Manual sections

Wiring diagrams

• A/c Compressor
• Abbreviations
• Accessory Drive Belts
• Adjustments
• Airbag
• Alarm, Doors, Lids & Locking - Removal, Replacement and Installation
• Anti-Lock/traction Control
• Application
• Automatic HVAC System
• Automatic Trans
• Auxiliary Emission Control Systems
• Axle Shafts
• Basic Trouble Shooting
• Blowers, Superchargers & Turbochargers
• Body - Removal, Replacement and Installation
• Body Electrical
• Brakes
• Cabin Air Filter
• Cables and Fuses - General Information
• Charging System
• Check Lists
• Climate Units - Removal, Replacement and Installation
• Clutches Manual & Hydraulic
• Computer Relearn
• Cooling System (Mechanical)
• Cruise Control Systems
• Diagnostic Connector Locations
• Door Locks & Anti-Theft Systems
• Drive Cycles
• Driveline/axles
• Driveshaft & Universal Joints
• DTC Index
• Electrical Component Locations
• Electronic Suspension
• Emission Applications
• Engine
• Engine Components - Removal, Replacement and Installation
• Engine Control Systems
• Engine Performance
• Entertainment Systems
• Exterior Body Panels
• Exterior Lights
• Exterior/interior Trim
• Frames, Subframes & Crossmembers
• Fuel System
• Fuses & Circuit Breakers
• Gauges & Instrument Panels
• General Servicing - All Makes
• Heater
• Identification
• Interior Equipment - Removal, Replacement and Installation
• Lubrication System
• Manual & Power Steering
• Mechanical
• Mechanical - Hydraulic
• Metric Conversions
• Oem General Information
• Paint/coatings
• Parking Brake System
• Passive Restraints
• Pin Voltage Charts
• Procedures
• Removal & Installation
• Reset Procedures
• Restraints
• Seats
• Seats, Interior Panels & Upholstery - Removal, Replacement and Installation
• Sensor Range Charts
• Specifications
• Starter
• Steering
• Steering Column
• Suspension Front
• Suspension Rear
• Testing & Diagnostics
• Theory & Operation
• Timing Belt
• Towing Systems
• Traction Control Disable
• Transmission
• Transmission - Removal, Replacement and Installation
• Wheel & Tire System
• Wheel Alignment
• Wheel Hubs
• Windows
• Wiper/washer Systems
• Wiring Diagrams - Engine Performance

Repair manual

Engine Components - Removal, Replacement and Installation Volvo V40 I facelift

Step-by-step instructions on "Engine Components - Removal, Replacement and Installation" for Volvo V40 I facelift (1999–2004). Pick an article — removal, installation, adjustment and diagnostics with illustrations.

142subsections

142articles

156illustrations

Replacing spark plugs

1 article

• Replacing spark plugs

Removing

1 article

• Removing

Installing

1 article

• Installing 5

Install the cover on the timing gear

1 article

• Install the cover on the timing gear

Camshaft seals, replacing

1 article

• Camshaft seals, replacing

Preparations

1 article

• Preparations 13

Secure the crankshaft position

1 article

• Secure the crankshaft position 6

Installing the timing covers

1 article

• Installing the timing covers

Installing the right-hand engine mounting

1 article

• Installing the right-hand engine mounting

Finishing

1 article

• Finishing

Checking work

1 article

• Checking work

Crankshaft seal rear, replacing

1 article

• Crankshaft seal rear, replacing 3

Installing the sealing ring

1 article

• Installing the sealing ring 2

Installing the gearbox

1 article

• Installing the gearbox

Checking the engine

1 article

• Checking the engine

Gearbox, fitting

1 article

• Gearbox, fitting 25

Cylinder head/gasket, replacing

1 article

• Cylinder head/gasket, replacing

Preparation

1 article

• Preparation 1

Exhaust manifold, removing

1 article

• Exhaust manifold, removing

Starter motor, removing

1 article

• Starter motor, removing

Components, removing

1 article

• Components, removing 2

Timing belt pulley, removing

1 article

• Timing belt pulley, removing 6

Installing the cylinder head

1 article

• Installing the cylinder head 3

Valve depressors and camshafts, installing

1 article

• Valve depressors and camshafts, installing 2

Camshaft cover, installing

1 article

• Camshaft cover, installing

Coolant pump's inlet pipe, installing

1 article

• Coolant pump's inlet pipe, installing 1

Front camshaft seal, installing

1 article

• Front camshaft seal, installing

Camshafts' timing belt pulley, installing

1 article

• Camshafts' timing belt pulley, installing 1

Right engine mount, installing

1 article

• Right engine mount, installing

Installing components

1 article

• Installing components

Inlet pipe, installing

1 article

• Inlet pipe, installing

Components, installing

1 article

• Components, installing 1

Exhaust manifold, installing

1 article

• Exhaust manifold, installing

Starter motor, installing

1 article

• Starter motor, installing

Checking performed work

1 article

• Checking performed work

Removing turbocharged engines with the transmission

1 article

• Removing turbocharged engines with the transmission

Conditions

1 article

• Conditions

Installing the lifting beam and lifting hook

1 article

• Installing the lifting beam and lifting hook

Removing the right-hand engine mounting

1 article

• Removing the right-hand engine mounting

Installing the right engine mounting

1 article

• Installing the right engine mounting 1

Installing the left-hand engine mounting

1 article

• Installing the left-hand engine mounting 1

Installing the front engine mounting

1 article

• Installing the front engine mounting 1

Installing the rear engine mounting

1 article

• Installing the rear engine mounting

Replacing the air cleaner (ACL)

1 article

• Replacing the air cleaner (ACL) 3

Installing the battery

1 article

• Installing the battery

Replacing the cover on top of the engine

1 article

• Replacing the cover on top of the engine

Replacing the oil pump and front crankshaft seal

1 article

• Replacing the oil pump and front crankshaft seal

Removing the timing belt

1 article

• Removing the timing belt 5

Installing the timing belt

1 article

• Installing the timing belt

Replacing the timing belt

1 article

• Replacing the timing belt 1

Removing the timing covers

1 article

• Removing the timing covers 1

Tensioning the tensioner pulley and the idler pulley

1 article

• Tensioning the tensioner pulley and the idler pulley 3

Installing timing covers

1 article

• Installing timing covers

VVT-unit, replacing/adjusting

1 article

• VVT-unit, replacing/adjusting

Engine components exhaust side, transferring

1 article

• Engine components exhaust side, transferring 2

Carrier plate, installing

1 article

• Carrier plate, installing 1

Removing the left-hand side drive shaft nut

1 article

• Removing the left-hand side drive shaft nut 5

Removing the poly V-belts

1 article

• Removing the poly V-belts 3

Removing the left-hand side cover

1 article

• Removing the left-hand side cover 2

Removing the air cleaner (ACL)

1 article

• Removing the air cleaner (ACL) 6

Removing the fuel line from the engine

1 article

• Removing the fuel line from the engine 6

Replacing camshaft seal (retaining ring) front side

1 article

• Replacing camshaft seal (retaining ring) front side

Install camshaft retaining ring

1 article

• Install camshaft retaining ring

Replacing engine mounting bolsters

1 article

• Replacing engine mounting bolsters

Prerequisites

1 article

• Prerequisites 1

Replacing engine mounting bolster at transmission side

1 article

• Replacing engine mounting bolster at transmission side

Replacing flange plate

1 article

• Replacing flange plate 1

Install flange plate

1 article

• Install flange plate

Replacing rearmost crankshaft retaining ring

1 article

• Replacing rearmost crankshaft retaining ring

Removing flange plate

1 article

• Removing flange plate 1

Installing flange plate

1 article

• Installing flange plate

Replacing the camshaft seals

1 article

• Replacing the camshaft seals 1

Position the engine according to the marking

1 article

• Position the engine according to the marking

Removing the timing gear pulley

1 article

• Removing the timing gear pulley

Replacing the camshaft seal

1 article

• Replacing the camshaft seal 1

Installing the camshaft timing gear pulley

1 article

• Installing the camshaft timing gear pulley

Check

1 article

• Check 1

Installing the cover on top of the engine

1 article

• Installing the cover on top of the engine

Replacing the cylinder head and gasket

1 article

• Replacing the cylinder head and gasket

Separating the exhaust system

1 article

• Separating the exhaust system

Removing the manifold and turbocharger (TC)

1 article

• Removing the manifold and turbocharger (TC)

Removing the starter motor

1 article

• Removing the starter motor

Removing the fuel line

1 article

• Removing the fuel line

Removing components

1 article

• Removing components

Removing the intake manifold

1 article

• Removing the intake manifold

Releasing the intake pipe for the coolant pump

1 article

• Releasing the intake pipe for the coolant pump

Removing the camshaft cover and cylinder head

1 article

• Removing the camshaft cover and cylinder head 1

Cleaning the gasket face

1 article

• Cleaning the gasket face

Aligning the crankshaft

1 article

• Aligning the crankshaft

When replacing or working on the cylinder head

1 article

• When replacing or working on the cylinder head 1

Installing the valve lifters and camshafts

1 article

• Installing the valve lifters and camshafts

Installing the camshaft cover

1 article

• Installing the camshaft cover

Installing the intake pipe for the coolant pump

1 article

• Installing the intake pipe for the coolant pump

Installing the front camshaft seal

1 article

• Installing the front camshaft seal

Installing the intake manifold

1 article

• Installing the intake manifold

Installing the fuel line

1 article

• Installing the fuel line

Installing the exhaust manifold

1 article

• Installing the exhaust manifold 1

Installing the starter motor

1 article

• Installing the starter motor

Replacing toothed (timing) belt

1 article

• Replacing toothed (timing) belt

Align timing gear and crankshaft according to the markings

1 article

• Align timing gear and crankshaft according to the markings 2

Install timing belt at lower side

1 article

• Install timing belt at lower side

Install cover plates

1 article

• Install cover plates 2

Check timing belt tension

1 article

• Check timing belt tension

Install engine bracket

1 article

• Install engine bracket

Install timing gear covers

1 article

• Install timing gear covers

Install auxiliaries belt

1 article

• Install auxiliaries belt 1

Place the hood in the service position

1 article

• Place the hood in the service position

Automatic transmission: Installing the gear selector mechanism cables

1 article

• Automatic transmission: Installing the gear selector mechanism cables 2

Fuel hose, routing and connecting

1 article

• Fuel hose, routing and connecting

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

1 article

• Charge air hose from the turbocharger (TC), upper hose, installing 3

Engine mounting rear, installing

1 article

• Engine mounting rear, installing 1

Front-rear member, installing

1 article

• Front-rear member, installing 1

Automatic transmission: Installing the oil pipes

1 article

• Automatic transmission: Installing the oil pipes 1

Lateral strut, installing

1 article

• Lateral strut, installing 1

Front wheel, installing

1 article

• Front wheel, installing

Air cleaner (ACL), installing

1 article

• Air cleaner (ACL), installing

Battery, installing

1 article

• Battery, installing 2

Poly V-belts, installing

1 article

• Poly V-belts, installing

Coolant, filling

1 article

• Coolant, filling

Removing the variable valve timing (VVT) unit

1 article

• Removing the variable valve timing (VVT) unit

Installing VVT-unit

1 article

• Installing VVT-unit

Installing the timing gear pulley

1 article

• Installing the timing gear pulley 1

Replacing the idle air control (IAC) valve

1 article

• Replacing the idle air control (IAC) valve

Replacing the mass air flow (MAF) sensor

1 article

• Replacing the mass air flow (MAF) sensor

Replacing the turbocharger (TC) control valve

1 article

• Replacing the turbocharger (TC) control valve

Replacing the variable valve timing (VVT) control valve

1 article

• Replacing the variable valve timing (VVT) control valve

Replacing the variable valve timing solenoid

1 article

• Replacing the variable valve timing solenoid

Removing the front-rear member

1 article

• Removing the front-rear member 1

Removing the oil pan

1 article

• Removing the oil pan

Cleaning

1 article

• Cleaning 2

Installing the front-rear member

1 article

• Installing the front-rear member

Replacing the oil and oil filter

1 article

• Replacing the oil and oil filter 3

Replacing the dual mass flywheel

1 article

• Replacing the dual mass flywheel

Preparatory work

1 article

• Preparatory work

Removing the flywheel

1 article

• Removing the flywheel

Installing the flywheel

1 article

• Installing the flywheel

Reinstall the transmission

1 article

• Reinstall the transmission

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

1 article

• Checking/replacing the clutch driven plate and self-adjusting clutch 7

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

1 article

• Check that there are no cracks or large scratches on the flywheel 2

Install the tools on the clutch

1 article

• Install the tools on the clutch 2

Removing the timing belt and mechanical timing belt tensioner

1 article

• Removing the timing belt and mechanical timing belt tensioner 1

Replacing piston cooling valves

1 article

• Replacing piston cooling valves