Servicing - A/t: Removal & Installation Volvo V40 I рестайлинг

Installation

Note. Take care not to damage the cable or sleeve by bending it excessively. Take care not to damage the cable boot.

1. Install the gearshift cable. Carefully insert the cable from the passenger compartment into the engine compartment. Install the cable sleeve in the gear selector assembly by pressing it into place. Install the cable on the gear selector with the pin. Install the frame over the rubber grommet in the cowl panel (2 nuts).
2. Install front center console. Slide the front center console over the gear shift selector with a twisting movement. Position the front center console correctly. Slide the front center console over the guide under the dashboard and the side panels for the front center console. Install the two screws at the front edge. see scheme 11
3. Install the connector for the radio. Install the radio. Enter the anti-theft radio code.
4. Install the rear center console. Install the gray connector. Install the rear center console, the screw (4) and guard (3). Install the gear selector panel (2). see scheme 10 Check that the clip has engaged. Install the rubber underlay (1).
5. Carefully reinstall the cable on the lever pin and studs. see scheme 6 Ensure that neither the gear selector or lever change position. Install the nuts. Tighten alternately to specification. See «TORQUE SPECIFICATIONS»(ref-157322-S14662941862003080800000). Install the washer and the retaining clip on the lever. Install the cable in the clip on the connector bracket. Check adjustment. See «GEARSHIFT CABLE»(ref-157322-S38881610432003080800000) under ADJUSTMENTS.
6. Install the air cleaner housing. Position the air cleaner housing and install the screws. Install the screws for the relay box. Install the preheating hose, the inlet hose and the assisted air control valve. Reconnect the vacuum hoses, connectors and wiring.
7. Install the battery. Install the cable on the battery positive terminal and the cable on the battery negative terminal. Install the front engine cover (if applicable).

Seal Replacement

1. Remove the front engine cover (if applicable). Remove the cable from the battery negative terminal. Remove the cable from the battery positive terminal. Remove the battery.
2. Remove the connectors from the Mass Air Flow (MAF) sensor and the assisted air control valve. see scheme 2 Disconnect the connectors, vacuum hoses and wiring from the air cleaner housing. Remove the assisted air control valve from the air cleaner housing. Remove the inlet hose from the terminal on the MAF sensor. Remove the preheating hose.
3. Remove the screws for the relay box. Move the box to one side. Remove the screws for the air cleaner housing. Release the clip holding the fresh air intake on the air cleaner housing. see scheme 3 Lift off the air cleaner housing assembly.
4. Remove the following gearshift cable components: Retaining clip from the lever (A). see scheme 9 Mechanical cable from the clip on the bracket for the connectors (B). Mechanical cable bracket and the cable from the lever (C). Heat deflector plate on the firewall (three nuts) (D).
5. Removing the connector from the transaxle. Disconnect the cable harness from the transaxle. Cut off the 2 tie straps. Separate the connector. Disconnect the connector from the bracket. Removing the PNP sensor. Remove the lever the nut, lock washer and rubber seal from the PNP sensor.
6. Remove the nut for the cable duct. Lift the cable duct to one side. Remove the two screws from the PNP sensor. Carefully lift the sensor off the gear shift linkage rod.
7. Replace the sealing ring for the gear shift linkage rod. Remove the old sealing ring using a small rounded off screwdriver. (Scheme 21) Take care not to damage the rod. Apply A/T fluid on the new sealing ring. Install the ring using appropriate seal installer.
8. Install the PNP sensor. Tighten the sensor screws lightly. Install the rubber washer, lock washer and the nut on the gear shift linkage rod connection. Tighten the nut. Lock the nut with the lock washer. Adjust the PNP sensor. See «PARK NEUTRAL POSITION SENSOR»(ref-157322-S01656600742003080800000) under ADJUSTMENTS.
9. Carefully reinstall the cable on the lever pin and studs. see scheme 6 Ensure that neither the gear selector or lever change position. Install the nuts. Tighten alternately to specification. See «TORQUE SPECIFICATIONS»(ref-157322-S14662941862003080800000). Install the washer and the retaining clip on the lever. Install the cable in the clip on the connector bracket. Check adjustment. See «GEARSHIFT CABLE»(ref-157322-S38881610432003080800000) under ADJUSTMENTS.
10. Install the air cleaner housing. Position the air cleaner housing and install the screws. Install the screws for the relay box. Install the preheating hose, the inlet hose and the assisted air control valve. Reconnect the vacuum hoses, connectors and wiring.
11. Install the battery. Install the cable on the battery positive terminal and the cable on the battery negative terminal. Install the front engine cover (if applicable).

Scheme 21

Removal

1. Remove the front engine cover (if applicable). Remove the cable from the battery negative terminal. Remove the cable from the battery positive terminal. Remove the battery.
2. Remove the connectors from the Mass Air Flow (MAF) sensor and the assisted air control valve. see scheme 2 Disconnect the connectors, vacuum hoses and wiring from the air cleaner housing. Remove the assisted air control valve from the air cleaner housing. Remove the inlet hose from the terminal on the MAF sensor. Remove the preheating hose.
3. Remove the screws for the relay box. Move the box to one side. Remove the screws for the air cleaner housing. Release the clip holding the fresh air intake on the air cleaner housing. see scheme 3 Lift off the air cleaner housing assembly.
4. Remove the following gearshift cable components: Retaining clip from the lever (A). see scheme 9 Mechanical cable from the clip on the bracket for the connectors (B). Mechanical cable bracket and the cable from the lever (C). Heat deflector plate on the firewall (three nuts) (D).
5. Disconnect the cable harness from the transaxle. (Scheme 22) Cut off the 2 tie straps. Separate the connector. Disconnect the connector from the bracket.
6. Remove the PNP sensor. Remove the lever the nut, lock washer and rubber seal from the PNP sensor. (Scheme 23)
7. Remove the nut for the cable duct. Lift the cable duct to one side. Remove the two screws from the PNP sensor. Carefully lift the sensor off the gear shift linkage rod.

Scheme 22

Scheme 23

1. Install the PNP sensor. Tighten the sensor screws lightly. Install the rubber washer, lock washer and the nut on the gear shift linkage rod connection. Tighten the nut. Lock the nut with the lock washer. Adjust the PNP sensor. See «PARK NEUTRAL POSITION SENSOR»(ref-157322-S01656600742003080800000) under ADJUSTMENTS.
2. Carefully reinstall the cable on the lever pin and studs. see scheme 6 Ensure that neither the gear selector or lever change position. Install the nuts. Tighten alternately to specification. See «TORQUE SPECIFICATIONS»(ref-157322-S14662941862003080800000). Install the washer and the retaining clip on the lever. Install the cable in the clip on the connector bracket. Check adjustment. See «GEARSHIFT CABLE»(ref-157322-S38881610432003080800000) under ADJUSTMENTS.
3. Install the air cleaner housing. Position the air cleaner housing and install the screws. Install the screws for the relay box. Install the preheating hose, the inlet hose and the assisted air control valve. Reconnect the vacuum hoses, connectors and wiring.
4. Install the battery. Install the cable on the battery positive terminal and the cable on the battery negative terminal. Install the front engine cover (if applicable).