Volvo 850 Accessories Manual
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Volvo 850 Accessories Manual

2.4l 5-cyl vin [55]
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See also: Service Manual , Owner's Manual
1995-96 ENGINES
Volvo - 2.4L 5-Cylinder
850
* PLEASE READ THIS FIRST *
NOTE:
For repair procedures not covered in this article, see
ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL
INFORMATION section. Repair information for this engine is
not available at time of publication.
ENGINE IDENTIFICATION
Engine may be identified by using Vehicle Identification
Number (VIN) stamped on a metal pad, located near lower left corner of
windshield. The sixth and seventh character identifies engine model.
Engine identification number, located on left side of
cylinder block below cylinder head, may be required when ordering
replacement parts.
ENGINE IDENTIFICATION CODES TABLE
¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡
Engine
2.4L (Non-Turbo)
¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Engine is equipped with hydraulic lifters. No valve
adjustment is necessary.
REMOVAL & INSTALLATION
NOTE:
For reassembly reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place
mating marks on other major assemblies before removal. Hood
removal is not necessary, as hood opens to horizontal
position. Removal and installation information for
turbocharger is not available at time of publication.
FUEL PRESSURE RELEASE
Fuel Pump Pressure Release
Before disconnecting any lines, cover fuel line connector
with shop towel to absorb any fuel left in line. With ignition key
removed from ignition switch, reconnect relay.
ENGINE
Removal
1) Remove expansion tank cap. Raise and support vehicle.
Remove splash guard and air baffle under engine. Drain all coolant by
......................................
2.4L 5-CYL VIN [55]
1995 Volvo 850
Code
55

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  • Page 1 2.4L 5-CYL VIN [55] 1995 Volvo 850 1995-96 ENGINES Volvo - 2.4L 5-Cylinder * PLEASE READ THIS FIRST * NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL INFORMATION section. Repair information for this engine is not available at time of publication.
  • Page 2 Plugs (5488) in drive shaft holes. Fig. 1: Removing Drive Shaft, Engine Mount Bolt & Torque Arm Courtesy of Volvo Cars of North America. 4) Remove front exhaust pipe nuts and springs. Remove front exhaust pipe bolts. Disconnect speedometer. Remove engine mounting shield bolt.
  • Page 3 (including injectors) aside. Remove engine wiring harness. See Fig. 2. Fig. 2: Removing Engine Wiring Harness Courtesy of Volvo Cars of North America. 13) Remove spark plug cover and attach Lifting Lugs (5459 and 5464) to engine. Lift servo pump and place aside. Remove A/C...

  • Page 4: Intake Manifold

    compressor and place on sub-frame. Lift out engine and transmission using Lifting Yokes (2810 and 5428). Installation 1) Attach Lifting Lug (5429) to rear of engine. Using Lifting Yoke (5428) and Lifting Tool (2810), lower engine and transmission into position. Guide engine mountings into position and tighten top nuts to 37 ft.

  • Page 5: Cylinder Head

    pipe-to-manifold nuts to end of threads. Do not tighten to more than 84 INCH lbs. (10 N.m). CYLINDER HEAD Removal 1) Disconnect negative battery cable. Remove expansion tank cap. Remove splash guard under engine. Open drain cocks on cylinder block and radiator and drain coolant. Remove exhaust manifold-to-front exhaust pipe nuts.
  • Page 6 Fig. 3: Exploded View Of Engine Assembly Courtesy of Volvo Cars of North America.
  • Page 7 Fig. 4: Removing Components From Rear Of Engine Courtesy of Volvo Cars of North America. Installation 1) Remove starter and protective plug. Install Crankshaft Locking Tool (5451). See Fig. 5. Turn crankshaft counterclockwise until stopped by tool. Using NEW gasket, install bottom half of cylinder head.
  • Page 8 Fig. 6: Cylinder Head Bold Tightening Sequence Courtesy of Volvo Cars of North America. 2) Install NEW cylinder head gasket and "O" rings in spark plug wells. Remove No. 1 and No. 5 spark plugs. Oil lower camshaft bearing seats. Using a roller, apply Sealing Compound (1 161 059-9) to upper section of cylinder head.
  • Page 9 (5452) at rear to secure camshafts. See Fig. 7. Fig. 7: Using Locking Tool (5452) To Secure Camshafts Courtesy of Volvo Cars of North America. 3) Install upper cylinder head. Tighten against lower section using 2 Press Tools (5454). Tighten retaining bolts to 13 ft. lbs. (17 N.m), starting from inside and working outward.
  • Page 10 Fig. 8: Aligning Camshaft & Crankshaft Timing Marks Courtesy of Volvo Cars of North America. 5) Remove upper timing belt cover. Install belt tensioner and tighten bolts to 18 ft. lbs. (25 N.m). Place timing belt over camshaft pulleys, around coolant pump, and press over tensioner pulley. Loosen camshaft pulley bolts and remove tensioner locking pin.

  • Page 11: Crankshaft Front Seal

    Start and run engine until it reaches normal operating temperature. Check for leaks. Fig. 9: Installing Seal Using Drift (5450) Courtesy of Volvo Cars of North America. CRANKSHAFT FRONT SEAL Removal 1) Remove spark plug cover and 2 fuel line clips. Remove expansion tank and place it on top of engine.
  • Page 12 Remove oil seal with a screwdriver. Fig. 10: Removing Crankshaft Belt Pulley Courtesy of Volvo Cars of North America. Installation 1) Clean seat and install new greased seal. Press in seal using Drift (5455) and crankshaft center nut. Install timing belt tensioner and tighten bolts to 18 ft.

  • Page 13: Timing Belt

    See TORQUE SPECIFICATIONS. Check tensioner for signs of leakage, no resistance when depressed, or a plunger that cannot be depressed. Fig. 11: Checking Tensioner & Idler Pulleys Courtesy of Volvo Cars of North America. Installation 1) Compress tensioner and tighten center nut. Wait until...
  • Page 14 Clean seats and check shafts for wear. Installation Using Drift (5449), install new front seal. Fig. 12: Using Counterhold (5199) To Hold Camshaft Stationary Courtesy of Volvo Cars of North America. Removal Remove air cleaner housing with hoses and connectors. Remove...

  • Page 15: Water Pump

    Tighten mounting bolts alternately to 15 ft. lbs. (20 N.m). Install timing belt. See TIMING BELT. Fill engine with coolant. Start engine and check for leaks. Fig. 13: Removing Water Pump Courtesy of Volvo Cars of North America. OIL PUMP...
  • Page 16 Removal 1) Remove spark plug cover and 2 fuel line clips. Remove expansion tank and place it on top of engine. Remove front timing belt cover and auxiliary drive belt. Remove right front wheel and release wheel arch liner to gain access to vibration damper. Remove vibration damper guard.
  • Page 17 Fig. 14: Removing Oil Pump Retaining Bolts Courtesy of Volvo Cars of North America. OVERHAUL CYLINDER HEAD Cylinder Head Ensure all mating surfaces are clean. Measure cylinder head warpage. If longitudinal warpage is less than .020" (.50 mm), or lateral warpage is less than .008" (.20 mm), resurfacing is not required.

  • Page 18: Cylinder Block Assembly

    Valve Seat Replacement procedure is not available at time of publication. Valves Check valve for wear or burning. Measure valve dimensions after refacing. Replace any valve that does not meet specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Measure valve stem installed height after refinishing valve or seat.
  • Page 19 Fig. 15: Intermediate Section Tightening Sequence (Typical) Courtesy of Volvo Cars of North America. Thrust Bearing Ensure thrust bearing is marked for reassembly reference. Cylinder Block 1) Wipe bores clean and visually check. Measure bores using Dial Gauge (9639), Micrometer (9704), and micrometer stand.

  • Page 20: Engine Lubrication System

    .95 qt. (.9L) if turbo oil cooler is drained. Oil Pressure Oil pressure is 14 psi (.10 bar) at idle and 43 psi (.30 bar) at 3000 RPM. See Fig. 16. Fig. 16: Engine Oil Schematic Courtesy of Volvo Cars of North America. TORQUE SPECIFICATIONS...

  • Page 21: Torque Specifications Table

    TORQUE SPECIFICATIONS TABLE ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ Application Ft.

  • Page 22: Fuel System

    Displacement Non-Turbo ......... 2.4L Bore Non-Turbo ........ 3.26" (83 mm) Stroke ........3.54" (90 mm) Compression Ratio Non-Turbo ........10.5:1 Fuel System Non-Turbo .......... Horsepower @ RPM Non-Turbo ........168 @ 6200 Torque Ft. Lbs. @ RPM Non-Turbo ........162 @ 3300 ¡...
  • Page 23 Pins Diameter ........905 (23.00) Rings No. 1 End Gap ......008-.016 (.20-.40) Side Clearance ....0019-.0030 (.050-.085) No. 2 End Gap ......008-.016 (.20-.40) Side Clearance ....0012-.0026 (.030-.065) No. 3 (Oil) End Gap ......009-.020 (.25-.50) Side Clearance ....
  • Page 24 Valve Open ...... 151 @ .9 (670 @ 24.5) ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ CYLINDER HEAD SPECIFICATIONS CYLINDER HEAD TABLE ¡...

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