Volvo 240 Repair Manual: DL, GL, Turbo, 240, 240DL, 240GL, 240SE 1983-1993

1. 1983-1985 Volvo DL
2. 1983-1985 Volvo GL
3. 1983-1985 Volvo Turbo
4. 1986-1993 Volvo 240
5. 1986-1993 Volvo 240DL
6. 1986-1993 Volvo 240GL
7. 1986-1993 Volvo 240SE

1. B21F
2. B21F-T (Tu
rbo)
3. B23F
4. B230F

CYLINDER BLOCK DISASSEMBLY

Disassembly and assembly procedures for Volvo engines are similar to those for most other water-cooled engines.

Because of engine variations, the instructions below cannot give every particular detail for every application. However, they do list all the main tasks that must be performed to disassemble and assemble any cylinder block.

The initial steps of disassembly involve removing external parts and accessories that attach to the cylinder block. Most of the operations are simple and straightforward. However, references are provided to the other repair groups where additional information on specific procedures is covered in greater detail.


TO DISASSEMBLE THE CYLINDER BLOCK

During disassembly, mark the position and orientation of all internal parts to ensure proper reassembly. Connecting rods, rod caps, rod bearings, pistons, main bearing caps and main bearings must all be assembled in specific locations and oriented in particular directions. This “assembly code” is critical to proper engine operation, especially if any of the parts are reused.

1. Remove the engine from the car and separate the transmission from the engine. Install the engine on an engine stand. See 210 Engine Removal and Installation.



2. On cars with a manual transmission, remove the clutch assembly from the flywheel. See 410 Clutch.



3. Remove the flywheel (manual transmission) or flexplate (automatic transmission) from the crankshaft. See 216 Crankshaft and Intermediate Shaft.



4. Remove the pilot bearing (manual transmission) or guide sleeve (automatic transmission) from the end of the crankshaft. See 216 Crankshaft and Intermediate Shaft.



5. Remove the engine oil filter.



6. Remove the cooling fan and lower radiator hose from the coolant pump. See 260 Radiator and Cooling System.



7. Remove the engine mounts and mounting brackets from the cylinder block.



8. Remove the ignition distributor and, on early B21 and B23 engines, remove the timing sensor. See 280 Ignition System.



9. Remove the alternator with its mounting brackets and V-belts. See 320 Alternator and Charging System.



10. Remove the engine oil dipstick and dipstick tube. (continued).

EXHAUST SYSTEM REPLACEMENT

New fasteners, clamps and rubber mounts are always recommended when replacing exhaust components. Gaskets should be replaced whenever flange joints are disconnected. NOTE: A liberal application of penetrating oil to cold exhaust system nuts, bolts and slip joints will make removal easier.


TO REMOVE AND INSTALL EXHAUST SYSTEM

1. Raise the car for access to the exhaust system. WARNING: do not work under a lifted car unless it is solidly supported on jack stands designed for that purpose. Never work under a car that is supported solely by a jack.



2. Disconnect the header pipe support brackets at the catalytic converter (Turbo only) and bellhousing.



3. Loosen all clamps and flange bolts.



4. On 1989 and later cars, disconnect the wiring harness connector leading to the oxygen sensor in the header pipe or catalytic converter. NOTE: If the header pipe or catalytic converter is to be replaced, remove the oxygen sensor and transfer it to the new part.



5. Unbolt the header pipe from the exhaust manifold or turbocharger.



6. Detach the rubber retaining ring and mounting blocks at the mufflers, then lower the system to the ground. NOTE: If the rear pipe is routed over the rear axle, it will be necessary to separate the pipe from the front muffler in order to completely remove the system.

• Technical Data
• Service and Maintenance
• Engine
• Electrical System
• Wiring Diagrams, Fuses, Relays
• Manual Transmission
• Automatic Transmission
• Brakes, ABS
• Suspension and Steering
• Shock Absorbers, Springs and Wheels
• Body
• Heating, Air-Conditioning
• Interior Equipment, SRS