke! modeis. The brackel is connected between the tur-
bocharger and cylinder block.
II is possibJe to install the new support bracke! on eadiar
models (see page 41).

Later design

,.. IMPORTANT I When filling a new support bracke! to tur-

bochargers equipped with 8 ,ing brackel, see tig, do not
delach the old support bracke!. This prevents turbo-whine
from being amplified by the ring bracket.

L5
Sealing flange : turbocharger to exhaust manifold
• The sealing flange is one of two types.
Earliermodels : sealing fl ange with a straight flangeand
gasket.
Later modeis : labyrinth seal (curved top of flange fits
into turbocharger). The seal belween the exhaust
manifold and turbocharger is not installed.
This change was introduced on 1981 modeis.

IMPORTANT I Do not interchange tomponents of earlier

2 and later design.

Earner design Lat er desilIn

e
" E[-.,
L6
B 21 Fl i ntercooler
Intercoolers were introduced on B 21 FT during the
1984 model year.
3 The major differences between B 21 FT and B 21 FT in-
tercooler are:

, - charge pressure controI system (rpm relay + soIenoid

valvel on interCOOler versions
- relay for disengagement of AC compressor on intercooler
versions
v
"

29
Group 25 Imake and exhaust systems
Turbocharger quick check, removal

,
M. Turbocharger, quick-check

M7
Turn off engine and listen to turbocharger. Rotat-
ing parts of turbocharger should continue to spin
for a short time after the engine is shut off
If not :
)
Oisconnect inlet hose from compressor housing and
check,
- that compressor wheel rotates freely
- axial play and side play ara normal
- that compressor wheel doas not contact housing
whan pressed towards il
l ~

•
N. Turbocharger
Special tool: 5230

Removal

N7
Remove :
- negative cable from the battery
- expansion tank from its holder

•
- expansion lank holdar (3 screws)

30
 Group 25 Imake and exhaust systems
Turbocharger removal

N2
Remove :
- prehealing hose belween the plale and air cleaner
- pipe and rubber betlows between the luel distribUlor
and the turbocharger. Withdraw the crankease ven-
tilation hose from the pipe
- pipe and connection between the turbocharger and
intet manifald, or between the turbo and the inter-
cooler (B 21 Fr with intercooler)
Cover the turbocharger inlet and outlet holes, to prevenl dirt
and dust entering the turbocharger.

N3
Detach exhaust pipe from turbo
Push the pipe to one side .

........

N4
Remove :
- ignllion leads from spark plugs
- uPPer heat-guard plate
- support bracKel between the turbo and the manifold (earli.
er deSIgn) .
- Iower heat-guard plate (unscrew retaining screw under-
neath the manilOld)

- support bracke! between the manifOk:l and Cylinder block

(later design)

' .~

31
Group 25 Intake and exhaust systems
Turbocharger removal

NS
Remove oil delivery pipe and manifold retaining ,
nuts and washers
Remove the oil pipe damp, retaining $Crews on the
turbo and the banjo union in the cylinder block (under
the manifoldl. Make sure no dirt gets into the oilways.
Remove the manifold retaining nuts and washers. let
one nut remain loosely installed in order to keep the
manifold in position.
Remove the oil delivery pipe. Coverthe openings on the
turbo.

N6
Detach fuel distributor from air cleaner
Slacken the clamps. Move the tuel distributor and the
lower section of the air deaner up onto the righthand )
wheel arch (place some kind of protection on the wheel
arch tirst).
Remove the air cleaner insen.

N7
»
Remove turbocharger and manifold
Take off the remaining retaining nut and washer.
lift forwards and upwards.
Remove manifold gaskets and the O-ring for the oil
return pipe from the cylinder block.

NB
Remove turbocharger from manifold
)
0'0'"
N9
Check the axial play
Check thatthe turbine and compressor wheel have nOl
scraped against the housing and that they do not scrape
when Ihe shaft is pulled axially.

•
32
 Group 25 Imake and exhaust systems
Turbocharger, disassembly

NIO
Check the radial play
Check thai the turbine and compressor wheel do not
scrape in the housing when depressed sideways and
turned at the same time.

Replacing turbocharger
In some cases turbochargers have been replaced unneces.
salily as a result of finding play in the turbine wft. How-
evet', since the shaft is 5Upported by full fIoating bearings a
certaln play ShOuId always be felt when inspecling the shaft
(the shalt Iloats on a film of oiI).
If the turbocharger has been replaced as a unit:
- transfer necessary parts. lise new gaskats.
- plug all the openings in the old compressor befora re-
tuming il (for repair, etc.)
- see page 36 before instaJling

Disassembly
Not.: Volvo does not recommend the dissassembly of
a turbocharger in a car still covered by the New·Car
Warranty. Nl1

Remove :
- the pressure hose from the nipple on the compressor
housing
- the return oil pipe
the Cirdip on the arm of the relief valve
- the waslegate and housing

9
-- NI2
Remove turbine housing
" Mark the location of the turbine housing and the con-
• sole for the pressure actuator. The marking must be
done carefully in order to allow reinstallation ofcompo-
nents in their original positions; otherwise, the connec-
tions between Iheturbo compressor and the engine will
not fit correctly.
The housing must be turned in order 10 rem ove all
bolts.
Notel Take care not to damage the compressor wheel.

-- 33
Group 25 Imake and exhaust systems
Turbocharger, c/eaning and inspecrion

Nl3
Remove turbine housing
Mark the position on the turbine housing. Mark clearly,
)
opposite a bolt.
The housing must be turned in order to remove all the
bolts.
Note! Take care not to damage the turbine wheel.

Cleaning and inspection

N14

• Clean and check:

- turbine and compressor housings )
- oil delivery and return pipes
- wastegate and housing
-' . Check the above parts for :
• damage, cracks
• wear and damage (the turbine/compressor wheel
does not stnke the housing etc.)
• smoolh contact surfaces
• burning damage to the wastegate (plate) and its con-
tact surface
• jamming of the wastegate arm
• dean oil and air passages of constrictions

N15
Clean turbin e and eompressor wheels
First tape over the oilways in the bearing housing. Care-
fully clean the wheels to avoid damage.
Check for damage and wear. If damaged, the bearing

• housing must be replaced, complete with wheels. Note:

under no circumSlances must any attempt be made to
reatign the wheel blades.
Check Ihal the shaft runs easily, does nol stick etc. Note
that there should always be a dearance belween shaft

.• ~
and housing due 10 Ihe construction of the floaling
bearings .
N16
5230
Cheek wastegate aetuator
Connect pressure gauge 5230 and a pressure pump.
Pump up the pressure and check when the !ink rod
starts 10 move. This should take place at about approx-

) imately
B 19/21 ET 50 kPa (7.1Ib/in 2 )

•
B21 Fl 36 kPa (5.1Ib/in 2 )
B 21 FTwith intercooler 52 kPa (7.4Ib/in 2 )
Pump up to a pressure of approximately 70 kPa (9.9
Ib/in 2 ). The pressure must remain constant for alleast
10 seconds.

34
 Group 25 Intalce and exhausr systems
Turbocharger, assembly

E-engines Assembly
Take care not to damage the wheels. Use new gaskets

With new compressor housing: N J7

Transfer nipple. plug and screw with clamp
Use Ihread sealer, Part No. 1161053-2 when installing
the parts.
1 '" plug
Note! Nipple and plug localion differ for the E and F
2 "" nipple
anginas of earlier models.
3 = scr.ew wi th clamp
On later models different housings are used for E and F
engines.
2

N1B
Assemble turbocharger
[] On same bolts, thread sealer must be used, and on
some, anti-sejze compound. II is also important thai the
studs are inst alled correctly. if not, the charge pressure
may be incorrecl.

Use new screwS.ln an emergency the old screws can be

used providad Ihese are coa lad wllh thread sealer (Part No.
1161053· 2J.
2 Antl -selze compound. ParI No. 1161035-9.

Assemble turbine housing and wastegatewith hous.ng.

Tighten to a torque of 20 Nm 115 ftlbs.).
Install a new gasket for the compressar housing on the
bearing housing. The housings must be turned in order
5 to install all the bolts.
Install the housings according to the alignment marks made
,. SUllable tools for tlghtenmg to eorrec! torc~ue:I
when dlsassembling. Tighten all balts even ly all around.

Torque wrench P.N. 1158687-2

Tighten to the following torques:
g Open ended Spannar 13 mm. P.N. 1158961 .1
- turbine housing 20 Nm (15 ftlbs)
- compressar housing 18 Nm (13 ftlbs)
o

e NI9
ft Adjust pressure actuator
g
Connecl pressure gauge 5230 and pressure pumplO the
pressure acluator.
6
Pump up 10 a pressure aL
819/21 ET 55 kPa /7.8 1b1in 2)
821 FT 41 kPa 15.8Iblin?)
821 FTwith inlercooler 57 kPa /8.1Iblin 2 )
,.d Push the wastegate arm forward {closed valvel.
AdjusI rad so thaI il fits exactly on thl:! pin on the arm
'I Disconnect pressure gauge and pressure pump. Con-
'I nect the hose to the compressor housing Ihose clampl.
'I
g Note! Pressure aClualor of earlier deSign can nOl be ad·
justed. ThiS IS saaled by the sieeve being riveled l O th e
actuator rad. If faulty. the pressure actuatOf must be re.
placed, see page 18.

35
Group 25 Intake and exhausr systems
Turbocharger assembly

N20
Check basic position of lin k rod

Link rod travel must be between 2-6 mm 10.08-0.24 in) to

obtaln correct operating function.

To adjust :
Dtseonneel rod sleeve from lever.
•
Mark position of rod al waslegate aetualOT.
Reeonneel sleeve to lever.
Measure diSlanee between mark and waslegate
aetuator.
Dislan ce "" 2--6 mm (0.08-0.24 inI
If ineoneet. replace wastegate aelualor. see instruet ions
on page 18.

N21
Install new cirelips

)
N22
Install oil return pipe
Use a new gasket . Check that the hole in the gasket is
suffieiently large, i.e. that it does not eonslriel the return
oil now.

Installation
N23
•
Measure bolts. turbo-manifold
Change bolts if needed
The bolts may be reused provided they are nol shorter
than 89 mm and 105 mm (3.5 in and 4.1 in) respeetively.

105mm
89m""

='-----~
,. *

36
 Group 25 Imake and exhausl systems
Turbocharger, assembly

N24
Assemble turbocharger and manifold
Earlier model : Tum the gasket between manifold and
turbo with the outward curve towards the turbo.
Smear the threads of the bolts and contact surlaces with
assembly paste, Part No. 1161078-9. The assembly
paste preven ts the inner securing plate from being de-
formed by the frictional forces when tightening .
Instal! inner securing plate and bolts.

N25
'Hm Tighten balts (nuts) with the following torque
In the fol!owing sequence and in three st ages:
I 1 Nm (9 inlbl
<$5Nm
l! 45 Nm (33 ftlbl
". '{..--~ III 45-

N26
Install outar securing plate
Knock the secu rin g plat e in position. Use a hammer and
sleeve.

N27
Bend in the inner securing plate
It is particularly important that the securing pla te for the
upper bolts is bent inwards at least 45°. This must be
done because the gap between the bolts and the engine
is small.
===,-----= ~-

N28
lift turbocharger with manifold inta position
Install new manifold gaskets, the marking UT must face
away from the engine.
Install a new Q-ring on the oi! return pipe. Coat the
O-ring with a little grease.
lift into pOsition and guide the oil return pipe through
the hole in the cylinder block. Ensure that the Q-ring is
installed p roperly. Install a washer and nut (new nut) to
ho ld th e turbocharger and manifold in position.

37
Group 25 Imake and exhaust systems
Turbocharger, assembly

N29
Install fuel distributor
Insert the air deaner insert.
Bend dawn and secure the luel distributor.

N30
Fil! turbocharger inlet with oil

N37
Install oil delivery pipe as weil as manifold
washers and nuts for manifold
Note : Check oil delivery pipe for sludge and if neces·
sary, dean pipe
Use new gasket far the oil delivery pipe and new
manifold nuts.
InSlall the oil delivery pipe in position. Install the banjo
union and washers, but do not tighten at this stage.
Make sure no dirt gets inta the pipe or anta the balt.
In stall the manifold washers and nulS. Do not forget the
lifting eye. Make su re the O-(lng on the oil return pipe is
fitted properly.
Connect the oil del ivery pipe to the tu rbo (new seal).
Tighten the banjo union in the cylinder block. Install the
damp for the oil delivery pipe.

N32
Install :
- uppe r heat-prOlection plate
mounting braeket between manifold and turbochar·
ger and/or th e mounting b racket between the cylin-
der block and turbocharger (see page 29)
- sparkplug cables

38
 Group 25 !nrake and exhaust systems
Turbocharger, assembly

N33
Install:
exhaust pipe. Smear the studs with anti-seize com-
pound. Tighten to a torque of 25 Nm '1a ftlbs)
- transmission front mounting

....... ,,'.

N34
Check that:
- throttle housing stud washers are in position
- O-ring SitS correctly and is undamaged
- connecting hoses/pipes are in a good condition and
do not contain loose partides. Aeplace hardened or
cracked hoses

N35
Install :
- the pipe with rubbar beflows between the tuel distributor
and the turbo. Connect the hose for the poSitive crank-
ease ventilation
- the preheating hose between the p1ate and the air cleaner
- the pipe between the turbo and the inJet manifold or be-
tween the turbo and the interCOOler (8 21 Fr with inter-
ooolec)
Make sure that the hosas/pipes are properly instaled and
thai the hose damps are tightened.

N36
Install :
- holder for the expansion tank
- expansion tank
- battery cable

39
Group 25 Intake and exhaust systems
Turbo, pressure pipe clamping

N37
Disconnect brown electric cable (from terminal
15) from the ignition coil. Run starter motor for
approximatelv 30 seconds. Reconnect electric
cable
Nate : This is done to ensure that the turbocharger re·
ceives lubrication.

N38
Start engine and check function
Idle the engine for a moment or two before revving up.
30 seconds

N39
Checkladjust charge pressure
See page 16.

N40
Sea I wastegate actuator
See page 17.

O. Air deliv,e ry pipe, clamping

B 21 Fl

01

• Two holders per hose clamp

• The holders to be positioned opposite each other as
shown in the illustration.

IMPORTANT
When installing the holders. make sure that they do not rest •
against the shoulders of the plpe.

B 21 Fl with intercooler 02
Parts required when installing hold ers
Part Quantity PIN.
Holder 8 1357202·9
16 {B 21 FT with intercooler)

40
 Group 25 Imake and exhaust systems
Insralling support braeket

P. Installing new type of support braeket

Operations Pl-ll

PI
Check type of exhaust manifold and turbocharger
If the hole for the support bracket screw is alreadv
threaded, it is not necessary to order the parts shown in
parentheses at the bottom of the list shown below.

Hole lor heat If there is not a hole it will be necessary to fi t a new

shield exhaust manifoid.
The exhaust manifold can be identified by checking the
Hole for support turbocharger flange facing the exhaust manifoid.
bracket
• straight flange = early type
• rounded flange "" late type (introduced in production

OJ
in July 1981)

h rl y type
:QJ
* ",_
la te r type
Required parts

Desc;ription Part number a ty

Support bracket 1 336 265· 2 l
Stav 1 336266-0 l
Spacer 1 257499·2 2
Bolt, M6S MS>.;l5 940 132-4 2
Stud. PS M81132" 1336261-1 l
Bolt. M6FS MSII 16 946440-5 l
Washer 419401 -5 l
Flange nut 94S 645-7 2
Ellhaust manifotd gasKet 463846-6 4
O-ring (oil return pipa) 1 306264 -1 l
Copper washers for delivery pipes 18671-8 2
Gasket for above 420475·6 l
Turbocharger bolts" 1 317067· 5 41
Outer lock plate l 326586-3 2)
Inner lock plate l 326222-5 2)
Ellhaust mamlold_ early type 1 336 238-9 11
Ellhaust manifold gasket. early type 1 276689-5
Exhaust manifoid, late type 1336237-1 "
11

• Stud 1336261-1 is made 0 1a special nickel alloy and must not be exchanged lor any other type of stud.
•• To be replaced onlyas feQU lred, see operBtion A12.

P2
Remove and dismantie turbocharger _ m anifold
See page 30, Nl-8.
Cover oilways to prevent dirt and dust entering tur-
bocharger.
Turbocharger - manifold assembly should only be dis-
mantled if the manifold is to be replaced.

P3
Remo ve exhaust m anifold
Grind east lugs flu sh u sing an emery cloth

41
Group 25 Imake and exhaust systems
Installing support braeket

P4
Assemble support bracket
Press "B" as far lO the rear as possible when lightening.
Tightening torque 23 5 Nm (17 hlbs).

Operations P5-9 do not apply to englnes with factory··

drilled hales.

PS
Drill and tap holes in cylinder block
25mm~
These holes may al ready be drilled and tapped on re·
cen t modeis.
Orm and tap Ihe first hole as described below, and use
the braeket lo mark the position of the second.
It is important that the hales are drilled at righ t angles to
3 mm the face.
Mark centre of lug on cyl inder block.
Drill a 4 mm diam. centering hale. Then drill a 6.8 mm
diam. hale to a depth of 25 mm (1.0 In). (Attach a pieceof
adhesive tape or hose lo the drill to indicat e the depth).
Tap the hale using a M8 tap lo a depth of 20 mm (0.8 in).
P6
Cut spacers to size
Remove 3 mm (0.1 in).
Nate : This IS not necessary on engines with factory
drilled hales.
P7
Mount new exhaust manifold on engine
Use the old gasket s as il is necessary t o remove the
manifold at a later stage, prior to final installation.
- Attach support braeke! wi th spacerstocylinder block.

P8
Check position
Check thaI hales in support braeket and exhausl
mani fal d caineide.
If necessary :
- adjusl by grinding spacers
- increase size of hale in "A" with a file

P9
Remove exhaust manifold

42
 Group 25 fntake and exhaust systems
Tu rbo, instaf/ing rod

PIO
Transferfollowing parts to new exhaust mani'old
B 19/ 21 ET: plug and gasket
B 21 Fl: lambda-sond.
Apply assembly paste PIN 1 161035-9 t o threads.

"' ..
Pl1
Modify lower heat shield

N ot e! Part number lor modified heat shield .. 1 336060.7

Hold shield in position and drill out rear hole to coincide

• with hole in exhaust manifoid .
Cul rear edge of plate to allowaspace for the new
support bracke!.

,
f
'" ...

6 PI2
I"stall turbocharger _ manifold
Install :

y - turbocha rger with manifold

- support bracke!
7 - front exhaust manifold
See page 36, and N23-40.
e
..
<.

,,. ~"':i~~C:llt~;---R,ng brackel IMPORTANTI When tining a new support bracke! to turbo-
Chargers equipped with a ring braCke! (see figl , do not
delach the old support bracket. This prevents turbo wnine
from being amplified by the ring braeket.

P9

43
Group 25 Intake and exhaust systems
Exhaust pipe and silencer

a. Exhau,st pipe and muftier

Type of exhaust system fitted to vehicle depends on model and marke!. The pictures below show same designs.

01
Genera l

• Usa new gaskets.

• The steel cone at the link should only be replaced jf the cone is damaged.
• The exhaust pipe must project approximately 40 mm (1 V:z") inta the silencer box.
• The rear muftier is mar1<:e.:l ".N" on the side to be coonectad to the exhaust pipe at the rear axle.
• Position the damps on the centre of the slattad section.
• The clerance between th.;! exhaust system and the undersida of the body must not be less than
20 mm (:V41.

02
Installing complete system
Follow the sequence below to avoid stresses in the system

A, E and F-engines

p. ~F
.,t t
l)
u=
1 loosen the mounting balts A between the exhaust
pipe's brackat and the bracket on the transmission
box .
2 Mount and align the entire system.
3 Tighten the nuts B front pipe-manifold.
4 Tighten the mounting balt C bracket-front pipe.

~ Make certain that the braeket on the exhaust pipe

rests against the bracket on the transmission box
and tighten bolts A .
5 Tighten the clamps D silencer-pipe.
C --\I D 6 If necessary. tighten cala lytic converter E.

~~r ~.Q 7 tf necessary, tighten link F.

8 Check that the system does not contact against the

"" body. Adjust as necessary.

ET and FT engines
1 loosen the balt A between the bracket and the
mounting iron.
2 Suspend and align the entire system.
3 Tighten the nuts B; front pipe-manifold.
4 If necessary, tighten mounting balt C brackeHront
t pipe.

," S If necessary, tighten mounting balt D bracket--

engine.
= 6 Tighten mounting balt E mounting iron-front pipe.
7 Tighten mounting balt A mounting iron-bracket.
8 Tighten the clamps F silencer-pipe.
9 If necessary, tighten link G.
10 Check thaI the system does nOl knock againstthe
body. Adjust as necessary .

44
'.-
 Group 25 Intake and exhaust systems
Crankcase ventilation

R. Crankcase ventilation

Rl
Cleoning/ checking
• clean/check hoses
• cfean the calibrated nipple (does not apply to turbo
engines)
• clean/repface ffame trap (does not appfy to turbo
engines).
A, E, F-engines 1975-80. see page . 46
Turbo eng inessee page ....... . 46
A, E, F-engines 1981- 85 see page . 47

R2
Blocked 'lame trop/ blocked system
A blocked fia me Irap will cause the crankcase ventila-
tion system to maffunction and resuft in high crankcase
pressure.
Symptoms are :
- oil dipstick "jumps out" of the pipe
- oil leakage al the seals in the cylinder block
- seafs need not always be replaced if they are feaking
due 10 a blocked ffame trap. Fix the name trap, clean
the engine and check whetherthe seals are feaking or
not
- the engine knocking (change to a new ffame trap if
necessary).
Reasans for a blocked flame trap may be:
- too long intervals between changing the engine oif
- the engine oil used is of inferior quaiity

45
Group 25 Intake and exhaust systems
Crankcase ventilarion

R3
A, E and F-engines 1975-80

~\
t::7c:::o:.,

D6a;p.
D [§~ O o air filter
DDCÖ::J

A-engines E/ F-engines

Turbo engines
R4

On turbo engines the crankcase gasses are vented "up-

stream" of the turbo. There is a constant negative
pressure when the engine is running, so no further
connection with the inlet pipe is required.
There is no flame trap on turbo enginas.

R5
Crankcase ventilation hose
An incorrectly installed crankcase ventilation hose may
result in starting difficulties (the air flow sensor plata
doas not l ift).
If the crankcase ventilation hose kinks, the result will be
that a positive pressure is formed in the crankcase. Th is
blocks the oil return from thelurbochargerwhich in turn
causes oil to leak anta the turbocharger shaft seais.
II is therefore important 10 check that the hose is not
kin ked at the nipple on the oil trap, nexl to the cold start
injector, or between the fuel line bracket and the line
elbow.
Cul the insu lating hose to half the diameter of the
hose at an angle of 45°.
2 Press thecrankcase ventilation hose up 10 the bead in
the pipe.
Install the insurating hose on the crankcase ven ti la-
tion hose so that it fits tight ly against the pipe.
3 Pull the crankcase ventilation hose over the cord start
injector.

46
 Group 25 Intake and exhaust systems
Crankcase ventilation

A , lE and F-engines 1981-85

A-en gines E/F-engines

'0-
R7
Drain hose
To ensure that the crankease ventilation functions ca r-
rectly the drain hose must be correctly installed, with
the outlet underneath the oil level in the oil sump.
If the drain hose is incorrectly installed or jf il is 100
shon, it is possible thaI Ihe crankease ventilation will
not function. The hose may, in addition, make cOnIact
with Ihe crankshaft and be damaged .

.•-
RB
When rem avin g oil t rap :
Make sure that the drain hose does not come up as weil.
If so, the oil sump must be removed to ensure that the
hose takes up Ihe correet position when inSlalled.

R9
Flame trap
Parts of a later design were introduced on models 1983.
If need be, Ihese can also be installed on ears of an
earlier model.
Flame !rap of a later design has larger channels and a
larger diameter than Ihose of a previous design.
Nate (Applies to both designs)
• The fia me trap must be checked and, if necessary,
cleaned/replaeed at ordinary service intervals .
• The flame trap must be p ositioned in the T-piece.

47
Group 25 Intake and exhaust systems
Catalyric converter

s. Cat.a lytic converter

Part nl,lmber
SI
I

/ I~
Type of calalytic converter filted to vehicle depends on

~
engine typa, modet and marke!.

~1
There is a plate on the converter, giving the part number
j;l and other data.
O Most designs also have an arrow indicating the direc-
~ l ian of now.

~ -
Dlrecllon 01 Ilow
.• ~

52

Same catalytic converters are fixad by means of a stud.

Do not replace the cenverter if the stud is broken. Drill
oul the stud instead and install a through-going bolt and
nut .

..•
53

The efficiency of the converter can be checked by

measuring and cemparing the CO con tent in front of
and behind the converler.

..-
48
 Group 25 Imake and exhausr systems
Air pump

T. A i r pump

valve
Distribution
plpe

IMPORTANT
• The air pump must not be dismantled or lubricated. If
faullV, it must be replaced as a complete UOlt .
• Never block the oullet from the diverter valve because
this may damage the air pump.

TJ
General
The air pump must be disconnected and plugged when
checking/adjusting the CO content, since the values witt
otherwise be incorrect.

IMPORTANT
Under no circumstances must the CO content be adjusted
after the air pump has been connected.

Checking system function

Operations TZ-5 .

T2
Check non-return valve
Remove the hose from the diverter valve.
Blow and suck alterna tely in the hose to check the func-
tion of the non-return valve.

49
Group 25 Imake and exhaust sys tems
Air pump

T3
Check air pump with drive belt
Check the drive belt; it should not have eraeks, be worn
or damaged.
Check that the air pump IS properly installed.
Plug the hose at the diverter valve (precaution).
Start the engine and listen to the air pump. The pump
has a distinctive sound especially when cold.

,.~

T4
Check diverter valve
The hose from the diverter valve must be plugged.
let the engine id le. Air shou ld now be blown out from
the outlet o f the diverter valve (A) .
Incrase the engine speed to approximately 50 rps
(3,000 rpm) and quickly release the throttle controI. The
alf now from outlet A Should cease for a few seconds and the
air should come out through the heles B in the side 01 the
valve.
If there is any 'ault, check 'irst the vacuum hose be-
tween the diverter valve and the engine's inlet p ipe. If
the hose is without any faults, test with a new diverter
valve.

T5
Stop the engine. Connect the hose to the diverter
v81ve

Changing drive belt

T6

If th e bel t is replaced because it has snapped, the 'unc-

tion of the non·return valve must also be checked be-
cau~e a faulty valve may have caused the da ma ge.

50
 Group 25 Intake and exhaust systems
Pulsair system

U. Pulsair system

General UJ

On ly carburettor engines of later models have shut-off

valves.
The valve disconnects the Pulsair system at a high
negative pressure in the inlet pipe. II theretore pre-
vents exhaust "puffs" from occurring when sh ifting
gears and braking with the engine.
If necessary the valve can be installed on older car-
burettor engines, see below.

U2
Installing shut·ott valve on previous models
Cut the hose from the air cleaner to the Pulsair system Cars with manual transmission :
and shorten il approximately 30 mm (1.2 in). Do this Remove the plug from the inlet pipe and screw the
same dlstance away from the bend on the hose. nipple inta posi tion.
Push the valve inta position. Nate! The arrow must Cars with Butomatic transmission :
point towards the engine. In stall the controi hose on the Cut existillg hose to the inlet pipe. In stall a T-nipple on
valve. The length of the hose should be approximately the hose.
550 mm (22 in).
Connect the contra I hose and clamp this with tie
damps.

Checking/adjustment CO contact
U3

The Pulsair system must be disconnected and plugged

when checking/adjusting the CO content, since the
values would otherwise be incorrect.
When Ihe system is connected the CD con ten I should
drop.

IMPORTANT
Undor no circumstances must tll0 CO cantent bo adJusted
with the Pulsair system connectod

51
Group 25 Intake and exhaust systems
Pulsa;r system

Checking system
U4
Check that :
- all connections are tightened and nOl reaking
- hoses are intact

U5
Che ck no n-return valves
,I" '. Remove the hose conneciWns from the non-return
valves.
Start the engine and hold your hand over the valves.
You should be able to feel thai air is being sucked in
through the valves, Le. no exhaust emissions.
Faulty non-return valves may result in backfiring, ex·
haust gases enter the air cleaner.
U6
Check s hut-off va lve
(on la ter carburenor engines only)
Checkthat the shutt·offvalve is open when the engine is
idling.
remove the hose from the air filter
cover (block) the hose wilh your hand. The CO con·
tent should increase
reconnect the hose

If the valve doas not open when the engine is idling the
reasan may be:
- faul1y valve
• - high negative pressure in the inlet pipa (may be caused
by too large a valve clearance or too-earl y ignilionl

When decelerating (high negative pressure in the inlel

pipa ) the shut-off valve should dosa.

Ifthe valve does nOl dose Ihis may result In exhaust "pu ffs "
when decelerating and when shilting gears.

Ul
Removingli nstalling distributio n pipe
When removinglinstalling the distribution pipe the ex·
haust manifold must be removed.

52
 Group 25 Intake and exhaust systems
Exhaust gas recirculation, on/off

v. Exhaust recirculation (EGR)

ON/OFF system
A-engines

\ VI

~ _·c
1978-81
This system can be found in the following markets!
modals.

n
Evaportallon
"0100
distrib"Io,
1
~~
sv:,,:.~m -~":::::J"'O
Market
Canada
Canada
Australia
Australia
Model year
1978--80
1981
1979-80
1981
Nordie countries 1981
Comments
Automatic
Manual
Automatic
Manual
Manual

'.1'5,
Nlpple
marked "E"

V2
1982-84
This system can be found in the following marketsl
modeis:
Market Model year Comments
Canada 1982-84 Manual
Australia 1982-84 Manual
Nordic countries 1982-84 Manual
Switzerland 1983--84 Manual

V3
Cleaning system
See instructions on page 64.

Evaporation system

53

j
 Group 25 fntake and exhaust systems
Exhaust gas recircufarion, on/off

ON/OFF system
E/F and ET-engines

V4
E-engines 1981-84
Th is system can be found in th e following marketsl
mode Is:
Market Model year Comment
Canada 1981-83 B 23 E manual
Nordic countries.
Australia 1981-84 B 23 E manual
Switzerland 1983-84 B 23 E manual

V5
F-engines 1976-78
Model 1978 This system can be found in the following marketsl
modeis:
Market Model year Comment
Modet
USA Federal 1976 Automatic
1975-77
Canada 1976-78 Automatic
Evaporation system

Ignition dlSlflbutor

V6
ET-engines 1984-85
This system can be found in the following markets/
modeis :
Market Model year
Nordic coun tries
and Switzerland 1984-85

V7
System cleaning
See instruct ions on page 64.
VB
Adjusting warning lamp
(on ly F-engines)
See instructions on page 65.

54
 Group 25 Intake and exhaust sys tems
Exhaust gas recirculation, on/off

Function test

V9
EGR valve should on ly open at part throttle with warm
engine. To check function of valve, observe movement
of link rod at different engine rpm and l emperatures.

Notalit may be dilficult at times to determine whether the

valve closes completely. The only way to check this is lO
remove Ihe pipe between the valve and the inlet maniiold
and to leel if the valve is leakmg ,

A valve which is open when the engine is idling resulls

in uneven idling, and the engine mayaiso stall.

Closed

VIQ
Check that EGR valve :
- is el osed at all engine rpm with cold engine, i.e.,
coolant temperature below 55°C (130"F)
- opens al part throttle with warm engine, i .e., coolan t
temperatures above 60"C (140 Fl
Vehicleswi th delayvaive : EGR valve opens approx. 2
seconds after engine is accelerated
- doses when engine speed drops to idle

IMPOATANT
Part numbar EGR valves ellist in various designs (different openlng
pressures, flow).
Open Ensure thaI correct valve IS used.
The vall/es are marked with Part Number

VI1

FAUL T SYMPTOM PROBABLE CAUSEJREMEDY

EGR valve opens when engine cold Defective thermosl at valve. Reptace. Thermostat I/alve
(coolant below 55 C = 130 Fl
Q
must open al 55-60 C (130- 140 Fl.

EGR valve does not open at part throttle with warm Vacuum hoses delective, kinked or incorrectly connected.
engine (coolant t emperature above 60"C "" 140°FI

Thermost at valve does not open. Test by remOl/mg

vacuum hose Irom EGA valve and blowing through hose
into valve.
Notel On vehicles with delay I/alve, disconneCI hose after
I/alve and check as above.

EGA valve seiled. Clean/replace va lve.

EGR valve does not dose when engine rpm drops to EGR valve seized. Clean/replace vatve.
idle

55
Group 25 Intake and exhaust systems
Exhausr gas recirculation, step/ess

X. Exhaust recirculation (EGR)

STEPLESS System
A-engines

XI
Delay valVB (on ly certain variations!.

Nipple marked "E" ~1982-84)

$hut·off valve
Pulsair -{<.::~..:..~

Evaporallon svstern

", ...

1981-84
This system is to be found in the lollowing markets:
X2
Market Model yea r Comments
Canada 1981-84 Automatic Checking/trouble-shooting system
Nordie countries 1981-84 Automatic
See instructions, page 12.
Australia 1981-84 Automatic
Switzerland 1983-84 Automatic

X3
Cleaning the system
See instructions, page 64.

56
 Group 25 Intake and exhausr systems
Exhausr gas recirculat;on, step/ess type

Y. Exhaust recirculation (EGR)

STEPLESS System type 1
F-engines

Plug

Evaporation system
Dislribulor

, ..

Yl
Y2
1976-77
Cleaning the system
This system is lo be found in the following markets :
See inSlruclions, page 64.
Mark et M o d el year Co mments
Japan 197&-77
USA, California 1976 Early mode Is
Y3
Adjusting warning lamp
See instruct ions, page 65.

57
Group 25 /ntake and exhaust systems
Exhaust gas recircu/ation, step/ess type J

Function check
Y4
EGR valve should on ly open at part throttle with warm
engine. To check function of valve, observe movement
of fink rod at different engine rpm and temperatures.

Notel II may be dlffleull at times to delermine whelher

vaeuum valve eloses eomplelely. The only way 10 check
this is to remove the pipe belween Ihe valve and the inlet
pipe and to feel if the valve is leaking .

A vaeuum valve which is epen when the engine is idling

results in uneven id li ng, and the engine mayaiso stall.

Y5
Closed
Check thet EGR valve :
is closed at all engine rpm with eold engine, coolant
temperature below 55"C (130~F)
If valve opens, I hermostat is defective. Thermostat
valve should open aI55-60~C (13Q-140<F)
- is closed al idle with warm engine and opens at part
throttle with warm engine
coolant temperature above 60G C ( 140"F).
If defeclive, see t rouble shooting seelion
- eloses quieklywhen engine rpm drops 10 idle. If valve
does nOl elose or eloses slowly, solenoid valve is
blocked or EGR valve has seized.

IMPORTANT
Vaeuum valves exist In variOUS designs (different opening
pressures. flow).
Ensure that eorreet valve is used.
Opan The valves are marked with part numbar.

Trou ble-shooting
Defective EGR svstern with warm engine
Operations Y~14
Plug Ii\?

Y6
Check hoses and connections
Check that the vaeuum hoses are intact eorrectly con·
nected and that they are not pinched.

Evaporation system
Dlstributor
,.-
58
 Group 25 Imake and exhaust systems
Exhaust gas recirculation, step/ess type 1

Y7
Check microswitch and solenoid valve
Turn on ignition.
Press microswitch to make/break circuit to solenoid. A
dick should sound from sotenoid.

Y8
If incorrect. check :
- microswi tch ground
- current supply to solenoid
- wire between microswitch and solenoid

Y9
Check microswitch adjustment
Connect a test tam p between microswitch and wire 10
solenoid.
Ignition should be on.
Place a 1.5 mm (O.06 in ) feeler gauge between stop
screw and boss. Test lamp shoutd tight up.
Change to a 2 mm (O.OB in) feeler gauge and check thai
test lam p is off.
Switch off the ignition.

Y10
Adjusting microswitch :
- place a 1.5 mm feeler gauge belween stop screw and
boss.
- slacken lock nut and unscrew upper stop screw until
lest lamp goes out
- screw in stop screw unlil lamp just lights. Tighten
lock nut
- check adjustment according to Y9

Yl1
Check thermostat valve
Disconnect thermostat valve hoses from 'S' on vacuum
amplifier and from solenoid val ve.
Blow through valve to check that it is open. Note ! En-
gine must be warm, 1.e., above 60°C (140"F).
Re-connec! hose 10 solenoid valve.

59
Group 25 /ntake and exhaust systems
Exhaust gas rec;rcu/ation, step/ess type

Yl2
Check EGR valve
Oisconnect vacuum hose from valve.
Connect hose 10 a vacuum pump and switch pump on.
Valve should open.
Ae-connect hose.

J
':MI"

Yl3
Check vacuum amplifier and solenoid valve
Slart engine and run at id le.
Oisconnect hose from connection 1 on vacuum ampli-
fier.
Connect a vacuum pump to connection 1.
Switch on pump and check funetion of EGA valve.
Valve should be dosed when engine idles. If valve
opans solenoid valve is defeclive.
Check forleaks invacuum amplifier and hoses by check-
ing thai pump gauge reading remains slable for at least
10 seconds.

I ..___~ Increase engine rpm and check that valve opens. If not,
"',.. solenoid valve or vacuum amplifier is defective.
Turn off engine.
Oisconnect vacuum pump and re-connecl hose 10
vacuum amplifier.

Yl.
Check air filter inlet
Check that air inlet is leakproof. leaks would cause too
low a depression at venturi end of inlet.
Check air filter, inlet hose and filter cartridge.

...
, ,

60
 Group 25 /ntake and exhaust systems
Exhaust gas rec;rculat;on, step/ess types 2 and 3

Z. Exhaust recirculation (EGR)

STEPLESS System types 2 and 3

<;~ ..........._....E~/F.engineS

Evaporallon system

Olstributor

..
' ..
'

Zl Z2
Type 2 Type 3
This system 15 to be found in the following markel s: This system is to be found in the following markels :
Market Model vear Comments Market Model year Comments
USA USA Federal 1978--79 B 21 F
California 1976 lale model Canada 1981-83 B 23 Eautomat ie
USA Federal 1977 Australia 1981-84 B 23 E aUlomatie
Nordie eountries
Switzerland 1983-84 B 23 Eautomatie

Z3 Z4
Cleaning system Resetting warning lam p
See instructions page 64. (Only F-engines)
See instruetions page 65.

61

J
Group 25 /nfake and exhaust systems
Exhaust recircu/ation, step/ess types 2 and 3

Function check
Z5
EGR valve should only open at part Ihrottle with warm
engine. To cheek function of valve, observe movement
of link rad at different engine rpm and t emperatures_
An open valvewill cau se erratie idling and passibly stall
the engine.

Note l II may be dilficull at times 10 delermine whelher Ihe

valve eloses eompletely. The on ly way 10 check this is 10
rem ove the pipe between the valve and the inlet manifold
Clo,ed and to leel if Ihe valve is leaking.

An open valve when the engine is idling resu lts in une-

ven idling, and the engine maya iso stall.

Z6
Check that EGR valve :
is dosed at all engine rpm wi t h cold engine, coolant
temperature below 55<><: (130C F)
If valve o pens, thermostat is defective. Thermostal
valve should open at 55-60-C (13Q-140"F)
- is closed al idle with warm engine and opens at pari
Ihrottle with warm engine
o... coolant temperalu re above 60"(; 1140' F).
If defeetive, see troubleshoOling sectian
IMPQRTANT doses quiekly when engine rpm drops to idle. If EGR
EGR valves e)(151 in variol,lS designs (differenl opening valve does not dose d.sconneet hose from valve and
pressures. flow). re -check. If valve still does not dose vacuum am pli-
Ensure Ihat eorreel valve IS used . fier is probably defective. Re-test with a new vacuum
amptifier. If valve still does not close it has probably
The valves are marked wilh pan number. seized and should be cleaned/replaced as necessary.

Trouble shooting
Defective EGR siystem with warm engine
Operations Zl-11

DiSlflbutor

Check hoses and connections

.•- Z7

Check that the vacuum hoses are intact. co rrectly con- vacuum hoses indi reclly eonneeted to the system, sueh
neeted and that they are not pinehed. Check alse the as the hose to the distributor.

62
 Group 25 /ntake and exhaust systems
Exhausl gas recirculation, step/ess types 2 and 3

ZB
Check thermostat valve
Disconnecl thermoslat valve hoses from intake mani-
fold and connection 'R' on vacuum amplifier.
Blow through valve to check thai it is apen. Notel
Engine must be warm, i.e., above 60°C f140°Fj.
Ae-connect hoses.

~~,
R l~
R "....
Z9
Check EGR valve
Disconnect vacuum hose from valve.
Connec! hose to a vacuum pump and switch pump on.
Valve should open.
Re-connect hose.

..
'

ct3 Z10

--
Check vacuum amplifier
Disconnect vacuum hose marked "V" from vacuum
amplifier.
Start engine and run at id le.
Connect a vacuum pump 10 vacuum amplifier connec-
tion 'V' and start pump. EGR valve should open if
vacuum amplifier is functioning correctly.
Turn off engine and re-connect hose 'V'.

Zl1
Check air filter inlet
Check thai air inlet is leakproof. leaks would cause too
low a depression at venturi end of inlet.
Check air filter, inlet hose and filter carlridge.

j
63
Group 25 Inlet and exhaust systems
Exhaust gas recirculation

AA. Cleaning of exhaust gas recirculation system

Applies to all systems

A ...ng ine. E/F...ngine.

.-.
AAI
Cleaning o f p art s
n ?,) ...Z1.....'1'1
~'~~J" ~ To clean EGA system, tap all parts lightly with a soft
k
mallet to remove carbon deposits.

J Aemove dirt from channels and nipples with a screw-

driver and blow parts clean with compressed air.
Check in particular that the valve seal in the EGA valve is
completely tree of carbon deposits,
On F-engines the warning lamp must be adjusted after
the system has been cleaned (see next page).
On B 21 F 1976 USA California, earlier model, and
Japan 1976-77 the microswitch must be set in connec-
tion with the cleaning, see page 59, operations Y7-1O.

IMPO RTANT
• The EGR valve must not becleaned in a solvent because
this might damage the diaphragm.
ET-engine. • The EGR valve must be held in the hand when cieaning.lt
must not be fixed In a vice or similar.
• When changing an EGR valve, make sure that a correct
valve is installed; check the part number.

64
 Group 25 Imake, exhaust system
Resetting ind icator lamp

AB. Resetting dashboard indicator lamp

F engines only

ABl
Indicator lamp will light each time the exhaust
gas recirculation system is due for service
Lamp is actuated by a switch connected t o ear odometer
and mounted on back of speedometer.
To reset switch, remove cover (shown adjacent) and
depress white push button (arrowed).
Re-fit cover afler adjustment.

65
Group 25 Imake and exhaust systems
Lambda-sond system

AC. Lambda-sond system

Appties to B 21 F/n-engines with el fuet injection system. Engines with LH-jetronic fuet injection system do not
have separate lambda-sond systern, as it is incorporated in the engine's fuat system.

AC,
Positiotrling of components

Earlv model

FreQuencV valve
Pressure differential
switch, 821 FT onlV
Later model
~
1 9~5 Tesloutlet

Charge air pressure.

switch on IV 8 21 FT

Controi unit

(~" ;~:::~
~~-. "

............
-. Jf
. ..
System relaV
LamMa -sond lhermostat valve
(821 Fl 1984-85) Thermocontact
(1982-85) .•
~

66
 Group 25 Intake and exhaust system
Lambda-sond system

Connection of vacuum ho ses

For pressure differential switch and charge air pressure switch

AC2
To charge air
overpressure SWItch
4
Pressure differential switch
(821 FT, 1984--1985)
2 Thermostat valve
3 Delay valve
(automatic only, 1982)
4 Charge air overpressure
switch

2
....'
,

AC3
Wiring diagram

I
SB GN

, sa
"L; 5
2
4
111>-----P- - - ,-m R
+

1 /.L 2· R

GN
SB
16
17
• BN
GR
GN
-
sa:

19!5 ...
.7
30

,,
r----- 7 15 -o ....
-19-81-«fo ~ 86 el From relay

l ,J , 5 8 SB
el-system
, .5
connection 87b
!GN ,'G N
6 M
38
0~
.....
4
..
, ".

Colour coding list of components

SB black R ,ed 1 lam bd a-sond
GR grey BN brown 2 Test outlet
W white BL blue 3 Therma l switch (1982)
GN green P pink 4 Charge air pressure switch (on ly B 2 1 FT)
5 Controi unit
6 Frequency valve
7 Pressure differential switch
(B 21 Fr on ly, 1984-1985)
8 System retay

67
Group 25 Intake and exhaust systems
Lambda-sond system

General instructions WhE!n working on Lambda·sond system

AC4
Removing connector from controi unit
Ignition should be turned off when removingJinstalling
connector.
Push lock spring up and fold out connector.
Do not pull connector straight out.

AC5
Checking terminals

CAUTION
Never check terminals Irom front 01 connector.
Experience has shown thaI terminals and circuit can be
damaged wllen tested Irom front.

Remove cover from connector.

Check terminals through holes in side of connector. 00
not use excessive force.
Tarminal numbers are stampad in side of connectOf.

68
 Group 25 Imake and exhaust systems
Lambda-sond system trouble-shooting

Fault symptoms

AC6

System faults can be :

- starling difficulties, especially with hot engine
- rough running
- rough idle with cold engine, below 15°C (60~ F). This
can result from a defective thermal switch
High luel consumption or bad driveabi lity with cold
engine (below 55°C"" 130°F) B 21 FT 1984-1985 en-
gine. Can resufl from defective pressure differential
switch
B 21 FT: low top speed/poor performance_ Can result
from defective microswitch.
The symptoms above can of cou rse result from other
engine faults.
A rough check of the system can be performed by start-
ing engine and listening to (feel ing) the frequen cy
valve.lf the valve "buzzes" the Lambda-sond system is
probably OK.

Trouble-shooting (checking) of Lambda-sond system

If possible, enginetemperature should be below 15°C (50°F) when checking Lambda-sond
system because it is necessary to check thermal switch when installed on vehicle.
Also, temperature must be below 50°C (120°F) when checking thermostat valve on vehicles
equipped with pressure differential switch.

AC?
Checking vacuum hoses
Check that these are correctly connected and that they
are not pinched or damaged.

Only B 2 1 FT 1984--1985 AC8

Checking thermostat valve
Coolant temperature below 50' C (120°F).
Disconnecl hose from pressure differential switch and
blow in hose.
Va lve should be open at temperatures beJow 55"C
(130 F).

69
Group 25 Intake and exhaust systems
Lambda-sond system, trouble-shooting

1982- AC9
Check the rmal s witch
Discannect wire from thermal switch.
Connect a test lamp between wire and a 12 V current
supply.
Test lamp shou ld light (switch clased) at coolant
lemperalures below 150(; (60"Fj and be off at tempera-
tures above 150(; (60"F).
Aecannecl wire.

In cases where switch function is suspect, remove switch

+ .. - and check separately.

AC10
Oisconnect lambda-sond

Acn

.
Connect 8 dwell meter
" Cannecl red wire 10 lest point.
:6~'DWELL Sel meter lo position for 4 cyl inder engine.

4 The dwell meter must have a measunng range of atleasl

70".

E'~ E)(ample of suitable instruments: Volvo Mono·Tester and

SUN instrument of later design.

Later design

-1977 AC12
_1 977 B 21 F
Remove the connector from the air fl ow meter.

70
 Group 25 Intake and exhaust systems
Lambda-sond system, trouble-shooting

1978- 1981_
1978-
B 21 F/ FT
Connect test relay 5170.
Note ! On 1981 models -Iexcept turbo) the connector
should also be removed from the igmtion system con-
trol unit. Be careful; do not loosen rubber seal in the
connector.

AC14
Switch on the ignitio n

AC15
Check m eter reading and listen to frequencV
valve
A bUZling sound should be heard from valve and meter
should show:
B21F 5 1-57"
B21 Fr 42-48"

DWEU. -----------V
Valve does not buu and
meter sho w s O
~

~
'.170 m eter d efl eets ----------r:7
Valve d oes not buzz but

Valve buues but meter - _ _-<~.. probably a break

sho w s O in the wire
to the test point

-----~
Valve buues but
m et er re adi ng t oo high

1982 models - AC16

Check enrichment (cold engine)
Oisconnect and earth wire from thermal switch.
Owett meter reading should change to:
B21 F

-"~
B 21 FT
Re-eonneet wire.
If readings are not accarding to above. check wiring
before testing with a new contral unit.

....
'

71
Group 25 Intake and exhaust systems
Lambda-sond system, rroubfe·shooting

OnfyB21FT AC!7
Check enrichment
Connect pressure gauge 5230 and test pump. Connect
to t he hose from the inlet manifoid.
Pump up the pressu re to 20.3 kPa (2.8IMn 21. The read·
ing on the dwell meter should then change to 64-70·
(pressure switch grounds the Lambda-sond controi
unitl.

Only B 2 1 FT 1984--1985 AC18

Check acceleration enrichment
Connect a vacuum pump to pressure differential switch
and st art pump.
Disconnect pump. W hen pump is disconnected, switch
doses and dweJl meter reading should ch ange t o 82° or
ahove for a short period, and then decrease.
If incorrect. connect a bridge wire across terminals of
con necto r. If mete r reading now changes t o 82° or
above, the wiring and contrei unit are OK, are switch
should be replaced.

AC 19
Switch off ignition

AC20
Connect wires and connector
1975-1977 1978-
Connect the connecto r to the ignition system controi
unit. Check t hat rubber seal is in place. Without the seal,
wa ter can leak in and cause oxidation etc.
197>1977 : connect connector to air flow meter.
197ft-: remove test relay 5170. Connect the wire to
....'
' ignition coil.

AC21
Connect measuring instrument
- rev counter
- CO meter. Connect the meter to the probe port in the
exhaust pipe in front of the catalytic converter

/
AC22
,.~
Start engine

72
 Group 25 Jntake and exhaust systems
Lambda-sond system, troubJe-shooting

821 FT 1984-1985 AC23

Check thermostat valve
Warm-up engine and disconnect hose from pressure
differential switch. Place finger over end of hose.
Thermal vacuum switch sh ou Id elose (i.e. no suction) at
approx . 55°C (130~F) .

~~•.. AC24
Warm-up engine
Wait at least 5 min ahercoolant thermostal has opened
before carrying out next step.

0=0 0=0
rpm co Check idle speed and CO content
AC25

l .•- Adjust if necessary.

AC26
Check Lambda-sond function
Connect Lambda-sond to dweU meter and CO meter.
Check rea di ng.
Owe!! meter reading should change slightly, usually
drop when sond is connected. CO level should drop to
less than 1.0 %.
If neither COcontent nor dwell meter reading changes :

"- Disconnect Lambda-sond and ground the wire. CO con-

tent and dwell angle should increase.
Wiring and contral unil are OK if meter reading in-
creases.
Re·test with a new Lambda-sond .
If meter reading does not change, either contral unit or
wiring to controi unit is defective.
CO content does not change, dwell meter reading
drops significantJy:
This indicates a defective frequency valve. Re-test with
a new valve.
CO content and dwell meter reading incraasa :
This indicales a defeclive Lambda-sond (internat short-
circuit). Re-test with a new Lambda-sond.

End of test

73
Group 25 Imake and exhaust systems
Lambda·sond system, troubfeshooling

From AC15 : Frequency valve does not bUlZ and meter shows O
On completion of repair proceed with operation ACJ6 on page 71.

AC27
Switch off ignition

AC28
Remove connector 'rom controi unit.
Remove cover

AC29
Switch on ignition . Check current supply
Cennect a test lamp between terminal 8 and greund.
Lamp should light.
If not. check wiring and system relay. see wiring dia·
gram on page 67.

AC30
Check ground connections
Connect a test lam p between term inalS and 5, and 8 and
16 respectively. Lamp should light in both cases.
If lamp doas not light, check greund connections at
intake manifoid.

AC31
If the above st eps de not indicate a fault, test system
with a new contre i uni!.

'.~

End

74
 Group 25 Intake and exhaust systems
Lambda-sond system, trouble-shooting

From AC16 : Valve does not buzz but meter deflects

On completion of repair conrinue with operation AC16 on page 71.

,
AC32
Check current supply to frequency valve
as Conne<:t a test lam p between the connect or pin (green
wire) and ground. Lamp should light.
If lamp does nOl l ight, check funchon of system relay
and wiring .

AC33
Check wire from frequency valve to controi unit
Connect a test lamp between both connector pins.
lamp shou ld ligh t (dim ly).
If lam p doas not light, controi unit or wiring to controi
unit is defective.

AC34
Measure frequency yalve resistance
Use an ohmmeter.
Aesistance should be 2-3 ohms.
Replace frequency valve if incorrect.

AC35
If the above steps do not indicate a fault, test system
with a new controi uni!.

End

75
Group 25 Intake and exhaust systems
Lambda-sond system, troub/e-shoo ting

From AC15: Valve buzzes but meter reading is too high

On camp/erion of repair pToceed with operation AC16 on page 71 .

B 2 1 FT 1984-1985

AC36
Check pressure differential switch with relay
Remove connector from switch. If meter deflection
drops, switch is defective (short-circuited) and must be
rep laced.
Re-connect switch connector.

AC37
Turn off ignition

AC38
Remove connector from controi unit
Remove cover

AC39
Turn on ignition

AC40
Check wiring to :
- thermal switch (1982- ) and microswitch (B 2 1 Fr) as
applicable
- pressure differential switch (B 21 FT 1984-1985) as
applicable
Connect a test tamp between terminals 8 and 11, and
between terminals 8 and 7 respectively.
lamp should not light in eithercase. lf lamp lights, wire
is short-circuited.

AC4J
Checking wires to Lambda-sond
Note! The Lambda-sond must be disconnected.
Connect an ohmmeter between terminals 2 and 4. The
resistance should be infinite. If the resistance is low
there is a short-circuit between the wires.

AC42
If the above steps do not indicate a fault, test system
using a new controi unit.

End

76
 Group 25 'make and exhaust systems
Lambda-sond

AD. Lambda-sond

AD7
Checking lambda-sond

As an alternative checking method, the Lambda-sond can

be checked by using a voltmeter.

Run the engine warm for at least 5 minutes after the

coolant thermostat has opened.
With the engine running, connect a voltmeter to the
sond. The meter must give areading (normally 0.5-
0.7 V) if the sond is in order.
•••

AD2
Replacing l a mbda-sond
Smear bOltjoint paste "Never-Seez" (PIN 1161035-9) on
Lambda-sond threads. Make sure that no paste enters
slot as this will inhibit function of Lambda-sond.
Torque to SS Nm (40 ttJbs).
When removinglinstalling a sond in B 21 FT engines,
use too1525O.

AD3
Resetting dashboard ind icator lamp

Indicstor lam p will light esch time the exhaust gas reeir-
culation system is due for service.
Lamp is actusted by a switch connected to ear odometer
and mounted on back of speedometer.

To reset switch, rem ove cover (shown adjacent) and

depress white push button (arrowed).

..-
Re-fit cover after adjustment .

77
Group 26 Cooling system
Conten ts

Group 26 Cooling system

Operation Page
Fault symptoms - poar caoling AEl 79
Coolant ........... . AF1-S 79
lesting cooling system . AGl 81
Radiator .... . AHl - 3 81
Thermostat ... . A1 1- 3 82
Temperature sensor ........... . AJl 82
Coolant (water) pump, replacement AKl- 18 83
Drive belts .......... . All-4 87
Cooling fan ..... AMI 89
Electric caoling fan ANl-4 90

78
 Group 26 Cooling system
Fault symptoms, eoo/ant

AE. Fault symptoms - poor cooling

Engine overheat s and/or poor operation o f ai r condit ion ing

POSSIBLE CAUSE REMEDY OPER·

ATION

Coolant leakage, Pressure·test system AG'

opening pressure of expansion tank cap 100 low

Radiator blocked by e.g. insects Clean AH'

Air bypasses radiator Check/adjust position AH3
Ignilion setting 100 low Check/adjust -
Retarded ignition increases engine combustion temperature

CO content too low Check/adjust -

Poor mixture (tow CO) increases engine combustion temperature

Id le speed too low Check/adjust -

Too low an id le reduces cooling

Radiator blocked with sludge Check radiator AH2

Incorreet type of coolant or aged coolant Check/dra in coolan! AF3
Incorrect coolant mixture Check/adjust mixture AF'
Fan clutch defeetive Aeplace fan clutch

Incorreet type of thermostat Check/replace Al 1- 3

Nate engine must not be driven for long periods without thermosl a!

Vehlcles with AC :
Idle speed compensation defective
-
Check/adjust

Electric cooling fan defective Check/adjust ANl-4

AF. Coolant

AF!
A C General
SInce aluminum is used in the engines, active corroslon pro-
tectJon JS necessary in the COOIant to help prevent corrosion
damage.
50% • Use genuine Volvo coolant diluted w ith clean water in
proportions of SO/50. This mixturs helps to prevent
corrosion and frost da mage.
Vehicles manufactured before 1981 were filled w ith
type A (red) cooiani whereas vehicles manufactured
after 1981 are filled with the improved typa C (blue-
green) coola n!.
• See overleaf

79
Group 26 Cooling system
Coolant
AF2
Topping-up cooling s ystem
Never add only water 10 lhe cooIing system. Use genuine
VOlvo cooIanl diluled lo a SO/50 ITlIxture with dean water.
Two different types of coolants are In use, type A ano
type C. When topping up a cooling system filled with
type A coolant - either use type A or add type Ccoolan!.
Note, however, that no mora than 25 % of the coolant
can be substituted with type C coola n!. If more coolant
is required the cooling system must be drained and
filled afresh with type C coolant.
E.g.lf cool ing system capacity ,., 9.5litres (10 US qts) no
more tha n 2.4 litres 9 (2.50 US qts) oftype C coolan t can
be used to top up system. (2.41 refers to diluted coolant
Le. 50 % water + 50 % concan t rated coolant).

AF3
Changing coolant
The coolan t must be replaced regularly since the corro-
sion protection in the coolant loses effect with lime.
Always fill cooling system with type C coolant.
Aemember t o change the decal (PIN 1 331 473-7) on the
expansion tank when changing to type Ccoolan!.

AF4
Draining
_ set dashboard heatar controi to max. heat
- disconnect battery
unscrew cap from expansion tank
- open drain cock on right side of cylinder block.
Attach hose to cock to prevent spillages
- disconnect lower radiator hose from radiator
_ dose cock, re·connect lower radiator hose and bat·
ter;

AF5

<cooQI TEMP llwAR~ Filling coolant

Capacity with manual gearbox 9.5 litres (10.0 US qts)
automatic 9.3litres (9.8 US qts)
ensure heater controls are set to max heat
- add coolant through expansion tank
- - warm-up engine and top up as required
- re-fit expansion tank cap.
'.'"
BO
 Group 26 Coo/ing system
Pressure testing coo/ing system, radiator

AG. Pressure testing cooling system

AG)

Check brealher hose belween radialar and expansion

tank. Replace hose if worn or cracked.
Connecl pressure tester belween radiator and ex pan·
sion tank.
Increase pressure and check opening pressure of ex·
pansion tank cap and for leaks:
- opening pressure '" 65-85 kPa (9.2-12.0 psi)
- check that pressure does not drop noticeably during

.•-
30 seconds .

AH . Radiator
Cleaning radiator
AH)

Remove flies, el e. from radialorgrille by hosing radiator

from inside as illustrated. 810w elean with compressed
air.
Nota l Do nOl spray water or blow air at 100 high a
pressure at radialar as dam ag e may result.

Checking radiator

AH2

Heat up engIne until thermostat apans and then for a few

more mnules
Turn off engine.
Detaeh fan shroud from radiator.
Check radiator with hand, warm and eold sections Indi ·
cate that radiator is partly blocked .

•••
Checking/adjusting position of radiator
AH3

Radiator must lie flush with front panel otherwise same

air will bypass radiator.
Adjust pOSition of front panel as required.

/ Plastie toa m can also be used to seal gap between

radiator and front panel.
- 2 strips 20x50x410 mm
- 1 str ip lOx25x660 mm

B'
Group 26 Cooling sys~
re
::m
.::... _ _ _ _ ____ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ __
Thermosrar, remperature sensor

Al. Coo lant thermost at

General
AI1
It is important that the corr€:ct type of thermostat is
fitted to vehicle because it determines flow of coolant
through cooling system.
Do not run engine for long periods wIthout thermostat
otherwise engine may overheat .

Repl acement
A/2
Drain the coolan! so that the level is below the thermo-
stal. Use the drain cock on the righthand side of the
cylinder block.
Clean contact surfaces on the thermostat housing and
cylinder head.
When inslalling, use a new sealon the thermostat.
Top up with coolanl aher the engine has been warmed·
up.

Testing A/3
Thermostat can be tested, if required, in hOI water. After
reaching opening temperature (see below) it should nol
take longer Ihan 2 minutes for thermostat lo open fully.
Three types of Ihermostal are in use:
M ark ing Begi ns FuHy
ope ning at open at
82 81-83 C 90-94 C
(178-181 CF) (194-201 ·F)
87 86-88"C 95-99 C
(187-190 Fl (203-210· F)
92 91-93 C 100-104 C
(196-199 Fl (212- 219 Fl

AJ. Coolant temperature sensor

AJ1
Locati on of sensor
Sensor is located on left side of cylinder head.

..
'

82
 Group 26 Coo/ing system
Coo/ant pump

AK. Coolant pump, replacement

AK7
General
Replacement of coolant pump, rubber sea Is or gasket
must always be preceded by pressure testing the cool·
ing system.
Coolant pumps are often changed unnecessarily, for
example when only a gasket is leaking. In the ca se of a
leakage, the system should Iherefore be pressure tested
(see AG1) in order 10 eslablish whether there is a leak·
age, and to avoid unnecessary pump replacement.

AK2
Chan ged m o untin g bolt for return pipe
The hexagonal balt has been replaced by a different
balt, PIN. 942247·8. This has been donelo make il easrer
to remove/install the balt on engines with Pulsair
system.
See page 85 regarding removal of hexagonal bolt on
engines with Pulsair system.

- Drain the cooling syst em

Move the heater controi to maximum heat.
Remove the cap from the expansion lank.
AK3

Open the drain cock on the righthand side of the engine

block.
Disconnect the lower hose from the radiator.
/

83
Group 26 Cooling system
Coo/am pump

AK4
Oisconnect the fan shroud and move it out of the
way

AK5
Loosen alternator belts
Loosen the alternatar mounting balt and the clamp balt.

AK5
Remove the fan
NOTEI There are 3 different types of fans:
fixed fan
- temperature·controlled clutch-type fan
- clutch-type fan

AK7
Remove :
- fan shroud
- timing gear casing
- lower radiator hose from coolant pump

84
 Group 26 Coo/ing system
Coo/am pump

AKB
Loosen return pipe at the coolant pump
Remove the bolt, washer and nut.

AK9
Removing hexagonal bolt on engines with Pulsair
system
There are two different methods for removing the old
hexagonal bah :
Cars without block heaters
Remove the rear mounting boll of the return pipe (rear
edge of cylinder block).
loosen and pull the coolant pump out slight ly. Remove
the balt.
Cars with block heaters
Drill away the head of the bol! (drill 08 mm).

AKlO
Remove the coolant pump
Remove all bOlts, washers and nuts.

AKl1
Clean gasket surlace and ,contact surlaces
Scrape off any traces of gasket material from the block
and coolant pump. Clean the rubber ring contac! area
on the cylinder head.

85
Group 26 Coo/ing system
Coolant pump

AK12
Install coolant pump
Use a new gasket between the pump and the cylinder
block.
Inslall a new O-ring on Ihe coolant pump.
Secure the pump with the two nuts.
Make sure thallhe O-ring is in position and thaI il is not
damaged. Tighten the nuts so that the pump does not
slip, but can be slid upwards.

AK13
Tension the coolant pump against the cylinder

J head
Install the remaining washers and bolts.
Tighten the bolts and nuts.

AK14
Install:
- the return pipe. NOTE! On cars with Pulsair system
the mounting bolt of the pipe must be replaced by a
bolt of the new type (see page 83!.
- timing gear casing

AK1S
Install :
- lower radia l or hose
- fan shroud. NOTE! Do nottighten the pulley and the
fan at thi s slage

86
 Group 26 Cooling system
Coo/am pump, drive be/t

AK16
Install fan shroud

AK17
Inst all all drive belts
Tension the belts.
With correct tension il should be possible to deflectthe
belts 5-10 mm (0.2-0.4 in) halfway between the pulleys.

AK18
FiII with coolant
Close the drain cock.
Filt the expansion tank to "maximum" level.
Aun the engine warm with the heater controi set in hot,
check that there is no leakage, and top up with coolant if
required.

AL. Drive belts

ALl
General
With correct lension II ShOldd be possible to deflecl the
bells 5-10 mm (0.2-0.4 in) halfway between the
pulleys.
Not e! When changing the alternator-fan belt, both belts
must be replaced.
When adjusting the drive belt for the cooling system on
cars with power steering and one drive belt, use tool
5197. See next page.

B7
Group 26 Cooling system
Drive bells, AC

Drive belts, air conditioning

A L2
Without power steering
Tension the belt by adjusting the position of the com-
5-10 mm pressar.

..
'

AL3
With power steering and two drive belts
Tension the belt by placing an appropriate number of
shims between the two halves of the crankshah pulleys.
One shim changes the belt tension by approximately 5
mm (O.2 in).

A L4
~5197 With power steering and one belt
Tension the belt by moving the power pump.
Check the bell tension by posilioning tool 5197 against
~
the belt between the crankshaft pulley and the pump.
The belt tension should be 17- 18 units .

...

BB
 Group 26 Cooling system
Fan

AM. Fan
Type of cool ing fan fined to vehicle depends on model year, market and engme type.

AMt
General
In order to gain access t o the fan, the two upper secur-
ing bolts on the fan shroud must be removed and the
sh roud moved rearward s.

Type 1 Fhced flin Type 2 hn of ctutch type, type 1

..,..

....
,
Type .. Tharmo-clutch type
Type 3 Flin of clutch typa, type 2

B9
Group 26 Cooling system
Electric cooling fan

AN. Elelctric cooling fan

AN!
General
This fan is installad on most B 21 FT 1984-1985 with intar-
cooIer and certain cars with air conditioning (AG) intendad lor
"hot" marltets.
A thermal swi tch in the lower radiator hose controls the
connection of the fan.
The fan is switched on when the coolanttemperature is
apprQ)(imatelv + 100~C (212 Fl and is switched off when
the temperature has dropped to approximatelv + 95 C
(203~FI.

Wiring diagram on next page.

AN2
Checking relav and electrical cooling fan
Turn on ignilion.
Connect a wire between terminals on thermal switch.
Fan should start. (Do not disconnect el<istlOg wires.)
If not, check tunClion of relav and wirlOg.
Tum off ignition.

,,,,.,
AN3
Check ing thermal switch
If required. the thermal switch can be tesled bv heating
il in an oil bath or ollen and observing the pointer of an
ohm meter connected between Ihe two terminals.
The switch should switch on al 97- 10l"C (207-216°F)
(small detlection).
On cooling 10 97_92°C (207-198 Fl the switch should
brea k the circuit (Iarge deflection).

Noteli! an oit ba th IS used to heat the switch care should be

laken 10 ensure that the swilch doas nOl louch the sides or
boltom of the bath. Also. the thermometer should be held
'a," near to the switch .

90
4

Group 26 Cooling system

Electric cooling fan

Wiring diagram

AN4

The diagrams show the position with tho ignilion on and coolan! temperature below + 100 C (212 Fl.

B 21 FT 1984-1985 with interco oler Othe r.

..
IL- R
.
3 , 5

" "
IL- Y

. @4 • " ~
7

ffi so

list of compone nts List of com ponents

1 Relay (electric caoling fan) 1 Banery
2 Aelay (dlsconnecllon 01 AC compressorl 2 Terminal box
3 Fuse box (tuse No. '3) 3 '9n;llon switch
4 Ignition switch 4 Fuse box (Iuse No. 13)
5 Connection (terminal board) 5 Relay (eleclrical coollng fan)
6 Thermal switch
6 Battery
7 Electric fan
7 Thermal SWitch
8 Electric fan

91
Group 27 Engine controls
Contents

Group 27 Engine controls

Choke control, setting Operat ion Pag e

A-enginas AQl-4 93
K-enginas A05-6 93
Thrattle contral, adjusting
A-enginas APl-4 94
K-engines AQl-2 96
ElF-anginas . AA 1-S 97
F-engineswith LH jetronic fuel system ASl-4 98
Turboengines ATl-4 ' 00

92
 Group 27 Engine controls
Choke control, adjusting

AD. Choke control, adjusting

A~engines

AD1
Check choke controi
Ensure lever makes full sweep when choke is pulled
out .
Push choke in and check that leve r is in lower stop
position and fast idle adjustment screw A does not
t:ontact lever. Adjust if necessary.

..
." , AD2
Connect tachometer - warm-up engine

AD3
Adjust fast idle
Pull out choke (approx . 25 mm = 1.0 in ) unti l mark
(arrowedlon lever is opposite fast idle screw.
AdjuSI the speed by means of Ihe fast id le screw lo
20.8-22.5 riS (1,250-1 ,350 rpm ).
Push in Ihe choke.

Solall (Zanith)
~-~. ,V=~,

\ ~
"~I
... ;;::::. 25mm
Stop engine . Remove tachometer

25mro. I i \"
AD4

Piarburg ( DVG)IL-----7.'.~,~
.
su III M,

K-engines
3 .1 mm
AD5
'--;-1 Checking/adjusting vacuum servo for choke
damper
: I
Pull out the choke conlrol completely so that the choke
damper closes.
I Push the rod of the vacuum servo st raight into botlom
position. If the rod is pushed at an angle the values will
I. .
be incorrecl .
The gap between the ca rburetlorthroat and the damper

I ~-:iJ
must be 3.1 mm (0. 122 in). Try with a 3.0 mm (0.118
tO, ...
in) drill and a 3.5 mm (0.137 in) drill.
Adjust Ihe screw on the vacuum servo.
93
Group 27 Engine controis
ThrorrJe contro/, adjusting

A D6
Check/adju st f ast idle
Push the choke coniroi fully i n.
The gap between the cam disk and the head of the fast
id le screw should be 1.9 mm f0.07 in}.
Measure gap with a feel er gauge. Adjust be means of
the fast idle screw.

•
AP. Throttle control, setting
A-engines

A P1
Disconnect link rod from carburettor
Check throttle valve and pulley
Detach clamp from swivel end and disconnect link rod.
Check that throttle valve and pulley move smoothly.

AP2

~
Adjust throttle cable
Pulley sheuld contac! end stop In id le position. Cable
mus! be laul .
Manual Automatic At full throttle pulley should centact full Ihrottle step.

The spring in the threttle pullev has different posi tions : one
for manual transmission and one for automatic transmis-
sion.

0\

94
 Group 27 Engine controls
Throttle contrOl, adjusting

•
AP3
Adjust kick-down cable (automatic)
Depress accelerator fo fl oor. Note ! Do nOl operate con-
Irol by hand olherwise sening will be incorrect.
At full throttle, distance between clip on cable and cable
sleeve:
BW35 .. 43-47 mm (1.7-1.9 in)
BW/AW55,AW71 . 50.4-52.6 mm (l .98--2.07 in)

A P4
Install and adjust link red

• Push !ink rod in position and bend in the locking tab .

Adjust link rod so that t here is a play of 0.5 mm (0.02 in)
between the tifling arm and the follower of the thro ttle
valve shaft.

'" 17'

Soie lI (Zenithl

{i,s ~
Pierburg (DVG)
i
0,5 mm ; SU ~-

95
Group 27 Engine controls
Throtrle control, adjusting

AQ. Throttle control, adjusting

B 19 K

AD7
Check throttle valve
Check that valve moves freely without binding.
The secondary barrel valve should start to open when
the primary barrel valve is about 2!3 rds open.

Not.1 That the choke contro l must be fullv closed for the
secondary valve to operale

.. ~

AD2
Checkladjust throttle cable
Pulley should contact end stop in idle position. Cable
must be taut.
At full throttle, pulley should con tact full throttle stop.

(~

96
 Group 27 Engine conrrofs
Throttle contral, adjusting

•
AR. Throttle control, adjusting
E/F-engine.

•
(Engines with LH-jetronic fuel system, see page 98) .

,
AR!
Checking throttle pullev
Disconnect the link rcd.
Check thai the pultey moves freely without binding .

Throttle pulley spring - 1979

Note ; two diHerent poSitions lor spring :
- one 'or vehlcles with Butomatlc transm ission
- one for vehides with manual transmission

• II
AR2
Adjust throttle cable
Pulley should eentac! end stop in idle position. Cable
must be ta ut.
At full throttle pulley sh ou Id eentac! full throttle stop.

AR3
Adjust kick-down cable (automatic)
Depress accelerator to floar. Note ! Do not operale con-
t rol by hand olherwise setting will be incorree!.
At fuil throttle distance between clip on cable and cable
sleeve :
BW35 43-47 mm (l .7-1.9 in)
BW/AW55,AW71 ..... 50.4--52.6mm (1.98-2.07 in)
Adjust cable at the cable sleeve if necessary.

97
Group 27 Engine controls
Throttle control, adjusting

A R4
Install and adjust fink rod
InSlall link rad.
Inser! a 1 mm 10.04 in) thick feeler gauge between the
throttle pulley and the stop. The play between the
adjustment screw and the lifting arm should then be
0.1- 0.3 mm !O.OO4-0.0 1 inI.

B 2 1 F 1 97~77 Japan
1976 early models USA/California

ARS
Adjust microswitch for exhaust gas recirculation
svstern (EGRl
Connect a lesl lamp in series between microswilch and
wire to solenoid valve.
Tum on ignition.
Place a 1.5 mm (0.039 in) feeler gauge between throttle
adjustment screw and end st op.
Lock nu t and unscrew upper adjustment screw until test
lamp g08s out.
Screw in adjustment screw until test lam p just lights.
Tight en lock nut.
Check adjustment wi th a 2 mm (0.079 ini feeler gauge.
Lamp should be o ff.
Disconnect test lamp. Tum off ignition.

AS. Throttle control, adjusting

Engines with LH-Jetronic fuel system

AS 1
Oisconnect fink rod from throttle pulley

98
 Group 27 Engine controis
Throttle contro/' adjusring

AS2
Check/ adju st throttle puffey and throttle cable
Check thai the pulley moves freely w ithout b ind ing.
Pulley should cont act end stop in idle position. Cable
must be taut but must not move throttle pulley. Depress
accelerator pedal and check t hat at full throttle, pulley
contacts full throttle stop.

• Check/ adjust kick-down cable (automatic)

AS3

• Depress accelerator to floo r . Note! Do not operate con·

trol by hand otherwise sening will be incorrect.
A t full th rottle, distance between clip on cable and cable
sfeeve - 50.4-52.6 mm (1.98-2.07 in).

• Attach/adjust fink red

AS4

Place a 1 mm (0.040 in) feeler 9auge between pu ll ey and

•
idle stop.
Adjust link rod to obtain a 0.1 mm (0.004 in) clearance
between lower adjustment screw and end stop.
Remove feeler gauge.

99
Group 27 Engine contrals
Throttle control, adjus ring

AT. Throttl.~ control, adjusting

Turbo engines

An
Disconnect link rod from throttle pulley
Check that the pulley moves freely without binding.
1

AT2
Checkl adjust throttle cable
In the idle position the pulley should contact the stop.
The cable must be taut, but must not move the throttle
pulley. Adjust as necessary at the cable sleeve.
At full-t hrottle the throttle pulley should contac! the 1
full· throttle stop.

AT3
Checkladju st kick-down cable (automatic trans-
mission)
Make a mark on the cable exacUy where it enters the
cable sleeve.
Press the accelerator pedal down completely. Do not
turn the throttle pulley by hand otherwise the setting
will be incorrect.
At full throttie the distance from the cable sleeve to the

....
'
mark should be 50.4-52.6 mm (1.98-2.07 in).
Adjust as necessary at the cable sleeve.

100
 Group 27 Engine controls
Thrortle contra I, adjusring

AT4

t Installing and adjusting link rad

Install link rad.
Insert a 1 mm (0.04 in) thick feel er gauge between the
throttle pulley and the stop. The play between the
adJustment screw and the liftlng arm should be 0.1- 0.3
mm (0.004-0.01 in).

•
•
t.
•

.'
101
Index

Index

Oper- Oper-
ation Page ation Page
Air pump Coolant tharmostat
general T1 4' general .......... AI1 B2
checking system operation T2-5 4' replacemant AI2 82
changing drive belt T6 50 testing AI3 B2

8 19/2 1 RT 11-8 22 Crankcase ventilation

821 FT Jl-7 24 cleaning/checking Rl 45
wastegate, replacemenl Kl-9 26 A, E, F-engines 1975-80 R3 46
changesintroduced U-6 2B Turbo engines ......... R4-5 46
quickcheck MI 30 A, E, F-engines 1981-84 R6-' 47
removal Nl-8 30 blocked flame Irap/blocked
axial and radial play, checking N9-10 32 system R2 45
replacement 33
dismantling . N11-13 33 Drive belts
cleaning and inspection Nl4-16 34 general . . . . . . . . . . -. . . . All B7
assembling N17-22 35 AC drive bel t Al2-4 BB
installing N23-40 36
pressure pipe, clamping . 01-2 40 Electric cooling fan
installing later models of rod on general . . ......... ANl 'O
Pl-12 41 wiring diagram . AN4
cars of earlier models .
checking fan and relay AN2 "'O
Catalytic converter
Choke controi
51-3 4B checking thermal switch AN3 'O 1
adjusting A-engines AOl-4 '3 EGR system
K-engines A05-6 '3 see "Exhaust Gas Recirculation"

Coolant Exhaust G.s Recircul.tion (EGR)

general
lopping-up
AFl
AF2
7'
BO
cleaning
"zeroing" conl rollamp
MI
ABl
65
64
'I
changing AF3 80
draininglfilling AF4-5 80
Exhaust mapifold
removingfinstalling 81-3 12
Cooling fan
general , AMI 8'
different models B' Exhaust systam
general . .. 01 44
Coolant pump installing complete system 02 44
general . . AKl B3
changed mounting boll for
return pipe AK2 83 Inlet manifold
replacernent AK3-18 B3 removal Al-2 B
installing A3-' 9
Cooling system
fault tracing - low cooling . AEl 7' lambda-sond
capacity pressure testing AGl Bl
checking ADl 77
Coolant temperature sensor replacing AD2 77
localion AJl B2 adjustment ofwarninglamp . AD3 77

102
 Index

Oper- Oper-

t Lambda-sond system
at ion Page

Stepiess EGR F-engines

ation Page

positioning of components ACl 66 Typa T

connection of vacuum hoses AC2 67 connection Yl 57
wiring diagram AC3 67 function test Y4-5 58
general instructions AC4-5 68 trouble-shooting Y6-14 58
faulttracing AC6 69 microswitch checking/adjusting Y7-TO 59
trouble-shooting .A.C7-42 69
Microswitches Throttle control, satting
A-engines . API-4
stepless EGR . 9.

•
K-engines AQT -2
F-engines, type l Y7-10 59 96
E/F-engines ARI-5 97
On/off EGR F-engines with LH-Jetronic fuel
system AST-4
connection VT-6 53 98
function test turboengines ATl-4
V9-lO 55 100
fault system Vll 55

•
Tightening torques
Pressure testing important 2
cooling system AGl 81
Turbo
Pulsair system
general Ul 51
important
trouble-shooting
routing of luel pipes
Cl-4
Dl
El
,.
13

15
shut-off valve, install ing U2 51
checking/adjusting ca content charge pressure, checking/-
U3 51
adjusting FT -9 16
system check U4-6 51
distribution pipe, removal/- pressure actuator replacement Gl-4 18
installing controi system for charge pres-
U7 52
sure (on ly B 21 FT with intercooler) Hl-lO 19
Radiator ignilion retardation, full load
enrichment and pressure sensor
cleaning . AHl 81
checking Warning lam p, F-engines
AH2 81
adjustmentof position AH3 81 exhaust recircu lalion (EGA) ABl 65
Lambda-sond system. AD3 77
Special tools 6

•
Wiring diagram
Spacifications electriccoolingfan . . AN' 91
2
Lambda-sond system AC3 67
Stepiess EGR A-engines controi system for charge
connection Xl 56 pressure B 21 FTwith intercooler H2 19
function testJtrouble-shooting Z5-1 l 62

• :t Stepiess EGR E/ F-engines

Types2and3
connection
function test
trouble-shoot ing
ZT-2
Z5-6
Z7-1 1
61
62
62

103
 •
- •

•
•
•

AS:
•• CERTIFIED

VOLVO SUPPORTS VDLUNTARY

IMECHANIC CERTlFICATlON
BY THE N.I.A.S.E.

(U S A on1vl

•
Service literature
Your
most important

••
special tool