Engine Components - Removal, Replacement and Installation: Removal & Installation Volvo V40 I рестайлинг

Ignition coil(s), replacement

Special tools

9995702

Scheme 3

1. Remove both engine covers.
2. Detach the connectors.
3. Disconnect the high voltage cable.
4. Remove the retaining screws.
5. Pull out the ignition coils.

Scheme 4

If necessary, remove the rubber and the spring from the spark plug or from the spark plug hole.

Check and clean the spark plug if necessary.

Clean the ignition coil.

Fit the new spring (1) with the countersink outwards. Guide in the new spring (1) with a small screwdriver by pressing down the lower part of the spring in the coil.

Note. Check that the spring (1) is raised out of the coil by approx. 5 mm.

Fit the new rubber in the groove on the ignition coil (2).

Scheme 5

1. Check the rubber and spring inside. Replace if necessary.
2. Fit the ignition coils in place and press them in.
3. Tighten the screw. Tightening torque 10 Nm .
4. Connect the high voltage cables.
5. Reattach the connector. NOTE: The grey connector is for the left-hand coil (cylinder 2 and 3), the blue connector is for the right-hand coil (cylinder 1 and 4).
6. Check the function.
7. Fit both engine covers.

Remove the cover from the timing gear

See Removing the cover on top of the engine .

Scheme 6

1. Remove the connector and the wiring beside the connector
2. Remove the screw
3. Carefully pull the device off
4. Remove the o-ring.

Scheme 7

1. Wipe up any spilled oil. Clean the mating surfaces
2. Install a new O-ring
3. Position the system. Turn the system into the correct position
4. Install the bolt. Tighten to 8 Nm
5. Connect the wiring.

Engine replacement, transferring components

See Engine replacement, transferring components

Replace the engine mountings

Special tools

9995006

9995383

9995460

Special tools

9985972

9992520

9992810

9995112

9995297

9995186

9995642

9995463

Scheme 8

1. Pull off the cover
2. Remove the support bracket from the intake manifold.
3. Remove the wiring from the starter motor.
4. Remove the mounting screws. Remove the starter motor.

Scheme 9

Remove the torque converter screws. Remove the screwed joint between the transmission and the engine where the flywheel cover is secured to the cylinder block.

Scheme 10

See Remove flange plate .

Scheme 11

Use engine stand 999 2520 and support 999 5297.

Remove the lifting tools.

Install an appropriate number of washers to compensate for the transmission guide pins.

Scheme 12

1. The upper cover
2. The ignition coils and wiring
3. Camshaft position (CMP) sensor
4. The lifting eyelet.

Remove camshaft seal at VVT unit side

1. Remove toothed belt, see «Remove auxiliaries belt»(ref-441341-S10635964492011121500000)
2. Remove the gear pulley at the side to be replaced, see «Removing the timing gear pulley»(ref-441341-S41630804122011121500000) .

Scheme 13

1. Remove the retaining ring with help of special tool «9995919»(ref-403953-S08553537872011061000000)
2. Clean the surfaces.

Replace front engine mounting bolster

Remove the nut and the bolt from the engine mounting bolster.

Remove the two mounting bolts and remove the mounting bolster.

Install the new engine mounting bolster (Position the hole towards the front of the car).

Tighten the

1. Two bolts (A) on the longitudinal member to 35 Nm .
2. Central bolt (B) in the bolster to 55 Nm .

Replace rear engine mounting bolster

Remove the splash guards from the underside.

Remove the drive shaft heat-shield.

Remove the two bolts (A) from the mounting on the body side.

Remove the bolt (B) of the mounting and pull the engine mounting down slightly.

Remove the two mounting bolts (C) and remove the mounting.

Install the mounting with the two bolts (C).

Position the hole (D) towards the rear of the car. Torque setting 35 Nm .

Replace the bolt (B). Finger-tighten.

Scheme 14

Install the two bolts (A). Torque setting 69 Nm .

Note. Position the rubbers in the correct position as shown. (The rear and the front of the center member must be in similar positions).

Loosen the front mounting-bolster bolt (B). First tighten the rear mounting-bolster bolt (torque setting 55 Nm ), then tighten the front mounting bolt again (torque setting 55 Nm ).

Install the heat shield and the splash guard.

Remove auxiliaries belt

1. Remove the right engine compartment cover and the cover above the right headlight unit
2. Release the auxiliaries belt by turning the pulley screw clockwise
3. Remove the auxiliaries belt
4. Release the belt tensioner (counterclockwise).

Remove upper timing gear covers

1. Remove two screws and remove upper cover by undoing the two clips at the side
2. Remove the screw and take the cover off.

Scheme 15

Note. Remove the nut from the body support.

Position the lifting beam 9995006 centrally above the engine and install the lifting lugs 9995460 in the lifting eyes.

Install the extra support 9995383 (if necessary).

Lift the engine up a few mm at the front.

Remove engine mounting on timing gear side

1. Remove three bolts and the screw from the mounting at body side and pull out the mounting with the rubber.

Scheme 16

1. Undo bottom cover and move backwards.

Scheme 17

1. Remove the four bolts and pull bracket from engine. Lift engine if necessary.

Turn wheel to the right.

Open lid in side cover.

Remove the engine splashguards

Remove

1. rear
2. front.

Remove timing belt at lower side

1. Remove the two bolts from the snow cap
2. Remove the timing belt and take it out with a turning movement
3. Clean surrounding.

See Ignition coil(s), replacement

See Engine replacement, transferring components

See Replace the engine mountings

See Ignition coil(s), replacement

See Engine replacement, transferring components

See Replace the engine mountings

Replace the oil pan

Special tools

9511205

See Replace the oil pan

See Replace the oil pan