Vehicle - New Car Features
MODEL900
GROUP
00
NUMBER
904
TITLE
NEW CAR FEATURES 1993 940/960
MARKET
US and CANADA
DATE
August 1992
REFERENCE: NONE
The most important new features of the 1993 940/960 models are described briefly in this bulletin.
The 1993 models will be assigned the designation P as the 10th digit in the V.I.N. Chassis numbers will begin as follows:
Model Chassis No.
940, 4-door 103 400
940, 5-door 580 50
960, 4-door 27 100
960, 5-door 10 000
This bulletin is intended for both service and parts personnel.
Major new features of the Volvo 940
A
- B230FD. This is a new engine variant with augmented emission control equipment in the form of electronically controlled Pulsair and EGR for California models.
B
- Piston cooling on all four-cylinder engines.
- B230F for USA/Canada combined with AW71L.
- New relays (not interchangeable with earlier types) in electrical central unit.
- New gear selector mechanism on automatics.
- Shift lock and key lock functions. The systems are basically the same as described for the Volvo 850.
- New Koyo steering gear with split valve housing and unique return hoses supersedes ZF steering gear on models with B230 engine.
- Torsional rigidity increased by fitting increased diameter anti-roll bars at front and rear. Rear anti-roll bar a new feature on station wagons.
D
- 75-litre (19.8 gallon) fuel tank.
- Factory-fitted wiring for wider range of accessories.
- The cigarette lighter will be equipped with 3 bimetallic protection. If, for example, the lighter remains too long in the depressed position, the bimetallic element will short-circuit the supply to ground and the ordinary fuse will operate. The element will reset automatically once. If the protection operates again, the lighter must be replaced.
- Electrical clock adjustment superseded by mechanical adjustment.
- Longer rear springs.
- Front side members reinforced by increasing material thickness from 1.6 to 2.25 mm. Material changed from high-strength to carbon steel.
E
- New SRS system with Volvo diagnostics.
F
- A/C system: CFC-free, non-ozone-depleting R134a refrigerant.
G
- New rear seat with three-point seat belt, integrated child booster cushion, and adjustable head restraint in middle position in station wagons.
- Redesigned bumpers with integral "cover strip" on top.
- Two front versions:
- 940 "base"; 940 with "luxury" option package: color-keyed molding between headlights and grille (all-chrome grille).
- 940 with "turbo" option package: foglamps between headlights and grille (gray "eggcrate" turbo grille).
Major new features of the Volvo 960
C
- B6304F: New injectors and control module (not California). Engine is marked B6304S but is designated F in the literature. The exhaust camshaft is equipped with a vibration damper and a new type of timing belt is fitted.
- The B6304 speed sensor wiring is reversed since the Motronic 1.8 control module now reads "holes" rather than "teeth" in the flywheel.
D
- 75-litre (19.8 gallon) fuel tank in station wagons
- Factory-fitted wiring for wider range of accessories.
- The cigarette lighter will be equipped with bimetallic protection. If, for example, the lighter remains too long in the depressed position, the bimetallic element will short- circuit the supply to ground and the ordinary fuse will operate. The element will reset automatically once. If the protection operates again, the lighter must be replaced.
- Electrical clock adjustment superseded by mechanical adjustment.
- New relays (not interchangeable with earlier types) in electrical distribution unit.
- New gear selector mechanism on automatics.
- Shift lock and key lock functions. The systems are basically the same as described for the Volvo 850.
- Rear anti-roll bar on station wagons.
- Longer rear springs.
E
- New SRS system with Volvo diagnostics.
F
- A/C system: CFC-free, non-ozone-depleting R134a refrigerant.
G
- New rear seat with three-point seat belt, integrated child booster cushion, and adjustable head restraint in middle position in stations wagons.
- Introduction of "big-front" radio with large, easily accessible controls in most markets supplied with a factory-fitted radio.
Engine Options: 940
Note:
Minimum required octane is 87.
** B23OFD **
A
EGR
The system is controlled by the ignition system control module. The module transmits a pulsating ground signal to the vacuum regulator which, in turn, controls the vacuum to the EGR valve. The vacuum is a function of engine temperature, load and speed.
The EGR system diagnostics are controlled by the EZ116K ignition system.
The ignition system control module receives information from a temperature sensor integral with the EGR valve. Three specific fault codes can be initiated. The temperature sensor signals are compared with predetermined values in the control module. The engine coolant temperature (ECT) sensor detects the temperature before the EGR valve is opened. If the temperature rise exceeds a given preset value, the diagnostic system will interpret the EGR system as being in operation, either through leakage or seizure of the EGR valve, and will store a fault code.
Oxygen sensor (Lambdasond)
The life of the oxygen sensor has been extended and the transition point altered by doubling the thickness of the sensor coating. The fuel control module has been reprogrammed to match the new transition point and the system components are no longer interchangeable with previous types. The connectors have been reversed to prevent confusion between the two types.
Pulsair
The system is controlled by the fuel system control module. The module actuates the solenoid valve which, in turn, opens the vacuum valve for approx. 100 seconds when starting from cold, while the ignition system control module retards the timing during the engine warm-up phase.
The Pulsair system solenoid valve can be checked with the LH2.4 control module in test mode 3, in which the valve is operated last in the cycle.
The Pulsair system reduces the quantity of unburned hydrocarbons (HC, CO) during the engine warm-up phase by admitting a certain quantity of fresh air to burn any fuel which escapes to the exhaust pipe. The EGR system reduces nitrogen oxide (NOx) emissions by an amount depending on engine running conditions, by recirculating a certain proportion of the exhaust gases to the intake manifold. Both systems are made of stainless steel piping and are connected to the engine management system for diagnostic purposes.
The components comply with the new California legislation specifying a service interval of 100,000 miles
(160,000 km).
** B23OF **
B
Introduction of new timing belt
The timing belt is made of a new material and is provided with a new tooth profile. The belt pulleys have been modified accordingly.
The new belt must not be installed with the original pulleys, or vice versa.
The belt material and tooth profile are the same as in the 850 engines.
Higher-capacity oil pump
The capacity of the oil pump has been increased to supply the piston cooling requirement.
Piston cooling
Although piston cooling is not used at low speeds, it nevertheless reduces engine noise by enabling piston clearances to be reduced.
The cooling nozzle in each cylinder sprays oil onto the underside of the piston skirt to cool the component. The oil is supplied from the main gallery passage in the cylinder block. Each cooling nozzle (one for each cylinder) is provided with a spring-loaded ball valve which opens at 1.7-2.1 bar, preventing an unnecessary drop in pressure at low speeds when piston cooling is not required.
C
** B63O4F engine **
This unit features a new type of injector with four injection holes for improved fuel distribution (not California).
The Motronic 1.8 control module has been adapted to suit the new injector.
The crash sensor incorporates Volvo diagnostics which are accessed through socket No. 5 on diagnostic unit B. In the event of a fault, the sensor will operate the warning lamp on the combined instrument and will store a fault code, which may later be displayed by means of the diagnostic unit.
The 940 is equipped with a new type of crash sensor but is not equipped, for the present, with a passenger side air bag. The system wiring is provided with orange insulation to warn against unauthorized interference.
D
75-litre (19.8 gallon) fuel tank
All 940/960 models with a live rear axle are equipped with a 75-litre (19.8 gallon) fuel tank. The tank is made of a new type of plastic with reinforced side ribbing. Since the tank is fitted with an anti-splash baffle, the method of removing the tank unit is different.
Air which collects in the front of the tank when filling is conveyed to the rear through a venting passage and evacuated to the filler pipe through a nipple.
The bottom of the tank carries an environmental stamp indicating that the material (93% polypropylene) can be recycled.
Fuel level measurement
The fuel gauge for the new tank incorporates a winding with a "reverse" characteristic, which gives a more accurate reading at low level.
The LED check when the ignition is switched on is discontinued.
The fuel level transmitter is designed to match the new gauge.
E
SRS (Supplemental Restraint System)
To improve occupant protection, 960 series models are equipped with an air bag on both the driver and passenger sides.
The passenger side air bag has an inflated volume of 160 liters, compared with 70 liters on the driver's side.
Warning:
Do not use child safety seats or child booster cushions/backrests in the front passenger's seat.
The knee bolsters have also been reinforced to protect unbelted passengers.
Principle of operation
The air bags and the pyrotechnical seat belt tensioners are deployed electrically in certain frontal/front angular impacts if the crash sensor detects deceleration of sufficient force to create a risk of personal injury. The tensioners take up any slack in the seat belts to restrain the occupants as the bags are inflated. The entire sequence takes approx. 25 milliseconds.
New refrigerant
The air conditioning system is filled with the new nonozone-depleting refrigerant, R134a, which operates at a different pressure and temperature to R12. The following components have been modified and adapted especially for use with R134a refrigerant:
- compressor (incl. temp switch)
- condenser
- all pressure switches
- expansion orifice
- receiver/dryer (new drying agent)
- rubber hose (new lining material)
- new compressor oil (PAG type)
- SAE standard filler valve
Since earlier components must not be used in the new system, the pressure switch, receiver/dryer and condenser connection threads have been altered from imperial to metric. The evaporator is the same as before.
Note:
Most of the torque specifications have been altered.
F
Under no circumstances may air conditioning systems using R134a be filled with the earlier R12 refrigerant. Only special PAG (PolyAlkylene Glycol) oil may be used. Use of the wrong refrigerant or compressor oil will cause the unit to overheat and seize, accompanied by failure of the hoses, seals and receiver/dryer. The consequences will be the same if an earlier system is filled with the new refrigerant or oil.
A label is provided in the engine compartment and a yellow tag is attached to the filler valve to warn that the system is filled with R134a.
Temperature switch
All compressor variants are equipped 7 with a temperature switch which interrupts the power supply if the unit becomes overheated, for example due to refrigerant leakage. The power supply is restored when the temperature returns to normal.
Compressor
Cars with four-cylinder engines are equipped with a rotary vane compressor instead of the earlier reciprocating type. The pressure rise is achieved by progressive reduction of the volume between the inlet and outlet ports as the unit rotates.
The sound from the new compressor is lower and somewhat different compared with the reciprocating type.
A linkage between the floor and a spring-loaded guide sleeve, in which one of the head restraint posts is supported, is used to retract the restraint automatically.
G
Five-door 940/960
These models are equipped with a new, split rear seat with three-point seat belts, integral head restraints in all positions, and the integrated child booster cushion.
The backrest is reinforced and is somewhat higher than before. The armrest is longer (incorporating the integrated child booster cushion with belt).
The seat belt reels in the outer positions are the same as for the existing front seat belts. The middle position reel is new.
The spacing between the backrest pivot point and the link attachment point in the floor creates the movement necessary to extend and retract the head restraint.