Home/Volvo/S40/Volvo S40 I facelift (1999-2004)/Repair manual/Transmission - Removal, Replacement and Installation (644 Body)/Adjusting shift cables, installing engine compartment compo…

Contents

Wiring diagrams Section: Transmission - Removal, Replacement and Installation (644 Body)

Oil, Changing

Conditions for changing

Filling, Continued

Checking the Oil Level

Preparations, continued

Installing components

Installing other components

Filling and checking oil

Replacing the carrier plate

Preparatory work

Removing the carrier plate

Finishing

Removing the air cleaner (ACL) housing, the intake manifold and the battery

Installing the connector on the transmission bracket

Installing the air cleaner (ACL) housing, the intake manifold and the battery

Replacing the boot and/or indicator panel

Removing the air cleaner (ACL) housing and intake manifold

Adjusting the gear-shift position sensor

Installing the air cleaner (ACL) housing and intake manifold

Replacing the right and left-hand differential seals

Replacing the sealing ring for the gear shift linkage rod

Removing engine compartment components

Removing the gear-shift position sensor from the gear shift linkage rod

Installing the gear-shift position sensor

Installing the gear-shift position sensor, continued

Installing engine compartment components

Replacing the sealing ring for the oil pump

Removing the transmission

Installing the transmission

Preparations

Checking the resistance of SLT, SLS and SLU

Replacing solenoids S1-S5

Installing the control system

Installing the vehicle speed sensor (VSS)

Installing the air cleaner (ACL) housing, the intake manifold and battery

Replacing the transmission

Detaching transmission connectors

Removing the heat deflector plate and member

Detaching the left-hand side drive shaft

Detaching the right-hand side drive shaft

Detaching oil pipes

Lifting engine and transmission

Installing the screws, transmission/engine

Installing the front and rear brackets

Installing the support member

Installing the oil pipes

Installing the shift cable

Adjusting the gear cable

Removing battery and air cleaner

Removing passenger compartment components

Installing the center console

Adjusting shift cables, installing engine compartment components

Shift lock and ignition switch interlock

Conditions

Check

Removing center consoles

Installing center consoles

Replacing boot/indicator panel

Replacing the kickdown switch (KD)

Replacing the S and W mode selectors

Installing the control module

Opening the control system

Replacing accumulator pistons/sealing rings B2/C2

Opening control system

Removing sticking valves and pistons

Reinstalling control system

Replacing accumulator pistons/sealing rings C3

Information for work with valves and pistons

Replacing control system

Cleanliness

Disconnecting connectors

Sealing cover

Replacing left-hand side drive shaft seal

Installing stub axle, brake hose and ABS line

Adjusting and checking

Replacing right-hand side drive shaft seal

Removing components

Installing drive shaft

Install cover

Installing splash guards and wheel

Replacing the engine speed (RPM) sensor

Replacing the gear-shift position sensor

Removing the gear-shift position sensor

Removing transmission

Oil pump sealing ring

Installing transmission

Readings, solenoids

Replacing solenoid

Removing the battery and air cleaner (ACL)

Installing the gear selector cable

Installing the rear center console

Adjusting the transmission cable. Installing engine compartment components

Replacing the primary shaft seal

Installing the clutch cylinder

Removing the clutch cylinder

Installing the extractor for the primary shaft seal

Installing the new primary shaft seal

Install the rubber pipe seal in the clutch cover

Checking the shift lock function

Install the control module

Removing the components on the left and right-hand sides

Disconnecting the drive shaft, left-hand side

Connecting the fixture

Installing

Install the AC compressor

Installing left/right drive shafts

Checking the drive shafts

Install the hose to the charge air cooler (CAC)/charge air pipe

Installing the splash guards and wheels

Install the Poly V-belt

Install the engine compartment components

Checking the transmission oil level

Installing the engine with the transmission

Removing the engine with the transmission

Adaptation of Transmission control module (TCM)

All sections

Adjusting shift cables, installing engine compartment components Volvo S40 I facelift

Transmission - Removal, Replacement and Installation (644 Body)

Adjusting shift cables, installing engine compartment components

Adjust the shift cable as described in Adjusting the mechanical cable for the transmission .

Install

the heat deflector plate (3 screws)
the battery shelf
air cleaner housing, see Installing the Air Cleaner (ACL) Housing
the battery Note when disconnecting and connecting the battery lead . Connect the cables.