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In the Service Manual they specify the lengths of the Linkage Rods. If the Length/s is/are not correct thing might not work right.
If the Injector Fuel Return Hoses are routed wrong it can prevent the Lever from moving properly.
Lever Bent?
In side of the Idle Screw is a Spring Loaded Plunger. At Idles speed the Throttle Lever on the Fuel Injection Pump rids on the Extended Plunger. When you use the Shutoff Lever you compress the Plunger Spring and move past the Idle Position; I have read of that Plunger being rusted and if that happen it could prevent the Plunger from being compressed enough.
The bottom red number 2 arrow in the pic points to the Plunger.
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84 300D, 82 Volvo 244Gl Diesel
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