Installing Volvo V40 I facelift

Installing

1. Check the rubber and the spring inside. Replace if necessary.
2. Check the spark gap: 0.7-0.8 mm.
3. Install the spark plugs. Screw the spark plugs in until the gasket is pressed against the cylinder head. Tightening torque 25 Nm . Use special tool «9995702»(ref-403953-S02394441542011061500000) .
4. Position the ignition coils. Press the ignition coils into place.
5. Tighten the screw. Tightening torque 10 Nm .
6. Connect the high tension cables.
7. Reconnect the connectors. NOTE: The gray connector is for the left coil (cylinders 2 and 3), the blue connector is for the right coil (cylinders 1 and 4).
8. Check the function.
9. Install both engine covers.

Scheme 23

Remove

1. the cover over the throttle cable.
2. the idle air control (IAC) valve connector.
3. the two screws.
4. the idle air control (IAC) valve and the gasket from the intake manifold.

Always use a new gasket.

1. Locate the new gasket. The tab must be pointing downwards to the right.
2. Tighten the idle air control (IAC) valve. Tightening torque 10 Nm .
3. Reconnect the connector.
4. Check the function.
5. Reinstall the cover over the throttle cable.

Start the engine. Read off any diagnostic trouble codes (DTCs).

Scheme 24

1. Remove the clamp and the air intake hose. Use a twisting movement.
2. Disconnect the connector.
3. Remove the two Tx 25 screws.
4. Remove the mass air flow (MAF) sensor.
5. Remove the O-ring.

1. Install a new O-ring.
2. Position the mass air flow (MAF) sensor with the connector upward.
3. Tighten the screws.
4. Connect the connector.
5. Clean the air intake hose. Press the air intake hose firmly into place on the mass air flow (MAF) sensor.
6. Tighten the clamp.
7. Check the function.

Scheme 25

Removing/disconnecting

1. The connector.
2. The turbocharger (TC) control valve from the air cleaner (ACL) housing.
3. The clamps and hoses on the valve.

Note. Note how the hoses are connected.

HINT: If it is difficult to pull off the hose: Cut the hose along its length at the connection.

Installing/reconnecting

1. The hoses in their original positions. The clamps. Red (on the intake pressure side) Yellow (to the boost pressure control (BPC) valve) White (to the by-pass valve)
2. The valve to the air cleaner (ACL) housing
3. The connector.

Scheme 26

Remove

1. the upper timing cover.

Scheme 27

Remove

1. the connector
2. the screws
3. the valve
4. the gasket.

Note. Clean the area around the variable valve timing (VVT) valve thoroughly to avoid contaminated oil entering the ducts/the variable valve timing (VVT) valve.