1995 Volvo 940 Service Repair Manual 95

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🏷️ Basic Information Identification Make: Volvo Model: 940 Year: 1995 Codes Chassis Code: 940 Series Platform: Volvo Rear-wheel drive platform (P90) 👋 Introduction Market Position Segment: Mid-size Luxury Sedan/Wagon (RWD) Target Demographic: Families valuing safety, durability, and a comfortable driving experience. Competitive Analysis Key Competitors: BMW 3 Series, Mercedes-Benz 190E, Audi 80/90, Saab 9000 Competitive Advantage: Volvo's reputation for safety, robust build quality, comfortable ride, and distinctive Scandinavian design. Key Features Safety Focus: Pioneering safety features including integrated side-impact protection, reinforced body structure, and often equipped with ABS. Durability: Known for long-term reliability and robust mechanical components. Comfort: Comfortable seating, compliant suspension, and quiet cabin for long-distance touring. 📋 Manual Details Coverage Areas Engine Coverage: 2.3L B230FK Turbocharged Inline-4, 2.3L B230F Naturally Aspirated Inline-4 Transmission Coverage: M47 5-speed Manual, AW71 3-speed Automatic, AW72 4-speed Automatic Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Safety Systems Page Count Page Count: Approximately 1000+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly and assembly of B230F and B230FK engines, including cylinder head, pistons, crankshaft, camshaft, timing belt, lubrication system. Fuel Injection System: Bosch LH Jetronic (B230F) and Bosch Motronic (B230FK) fuel injection system diagnostics, component testing, pressure testing, injector servicing. Ignition System Ignition System: Distributor ignition system (B230F), Coil-on-plug ignition system (B230FK), timing adjustments, component replacement. Cooling System Cooling System: Radiator, water pump, thermostat, coolant hoses, heater core replacement, flushing procedures, pressure testing. Exhaust System Exhaust System: Catalytic converter, muffler, exhaust manifold replacement, oxygen sensor (lambda sensor) servicing. Transmission Manual Transmission Manual: M47 5-speed manual transmission overhaul, clutch replacement, gear linkage adjustments. Transmission Automatic Transmission Automatic: AW71 (3-speed) and AW72 (4-speed) automatic transmission diagnosis, fluid change procedures, seal replacement, torque converter servicing. Drivetrain Drivetrain: Rear-wheel drive axle, driveshaft, universal joints, differential servicing. Suspension Front Suspension Front: MacPherson struts, control arms, ball joints, sway bar bushings, spring replacement, shock absorber replacement. Suspension Rear Suspension Rear: Multi-link rear suspension, trailing arms, shock absorbers, bushings, spring replacement. Steering System Steering System: Power steering pump, steering rack, tie rod ends, power steering fluid flush. Brake System Brake System: Front ventilated discs, rear solid discs (or drums on some models), brake pad and rotor replacement, brake caliper servicing, hydraulic system bleeding, ABS system diagnostics. Electrical System Electrical System: Wiring diagrams, fuse box locations, relay functions, alternator, starter motor, battery charging system, lighting, instruments, power windows, power locks, central locking system. Bodywork Bodywork: Body panel repair, door hinge adjustments, glass replacement, seal replacement, rust prevention and repair. Climate Control Climate Control: HVAC system diagnosis, blower motor replacement, evaporator and heater core service, refrigerant recharge (R134a). Safety Systems Safety Systems: Seatbelt servicing, SRS airbag system (if equipped) diagnostics and precautions. Procedures Included Troubleshooting Guides: Comprehensive diagnostic flowcharts and symptom-based troubleshooting for all major systems. Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, brake fluid flush, coolant flush. Repair Procedures: Step-by-step instructions for component removal, installation, and repair for nearly every part of the vehicle. Torque Specifications: Precise torque values for all critical fasteners and bolts throughout the vehicle. Diagnostic Tools: Information on required diagnostic tools and special equipment for specific procedures. Technical Depth Diagnostic Capability: Advanced diagnostics for engine management, ABS, and other electronic systems. Rebuild Procedures: Detailed rebuild procedures for engines, transmissions, and differentials. Calibration Procedures: Procedures for setting ignition timing, idle speed, and other critical adjustments. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes Printable: Yes Print Quality Diagram Clarity: High-resolution, clear diagrams and illustrations. Image Quality: Sharp, detailed photographs and illustrations. Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: B230F Engine Type: Inline-4 Cylinder, SOHC Displacement: 2.3 Liters (2316 cc) Bore X Stroke: 96.0 mm x 80.0 mm Compression Ratio: 8.8:1 Fuel Delivery: Bosch LH 2.4 Jetronic Multi-port Fuel Injection Horsepower: 114 hp @ 5000 rpm (approx.) Torque: 132 lb-ft @ 2500 rpm (approx.) Performance Engine Code Turbo: B230FK Engine Type Turbo: Inline-4 Cylinder, SOHC, Turbocharged Displacement Turbo: 2.3 Liters (2316 cc) Fuel Delivery Turbo: Bosch Motronic EZK/LH 2.4 Turbo Fuel Injection Horsepower Turbo: 162 hp @ 5000 rpm (approx.) Torque Turbo: 177 lb-ft @ 2500 rpm (approx.) Fuel System Fuel Type: Unleaded Gasoline (87 octane or higher) Fuel Tank Capacity: 15.8 US gallons (60 Liters) 🔧 Transmission Standard Transmission Type Std: M47 5-Speed Manual Optional Transmission Type Opt1: AW71 3-Speed Automatic Transmission Type Opt2: AW72 4-Speed Automatic (with Overdrive) Features Clutch Type: Single dry plate, hydraulically operated Automatic Features: Lock-up torque converter (AW72), electronic control (later models may feature more advanced control), sport/economy modes (on some AW72). 📐 Dimensions Exterior Length: 188.2 in (4780 mm) Width: 69.5...

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Description

🏷️ Basic Information

Identification

Make:

Volvo

Model:

Year:

Codes

Chassis Code:

940 Series

Platform:

Volvo Rear-wheel drive platform (P90)

👋 Introduction

Market Position

Segment:

Mid-size Luxury Sedan/Wagon (RWD)

Target Demographic:

Families valuing safety, durability, and a comfortable driving experience.

Competitive Analysis

Key Competitors:

BMW 3 Series, Mercedes-Benz 190E, Audi 80/90, Saab 9000

Competitive Advantage:

Volvo's reputation for safety, robust build quality, comfortable ride, and distinctive Scandinavian design.

Key Features

Safety Focus:

Pioneering safety features including integrated side-impact protection, reinforced body structure, and often equipped with ABS.

Durability:

Known for long-term reliability and robust mechanical components.

Comfort:

Comfortable seating, compliant suspension, and quiet cabin for long-distance touring.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.3L B230FK Turbocharged Inline-4, 2.3L B230F Naturally Aspirated Inline-4

Transmission Coverage:

M47 5-speed Manual, AW71 3-speed Automatic, AW72 4-speed Automatic

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Safety Systems

Page Count

Page Count:

Approximately 1000+

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly and assembly of B230F and B230FK engines, including cylinder head, pistons, crankshaft, camshaft, timing belt, lubrication system.

Fuel Injection System:

Bosch LH Jetronic (B230F) and Bosch Motronic (B230FK) fuel injection system diagnostics, component testing, pressure testing, injector servicing.

Ignition System

Ignition System:

Distributor ignition system (B230F), Coil-on-plug ignition system (B230FK), timing adjustments, component replacement.

Cooling System

Cooling System:

Radiator, water pump, thermostat, coolant hoses, heater core replacement, flushing procedures, pressure testing.

Exhaust System

Exhaust System:

Catalytic converter, muffler, exhaust manifold replacement, oxygen sensor (lambda sensor) servicing.

Transmission Manual

Transmission Manual:

M47 5-speed manual transmission overhaul, clutch replacement, gear linkage adjustments.

Transmission Automatic

Transmission Automatic:

AW71 (3-speed) and AW72 (4-speed) automatic transmission diagnosis, fluid change procedures, seal replacement, torque converter servicing.

Drivetrain

Drivetrain:

Rear-wheel drive axle, driveshaft, universal joints, differential servicing.

Suspension Front

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar bushings, spring replacement, shock absorber replacement.

Suspension Rear

Suspension Rear:

Multi-link rear suspension, trailing arms, shock absorbers, bushings, spring replacement.

Steering System

Steering System:

Power steering pump, steering rack, tie rod ends, power steering fluid flush.

Brake System

Brake System:

Front ventilated discs, rear solid discs (or drums on some models), brake pad and rotor replacement, brake caliper servicing, hydraulic system bleeding, ABS system diagnostics.

Electrical System

Electrical System:

Wiring diagrams, fuse box locations, relay functions, alternator, starter motor, battery charging system, lighting, instruments, power windows, power locks, central locking system.

Bodywork

Bodywork:

Body panel repair, door hinge adjustments, glass replacement, seal replacement, rust prevention and repair.

Climate Control

Climate Control:

HVAC system diagnosis, blower motor replacement, evaporator and heater core service, refrigerant recharge (R134a).

Safety Systems

Safety Systems:

Seatbelt servicing, SRS airbag system (if equipped) diagnostics and precautions.

Procedures Included

Troubleshooting Guides:

Comprehensive diagnostic flowcharts and symptom-based troubleshooting for all major systems.

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, brake fluid flush, coolant flush.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for nearly every part of the vehicle.

Torque Specifications:

Precise torque values for all critical fasteners and bolts throughout the vehicle.

Diagnostic Tools:

Information on required diagnostic tools and special equipment for specific procedures.

Technical Depth

Diagnostic Capability:

Advanced diagnostics for engine management, ABS, and other electronic systems.

Rebuild Procedures:

Detailed rebuild procedures for engines, transmissions, and differentials.

Calibration Procedures:

Procedures for setting ignition timing, idle speed, and other critical adjustments.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Printable:

Print Quality

Diagram Clarity:

High-resolution, clear diagrams and illustrations.

Image Quality:

Sharp, detailed photographs and illustrations.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code:

B230F

Engine Type:

Inline-4 Cylinder, SOHC

Displacement:

2.3 Liters (2316 cc)

Bore X Stroke:

96.0 mm x 80.0 mm

Compression Ratio:

8.8:1

Fuel Delivery:

Bosch LH 2.4 Jetronic Multi-port Fuel Injection

Horsepower:

114 hp @ 5000 rpm (approx.)

Torque:

132 lb-ft @ 2500 rpm (approx.)

Performance

Engine Code Turbo:

B230FK

Engine Type Turbo:

Inline-4 Cylinder, SOHC, Turbocharged

Displacement Turbo:

2.3 Liters (2316 cc)

Fuel Delivery Turbo:

Bosch Motronic EZK/LH 2.4 Turbo Fuel Injection

Horsepower Turbo:

162 hp @ 5000 rpm (approx.)

Torque Turbo:

177 lb-ft @ 2500 rpm (approx.)

Fuel System

Fuel Type:

Unleaded Gasoline (87 octane or higher)

Fuel Tank Capacity:

15.8 US gallons (60 Liters)

🔧 Transmission

Standard

Transmission Type Std:

M47 5-Speed Manual

Optional

Transmission Type Opt1:

AW71 3-Speed Automatic

Transmission Type Opt2:

AW72 4-Speed Automatic (with Overdrive)

Features

Clutch Type:

Single dry plate, hydraulically operated

Automatic Features:

Lock-up torque converter (AW72), electronic control (later models may feature more advanced control), sport/economy modes (on some AW72).

📐 Dimensions

Exterior

Length:

188.2 in (4780 mm)

Width:

69.5 in (1765 mm)

Height:

56.1 in (1425 mm)

Wheelbase:

109.1 in (2770 mm)

Front Track:

57.7 in (1465 mm)

Rear Track:

57.0 in (1450 mm)

Interior

Front Headroom:

38.5 in (978 mm)

Rear Headroom:

37.6 in (955 mm)

Front Legroom:

42.1 in (1069 mm)

Rear Legroom:

35.2 in (894 mm)

Cargo

Cargo Volume Sedan:

15.9 cu ft (450 L)

Cargo Volume Wagon:

38.8 cu ft (1099 L) / 73.4 cu ft (2078 L) with rear seats folded

Weights

Curb Weight Sedan:

3150 - 3300 lbs (1430 - 1500 kg) approx.

Curb Weight Wagon:

3250 - 3450 lbs (1475 - 1565 kg) approx.

Gross Vehicle Weight Rating:

4400 - 4600 lbs (2000 - 2100 kg) approx.

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3/5 stars (typically)

IIHS Side Impact:

Good (for its era, due to structural integrity)

Active Features

Anti-lock Braking System (Standard on most 1995 models)

Traction Control:

Traction Control System (TRACS) available on some models, especially with automatic transmission.

Passive Features

Airbags:

Driver and Passenger Supplemental Restraint System (SRS) airbags were standard.

Body Structure:

Reinforced safety cage, side-impact protection beams, energy-absorbing crumple zones.

Seatbelts:

Three-point inertia-reel seatbelts for all outboard seating positions, often with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette stereo with optional CD player. Multiple speaker configurations available.

Climate Control Type:

Manual or automatic climate control (ECC - Electronic Climate Control) depending on trim level.

Driver Assistance

Cruise Control:

Standard on most models.

Power Accessories:

Power windows, power door locks, power mirrors were common features.

Connectivity

Phone Integration:

No integrated Bluetooth or smartphone connectivity in the original factory systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km).

Fuel Filter Replacement:

Every 20,000-30,000 miles (32,000-48,000 km).

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs; platinum/iridium plugs may last longer.

Timing Belt Replacement:

Every 60,000-90,000 miles (96,000-145,000 km) or 5-7 years, as the B230 engine uses a timing belt.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 5W-30 or 10W-30 (depending on climate).

Engine Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter change.

Coolant Type:

Volvo Blue Coolant (Ethylene Glycol based) or equivalent, mixed 50/50 with distilled water.

Automatic Transmission Fluid:

Dexron III or MERCON approved ATF.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Power Steering Fluid:

ATF Dexron II/III or a dedicated power steering fluid.

Brake Fluid Type:

DOT 3 or DOT 4 (check reservoir cap).

Known Issues

Oil Leaks:

Common leaks from valve cover gasket, oil pan gasket, and rear main seal.

Cooling System:

Plastic coolant reservoir can become brittle, hose failures, radiator leaks.

Electrical Gremlins:

Aging wiring harnesses, faulty relays (e.g., fuel pump relay), and corroded grounds can cause intermittent issues.

Suspension Wear:

Worn control arm bushings, ball joints, and sway bar links can lead to clunks and alignment issues.

Fuel Pump Failure:

Fuel pump can be a wear item over time.

Heater Core:

Heater core leaks can lead to coolant loss and fogged windows.

📚 Vehicle History

Brand Heritage

Volvo Safety Legacy:

Volvo's long-standing commitment to automotive safety, dating back to the invention of the three-point seatbelt.

Model Evolution

900 Series Introduction:

The 900 Series was introduced in 1990, evolving from the 700 Series, featuring a more aerodynamic and modern design while retaining the classic Volvo rear-wheel-drive platform.

940 Designation:

The '940' designation typically referred to models with the 2.3-liter 4-cylinder engine, positioned below the 960 (which featured a 6-cylinder engine or the more advanced suspension).

Production

Production Years:

1990-1998

Manufacturing Locations:

Sweden (primarily Ghent, Belgium and Uddevalla, Sweden)

Market End:

The 900 series was largely succeeded by the Volvo S80 and V70 (based on the newer front-wheel-drive platform) towards the end of the decade.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Consistently recognized for safety by independent testing agencies and consumer publications of its era.

Ratings

Consumer Reports Durability:

Often rated highly for reliability and durability by publications like Consumer Reports.

Certifications

Euro Ncap Rating:

N/A (Euro NCAP was not established in its current form during its primary production years, but Volvo's internal testing and reputation were strong).