Home/Volvo/V40/Volvo V40 I рестайлинг (1999-2004)/Repair manual/Engine Components - Removal, Replacement and Installation/Preparation

Contents

Section: Engine Components - Removal, Replacement and Installation

Replacing spark plugs

Removing

Installing

Install the cover on the timing gear

Camshaft seals, replacing

Preparations

Secure the crankshaft position

Installing the timing covers

Installing the right-hand engine mounting

Finishing

Checking work

Crankshaft seal rear, replacing

Installing the sealing ring

Installing the gearbox

Checking the engine

Gearbox, fitting

Cylinder head/gasket, replacing

Preparation

Exhaust manifold, removing

Starter motor, removing

Components, removing

Timing belt pulley, removing

Installing the cylinder head

Valve depressors and camshafts, installing

Camshaft cover, installing

Coolant pump's inlet pipe, installing

Front camshaft seal, installing

Camshafts' timing belt pulley, installing

Right engine mount, installing

Installing components

Inlet pipe, installing

Components, installing

Exhaust manifold, installing

Starter motor, installing

Checking performed work

Removing turbocharged engines with the transmission

Conditions

Installing the lifting beam and lifting hook

Removing the right-hand engine mounting

Installing the right engine mounting

Installing the left-hand engine mounting

Installing the front engine mounting

Installing the rear engine mounting

Replacing the air cleaner (ACL)

Installing the battery

Replacing the cover on top of the engine

Replacing the oil pump and front crankshaft seal

Removing the timing belt

Installing the timing belt

Replacing the timing belt

Removing the timing covers

Tensioning the tensioner pulley and the idler pulley

Installing timing covers

VVT-unit, replacing/adjusting

Engine components exhaust side, transferring

Carrier plate, installing

Removing the left-hand side drive shaft nut

Removing the poly V-belts

Removing the left-hand side cover

Removing the air cleaner (ACL)

Removing the fuel line from the engine

Replacing camshaft seal (retaining ring) front side

Install camshaft retaining ring

Replacing engine mounting bolsters

Prerequisites

Replacing engine mounting bolster at transmission side

Replacing flange plate

Install flange plate

Replacing rearmost crankshaft retaining ring

Removing flange plate

Installing flange plate

Replacing the camshaft seals

Position the engine according to the marking

Removing the timing gear pulley

Replacing the camshaft seal

Installing the camshaft timing gear pulley

Check

Installing the cover on top of the engine

Replacing the cylinder head and gasket

Separating the exhaust system

Removing the manifold and turbocharger (TC)

Removing the starter motor

Removing the fuel line

Removing components

Removing the intake manifold

Releasing the intake pipe for the coolant pump

Removing the camshaft cover and cylinder head

Cleaning the gasket face

Aligning the crankshaft

When replacing or working on the cylinder head

Installing the valve lifters and camshafts

Installing the camshaft cover

Installing the intake pipe for the coolant pump

Installing the front camshaft seal

Installing the intake manifold

Installing the fuel line

Installing the exhaust manifold

Installing the starter motor

Replacing toothed (timing) belt

Align timing gear and crankshaft according to the markings

Install timing belt at lower side

Install cover plates

Check timing belt tension

Install engine bracket

Install timing gear covers

Install auxiliaries belt

Place the hood in the service position

Automatic transmission: Installing the gear selector mechanism cables

Fuel hose, routing and connecting

Charge air hose from the turbocharger (TC), upper hose, installing

Engine mounting rear, installing

Front-rear member, installing

Automatic transmission: Installing the oil pipes

Lateral strut, installing

Front wheel, installing

Air cleaner (ACL), installing

Battery, installing

Poly V-belts, installing

Coolant, filling

Removing the variable valve timing (VVT) unit

Installing VVT-unit

Installing the timing gear pulley

Replacing the idle air control (IAC) valve

Replacing the mass air flow (MAF) sensor

Replacing the turbocharger (TC) control valve

Replacing the variable valve timing (VVT) control valve

Replacing the variable valve timing solenoid

Removing the front-rear member

Removing the oil pan

Cleaning

Installing the front-rear member

Replacing the oil and oil filter

Replacing the dual mass flywheel

Preparatory work

Removing the flywheel

Installing the flywheel

Reinstall the transmission

Checking/replacing the clutch driven plate and self-adjusting clutch

Check that there are no cracks or large scratches on the flywheel

Install the tools on the clutch

Removing the timing belt and mechanical timing belt tensioner

Replacing piston cooling valves

All sections

Preparation Volvo V40 I рестайлинг

Engine Components - Removal, Replacement and Installation 1 illustration

Preparation

Remove the cable from the battery negative terminal. First read Note when disconnecting and connecting the battery lead .

Scheme 77

Scheme 77: Coolant, draining

Scheme 77: Coolant, draining

Remove the front air baffle.
Open the engine nipple.
Drain the coolant into a container.
Close the nipple.
Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.