Volvo 240 1989 Скачать руководство пользователя | Manualshive

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Содержание 240 1989

Страница 1: ...Service Manual Fault tracing Design Repairs Function Maintenance TP 31361 1 12 88 Section 2 23 lH Jetronic 2 4 fuel system Engine B 230 F 240 1989 19 ...

Страница 2: ... F Gasoline engine with fuel injection and catalytic con erter system 2 3 titer cylinder volume Two valves per cylinder LH 2 4 fuel system To identify the system with certainty look for the following item see illustration Diagnostic socket ...

Страница 3: ...System relay fuses _ _ 16 EVAP system _ _ _ _ 16 Diagnostic system __ _ 17 Fault tracing repairs maintenance Detailed table of contents 18 Wiring diagrams _ 54 lihe first section of this manual covers the Design and Function of the fuel system Reading it will provide the necessary background for understanding the second section Fault tracing Repairs and Mainte nance Order No TP 31361 1 We reserve ...

Страница 4: ... connectors 2 and 3 25 4 0 n Throttle switch Volvo PIN 3517068 7 Bosch PIN 0 280120 325 Conlrol unit part numbers Wilh EGR California Volvo PIN 3501687 2 Bosch PIN 0 280 000 556 Without EGR remainder of USA Europe Volvo PIN 3517407 7 Bosch PIN 0 280 000 561 0 280 160 Fuel pressure regulator VolVO PIN 3517064 6 Bosch PIN 0 280 160 294 Syslem pressure fuel pressure above intake manifold pressure 300...

Страница 5: ...apacity around 165 cmJ min 0580464 Fuel pump Volvo PIN 1389449 8 Bosch PIN 0 580 464 039 Pump capacity al 300 kPa 42 psi and 20 C 68e F 12 V 130 liters hour 1 0 litersl30 sec 11 V 108 liters hour 0 8litersl30 sec 10 V 65 Utersthour 0 6 lilers 30 sec Current consumption at 300 kPa 42 psi 20 C 68 F and 12 V maximum 6 5 amp Safety screen Fuel filter Volvo PIN 1389450 6 Filters particles down to min o...

Страница 6: ... 1 and 2 8 n Coolant temperature sensor Volvo PIN 1346030 8 Bosch PIN 0280130032 Resistance in ls at 10 C 14 F 8260 10560 20 C 68 F 2280 2720 80 C 176 F 290 364 For other values see chart Q 1I l JP I 0258 003 Lambda sand Volvo PIN 3501753 2 Bosch PIN 0258 003 034 Resistance pre heating resistor cold sond 20 C 68 F 3 n hot sond over 350 C 660 F 13 n Tightening torque 55 Nm 40 IUb Apply Never Seez p...

Страница 7: ...with 5116 5265 5266 5116 2 Hose connecting pressure gauge 5011 5151 9 Adaptor CO meter 5843 1 Vacuum pump check ing pressure regu lator 6450 4 Volt Amp meter fault tracing 6525 3 Multimeter volt amp ohm diode 9724 0 Ohm diode meter fault tracing 9921 0 Volvo Mono Tester setting ignition idli ng speed Q V 515 1 CO 6450 9724 5 ...

Страница 8: ...el Y t 1t Wl Idlellllive Fuel Jystam control unit Qiagnostic unit o Throttle _ W_ _ h____________ Au mllill 2 meter V CIort on ml h lomb ON Fuol hlt_ mp RO 17 v V Coolant romp_ 18nsor Primary pump The circled numbers til the drawing reter to the same numbers in the following listing 6 ...

Страница 9: ...tder It provides a richer fuel mixture to counteract knock when the fuel system s anti knock control system has been unsuccesslul at reducing knock by adjusting downward several degrees It requires no adjustment of CO because of the adaptive function It has a limp home seMing at the idle valve In case ofloss of current the idle valve remains open to provide emergency air intake In the USA It has a...

Страница 10: ...tive in that it adjusts its calcu lations according to assimilated input Sell adjusting Idle speed regulation In time wear and coatings will affect the operation of the throHle valve causing less aIr to enter the intake system Instead 01 working from a pre programmed value the idle valve receives a signal that is adapted to the experiences which the control unit has learned from previous driving p...

Страница 11: ...r Sets the voltage of Ihe system by grounding the system relay Breaks the system relay ground if engine turns ovartoo slowly engine has stopped This keeps the battery trom being drained and cuts off fuel flow from the fuel pump when the engine isn t in operation Grounds Ihe injectors which regulates opening liming and injection duration Controls air valve tor constant idle speed CIS Is connected t...

Страница 12: ... a richer fuel mixture to counteract knock when the fuel system s anti knock control system has been unsuccessful at reducing knock by adjusting downward severat degrees on all cylinders Knock cause high combustion temperatures When knock occurs the control unit increases the amount of fuel in order bring the combustion temperature down and reduce the knock Excess rpm is prevented via a rotation s...

Страница 13: ...ect temperature The amount of current required Is used to catculate the air mass taken In When the engine is turned oN any dirt on the wire is burned oN electrically by heating the wire to over 1000 C tBOO F Any dirt remaining on the wire would cause it to send incorrect information to the control unit and result In an Incorrect fueUair mixture Protective grille Earlier models of the air mass mete...

Страница 14: ...djust the amount of fuel injected o Throttle switch Tells the fuel system and ignition system control units whether the throttle valve is closed or fully open o Lambda sond Under normal conditions the optimum mixture ratio is 14 7kg air to 1kg fuel The ratio is monitored by post combustion measurement of the oxygen con tent in the exhaust gas using the Lambda sond This particular model of Lambda s...

Страница 15: ...ppen if a large amount of unburnt fuel reaches the catalytic converter prior to starting It can also happen if there is a loose ignition cable and a cylinder pumps unburned fuel into the exhaust Lead in the fuel will quickly aHect the Lambda sond and cause the exhaust gas cleaning function to stop working If tllis happens the Lambda sond will stop providing the information needed by the control un...

Страница 16: ...jectors and delivers the fuel more as a gas Ihan as drops The cold slart valve is controlled directly by the conlrol unit ralher than by the thermal time swifCh It culS in when the temperature is aboul 15c C 5 F and when Ihe engine rolation is below approx 900 rpm It culs out permanently if the rpm exceed the permissible limit Fuel pump The fuel pump is an eleclric roller pump cooled by the fuel w...

Страница 17: ...e idle valve is not affected by air leaks or a jammed throttle valve When the current is off a spnng sets the idle valve opening for an idle speed between 1 000 and 1 100 rpm Once the engine is running the control uni t ensures that the idle valve is more or less open al all rotation speeds in order to prevent the development of unnec essarily high negative pressure in the intake manifofd when the...

Страница 18: ... engine is not in operaH on Reservoir carbon IIIter The fuel vapors from the fuel tank enter the top of the active carbon filter and are absorbed Air is pushed out through a channel in the bottom of the filter Depending on temperature and other conditions the filter can bind approx 90 grams of fuel Roll over valve If the vehicle leans sideways at more than a 45 angle this valve closes helping to p...

Страница 19: ...ighteen different fault codes in the diag nostic system It is capable of storing up to three fuel system faults The fuel system control unit carries out continuous checks of the following functions while the engine is running The control unit s own internal functions Lambda sond and Lambda settings Coolant temperature sensor Air mass meter Battery voltage Throttle shutter Ignition settings and eng...

Страница 20: ...tant Group 20 General Page _ 19 _ 21 Group 23 Fuel system Placement of components 22 Fault tracIng 24 31 Function AI A15 Complete overview 01 the luel system Fuses grounding connections connectors 32 Air leakage and throttle shutters 33 34 Pumps pressure regulator fuel lines 35 37 Components cabling 38 50 81 84 Cl C6 Dl D6 El E28 Quick check of injectors 51 Fl Injectors luel distribution pipe and ...

Страница 21: ...inal 1 on tho Ignition cOil to prevent arcing affecting tho olOCHIcal system s control units remove connectors from injectors to aVOId flooding the engine ddUTlon of 011 etc Turn off ignition when connecung dlsconnectlng les equlpm nt connectmg dlsconneCling conuol unit connector connecllng dlsconnoctlng leads to Ign1llon cotl and plug Banery do not runmng djseonn c disconnect battery w hon the ba...

Страница 22: ...rnponenls Otherwise a faul can d lmage the new control unit in the same way as the old Cleanliness The utmost cleanliness must be obs erved when work In9 with tho fuel system Clean all con nect ions before removal Gasket seals Install new gasket se al If a fuel pIpe connec tion IS loosened Battery I is important w nen te sti ng the differe nt components to ensure that the battery volt age IS w ith...

Страница 23: ...efore carrying out any fault diagnosis of the LH Jetronic system it Mechanical compression valve clearance vacuum hoses ana connections w 1 1 _ throUle control air cleaner Electrica l spark plugs and HT leads distributor cap ali electrical connections Emission controls crankcase ventilation evapora te control system 21 ...

Страница 24: ... Components cabling El E28 38 50 Quick check of injectors Fl 51 Injectors fuel dislribution pipe and pressure regulator 52 Placement of components The Lambda sond is mounted in the exhaust gas mani fold about 15 cm Sin in front of the catalytic converter Ignition system lI onlol unlt System reley Fuel synem control unit The fuel syslem control unit and system relay and he tgnition syslem control u...

Страница 25: ...ank pump pre pump Inside fuel tank Iuel level sensor section Fuel pump and fuel filler On a shelf below the vehicle under the backseat Idle lilve Airmass EG R Fuel distribution Cold ttart Throttle pipe Prusur ragulator switch temperature met Callforni nsor 23 ...

Страница 26: ...light diode and a selector cable When carrying out tault tracing tor the fuel system the selector cable is placed in socket 2 of Ihe 6 available Depressing the button once twice or three times chooses the desired fault trating function Faults stored in IIle memory are read via a system of flashes from the diagnostic socket light diode All lault codes have threenumbers each one capable of ranging t...

Страница 27: ...Control function 2 This tunction tests the various fuel system breakers As each one is activ ted functions information is provided by the diagnostic socket diode in the form of ftash series The functions test is generally used aHer such activi ties as repairs to check that certain controls are connected and operating correctly Control function 3 This test is carried with the engine off It tests th...

Страница 28: ...diagnostic unit the diode will flash 1 1 1 and the luel system is operating correctly Continue at A7 II the light diode doesn t flash when the button is de pressed or il no code is flashed reler 1081 82 El E4 and Ell A2 Check to see if any lault codes are stored in the memory Depress the button again Make a note 01 any additional lault codes Depress the button a third time to see if a third fault ...

Страница 29: ...1rottleswitch Idle setting faulty possible grounding short Lambda sand signal mi ing or is faulty 2 1 3 2 2 1 2 2 3 Throttleswitch full load setting faufty possible groundlllg short Lambda sond not operating Signal missing toltrol l l KlIe valve 2 3 1 2 3 2 2 3 3 Self adjusting Lambda sand not operating Sell adjusting Lambda sand not operating Idle valve closed possibly leaking air 3 1 1 3 1 2 3 2...

Страница 30: ...uld stop shining A5 To check that the memory is erased depress the button once for more than 1 second but not more than 3 seconds Flash series 1 1 1 denotes erased memory Start and run engine If the engine won t start see control function 2 A7 8 and All NOTE The throttle control does not have to be turned to full load position Turn off engine A6 Check if new fault codes have been stored in the mem...

Страница 31: ...ol to full load position A8 Depress the bullon in the diagnostic socket twice Each time the button is depressed it should be kept in for at least 1 second but not more than 3 The lighl diode should begin to flash A9 Release throttle control II the flash series 3 3 3 comes up the function of the shutter switch is correct in full load position lithe light diode continues to flash rapidly see C4 and ...

Страница 32: ...ect II the engine won t start run the starter molO until the diode turns off II the diode continues to flash rapidly the ignition system must be checked If the ignition system is faultfree see A13 and E1 12 A12 Vehicles with AC Check the onloff funcllon of the compressor Place the AC controls in the on position If the light diode turns off and then ashes the 1 4 code series the switch is OK II the...

Страница 33: ...e E22_ Turn engine olf Control function 3 the selector cable 10 pin A14 Turn on ignition Open the diagnostic socket cover and connect no 2 A15 Depress the button In the diagnostic socket three Urnes Each time ttle button is depressed it should be kept in for at least 1 second but not more than 3 While the light diode continues to flash with the same frequency each of the tollowing should hegin to ...

Страница 34: ...oms Check the grounding connection lor I he lambda sond althe right Iront mudguard iJ 1 14 IJ IJ 0 m m B2 Check Ihat the luses for the pump relay and the primary pump are OK Pump relay fuse In line fuse In he engine compart ment Tank pump fuse fuse No 4 in luse box B3 Check connectors lOt air mass meter idle valve knock sensor coolant temperature sensor Check for installation and connection B4 Che...

Страница 35: ...ect throttle switch connector Remove housing Clean with solvent but ensure that none enters the throttle switch Important A clogged incorrectly mounted or damaged air filler will result in a dirty throttle housing Install throttle housing Use new gasket Connect air hoses and throWe swilch connector Basic throtlle selling C3 Loosen locknut Loosen adjuslment screw until throttle Is oompletely closed...

Страница 36: ...ckladjusl control pulley and ttuoltle cable The control pulley should move smoothly The throttle cable should be extended in idle position without affecting the pulley position The pulley should abut the idle stop Adjust cable where necessary Depress gas pedal all the way and check that the pulley abuts the full throttle stop C6 Connect and check adjust lInkarm Install a 1 mm leeler gauge between ...

Страница 37: ... fuel pumps Remove panel under right side of instrument panel Remove system relay Disconnect syslem relay connector Connect an eleclrical lead between terminals 30 and 87 2 The fuel pumps should start To check if the main luel pump isoperating remove cap fromthe filler pipe and listen II fuel pumps don I start Remove lead between tenninals 30 and 87 2 Ched for voltage atlermlnal3O Iflhere is none ...

Страница 38: ...n pipe If both hoses are open the pressure regulator is faulty Replace it and recheck pressure Too low system pressure Squeeze relurn hose by hand and check if pressure rises Important Do not allow the pressure to exceed 600 kPa 84 psi If the pressure rises rapidly the pump and hoses are OK Replace pressure regulator and recheck pres sure If the pressure rises slowly the fuel filter fuel pump stra...

Страница 39: ...ure should lall as much as the pressure in the regulator lalls 300 kPa 42 psi minus pressure drop equals system pressure 86 1 87 2 D5 Turn oU fuel pumps Remove lead bAtween terminals 30 and 8712 on the relay base Install system relay D6 Remove pressure meter 50 Hold a paper under the luel line to soak up any luel which comes out when the meter is removed Important Any plastic tie bands removed fro...

Страница 40: ...tions They should make good contact and fit tightly E2 Turn off Ignition Remove control unit connector Important Ignition must be off before remov ing or installing the connector Press up catch and fold out connector E3 Remove connector protective sleeve Important Never check connections from the front Experience has shown that they can be damaged and any faults made worse Check connections throug...

Страница 41: ...onnect selector cable to position 2 on diagnostic socket GN 58 V 3 Connect voltmeter betweon ground and no 12 con nection on controlunilconnector Reading should be 12 V Derress button on diagnostic socket Reading should be 0 V II there is no voltage allhe conlrol unit take reading at diagnostic socket connector II voltmeler reading remains at 12 V when buNon is depressed check diagnostic socket 4 ...

Страница 42: ...ng should be 0 n 7 Connect diode tester between diagnostic socket tight diode and selector cable Connect red test pin on diode tester to pin under tight diode and black test pin to selector cable A reading on the diode tester indicates correct light diode function With no reading replace diagnostic socket 5 Check ignition lock voltage Turn on ignition CO ct voltmeter between ground and no 35 con n...

Страница 43: ...creening lead Should be connected to no 5 connection on control unit connector E8 Check rpm sensor lead from Ignition system control unit Connect voltmeter between ground and no 1 con nection on fuel system control unit connector Run starter motor Reading battery voltage E9 Check throttle switch 1 Connect ohm meter between ground and no 2 con nection on control unit connector Reading should be 0 0...

Страница 44: ...round connection at intake manifold E10 Check air mass meter Connect ohm meter between connections 6 and 7 on control unit connector Reading should be 2 5 4 00 See also E13 and E27 for checking air mass meter E11 Check system relay primary relay Connect voltmeter between ground and no 9 con nection on control unit connector Connect lead between ground and no 21 connection on control unit connector...

Страница 45: ...lrom no 20 connection bul leave conneclion 10 no 21 y II 21 1 20 9 OR v E13 ChlM k air mass meter 1 Remove rubber sleeve from air mass meier connec lor to Iree leads Colour COOl S8 s Blll ch fl N II Brown _ Grecn R rl V Vdlow OR J1l n W hitc P Pink VO Viufc l R Red nr Blu r ell opper 2 Connect vollmeter between ground and no 5 con nection on alr mass meter connector Reading should be approx 12 V v...

Страница 46: ... connection from no 20 connection but leave connection to no 21 E13 Check air mass meter 1 Remove rubber sleeve from air mass meter connec tor to free leads Colour cOfle su Dlurk UN Drown G Green OR re Y z Yl lIuw OR Orange W Wllite P Pink VU Vinlet R Red RL n Ulu CU Copper J G 1 0 2 Connect voltmeter between ground and no 5 con nection on air mass meter connector Reading should be approx 12 V 21 ...

Страница 47: ...nsor Connect ohm meter between ground and no 13 con nection in control unit connector Resistance depends on temperature Guide line values Resistance at 10 C WF 8 260 10 560n 20 C 68 F 2 280 2 720n 80 C 176 F 290 364n 13 See Specifications for chart If fault occurs Measure at sensor to see if fault is in sensor or in leads Check ground connection to intake manifold BL R E15 Check lead 10 AC compres...

Страница 48: ... a IHue CU CIJPpcr If the measured resistance is wrong Remove injector connectors and test them sepa rately Reading tor individual injectors should be 16H X ________ J 18 OR 9 OR Ell Check Injectors Connect ohm meter between connections 9 and 18 on conlrol unit connector Reading should be 4 U If the reading is higher current is not going through the Injeclors If resistance is Approx 5 3 n Faull in...

Страница 49: ... approx 10n 28 BN W system approx 0 7 V E19 Check knock enrichment sIgnal trom Ignltron Tum on Ignilion Connect voltmeter between ground and no 28 con neelion on control unit connector Reading should be Turn 011 Ignilion E20 Check Idle valve Conneel ohm meIer between connections 9 and 33 on control unH connector Reading should be approx 8 n 46 ...

Страница 50: ... is missing Reconnec speedometer cable and remount panel under instrument panel E22 Automatic transmission Check gear selector signal Put gear selector in position N Neutral Connect ohm meter between ground and no 30connection on conlrol unit conneclor Reading should be 0 U Move gear selector 10 position D Drive Reading should be resistance The reading should be 0 in all gears for vehicles with ma...

Страница 51: ... righl wheel house Lambda sond temperature Cold 20 C 68 F approx 3 n Hoi 350 C 660 F approx 13 n Hot temperature achieved on idle with hot engine E24 Final check of control unit Important The ignition must always be oft when removinglin stalling connector Connect connector Be sure the connector s rubber gasket is reinstalled before connecting to conlrol unit Start engIne If englne does not start a...

Страница 52: ...r checking Lambda sond in next step E26 Check Lambda sond 1 Disconnect Lambda sand connector 2 Ground lead to control unit CO content reading should se indicating that con trol unit and its connections are OK 3 Connect vollmetertoLambda sond Indicator should swing back and forth 0 show function 01 Lambda sond Reading at correct CO content should be approx 0 5 V Connect Lambda sand connector 49 ...

Страница 53: ...unit 2 Connect voltmeter between connections 1 and 4 Rev engine to approx 35 rls 2 100 rpm Turn off engine After approx 4 seconds the voltmeter indi cator should swing back and forth for approx 1 second burn off cleaning Remove voltmeter Install rubber sleeve over connector E28 Check CO content the engine does not run satisfactorily even though no faults have been found or If faults that have been...

Страница 54: ... by turning 0 the Ignilion or by changing oontrol function via the selector button 2 listen to and feel by hand each injector to make sure they all work If one does not function no click can be heard change connector to a valve Ihal does work It the fault moves to one Ihal was O K before tilen the faull Is in the connector lead 3 It Ihe injeclor still doesn l wOrk Ihe fault is probably in the inje...

Страница 55: ...ounded when reconnecting them Removelinstall fuel distribution pipe injectors and cold stare valve as one unit Use brace to loosenltighten fuel lines and all other fasteners Check O rings Lubricate them with vaseline or a similar substance Place pressure regulator against fuel distribution pipe and bolt it to the bracket Check vacuum hose and return hose 52 ...

Страница 56: ...PAGE 53 Intentionally Left Blank ...

Страница 57: ... 58 o R Sa III 0 BL SB 11 1 SR 162 i l l J 131 132 162 21 1 212 214 215 R D R sa 2 11 218 nL su y_W y_w BI R 22 1 c t f ilL 32 2 0 p p 223 GN 0 GN Diagnostic unit Idle valve Lambda ond Electronic control unit EZl16K In line fuse Electronic control unit LH2 4 Air mass meter pl l 1 14 o 217 218 221 223 225 Main relay Throttle switch Coolant temperature sensor AC pressure switch Injectors IlL Y o UI ...

Страница 58: ...LH Jetronic 2 4 B 230 F 3 211 0 214 10 I J ti1 r lJUI l 212 t I 132 55 ...

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