Section 33 (Engine And Engine Components - Removal And Installation (644 Body))
WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.
- Component Replacement (B4204T2 CVVT; 2000)
- Component Replacement (B4204T3; 2004)
- Component Replacement (B4204T3 (Ca) (Us); 2001-2003)
- Component Replacement (B4204T4; 2003-2004)
- Oil Pan (B4204T2 CVVT; 2000)
- Oil Pan (B4204T3; 2004)
- Oil Pan (B4204T3 (Ca) (Us); 2001-2003)
- Oil Pan (B4204T4; 2003-2004)
- Replacing Components (B4204T2 CVVT; 2000)
- Engine replacement, transferring components
- Overview
- Notes
- Starter motor, removing
- Transmission, removing
- Carrier plate, removing
- Engine on mounting stand, installing
- Engine components left-hand side, transferring
- Engine components exhaust side, transferring
- Engine components air intake side, transferring
- Carrier plate, installing
- Transmission, installing
- Starter motor, Installing
- Removing turbocharged engines with the transmission
- Overview
- Notes
- Radiator and engine, draining coolant
- Removing the left-hand side drive shaft nut
- Removing the air conditioning (A/C) hose from the fan shroud
- Removing the front and rear splash guards under the engine
- Removing the lateral strut
- Removing the front-rear member
- Removing the down pipe from the exhaust manifold
- Removing the rear engine mounting
- Removing the front engine mounting
- Removing the poly V-belts
- Removing the air conditioning (A/C) compressor
- Removing the oil pressure sensor and generator (GEN) connectors
- Removing the right-hand drive shaft from the transmission
- Removing the left-hand side cover
- Removing the left-hand side drive shaft assembly
- Automatic transmission: Disconnect the transmission oil pipes
- Draining the fuel injection system
- Removing the battery and battery shelf
- Removing the air cleaner (ACL)
- Disconnect the battery positive and negative leads
- Removing the gear selector mechanism cables
- Removing the vacuum hose from the canister purge (CP) valve
- Removing hoses from the turbocharger (TC)
- Removing the throttle cable
- Removing the cover, the mounting and the connectors
- Removing the fuel line from the engine
- Removing the cable harness
- Removing the coolant hoses
- Removing the heater hoses from the engine connection
- Removing the power steering pump from the engine
- Place the hood in the service position
- Removing the engine with the transmission
- Replacing camshaft seal (retaining ring) front side
- Replacing engine mounting bolsters
- Replacing flange plate
- Replacing rearmost crankshaft retaining ring
- Replacing the camshaft seals
- Notes
- Preparations
- Removing the timing covers
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Replacing the camshaft seal
- Secure the crankshaft position
- Installing the camshaft timing gear pulley
- Installing the timing belt
- Tightening the timing gear pulley
- Check
- Installing timing covers
- Installing the right engine mounting
- Finishing
- Checking work
- Replacing the cover on top of the engine
- Replacing the cylinder head and gasket
- Notes
- Preparation
- Draining the coolant
- Separating the exhaust system
- Removing the manifold and turbocharger (TC)
- Removing the starter motor
- Draining the fuel line
- Removing the fuel line
- Removing components
- Exposing the cable harness
- Removing the intake manifold
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the intake pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning the gasket face
- Installing the cylinder head
- Notes
- Aligning the crankshaft
- When replacing or working on the cylinder head
- Installing 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 camshaft timing gear pulley
- Installing the timing belt
- Tightening the timing gear pulley
- Check
- Installing the right engine mounting
- Finishing
- Installing the intake manifold
- Installing components
- Installing the fuel line
- Installing the exhaust manifold
- Assembling the exhaust system
- Installing the starter motor
- Checking work
- Replacing toothed (timing) belt
- Notes
- Belt Service Interval
- Remove auxiliaries belt
- Remove upper timing gear covers
- Install lifting beam and lifting lug
- Remove engine mounting on timing gear side
- Remove lower timing gear cover
- Remove engine bracket
- Align timing gear and crankshaft according to the markings
- Remove timing belt at the top side
- Check idler pulley
- Remove the engine splashguards
- Remove timing belt at lower side
- Install timing belt at lower side
- Install cover plates
- Install new timing belt and tensioner pulley
- Adjusting timing belt tension
- Check timing belt tension
- Install engine bracket
- Install timing gear covers
- Install auxiliaries belt
- Install engine suspension on timing gear side
- Turbocharged engine assembly with the transmission, installing
- Turbocharged Engine Assembly With the Transmission, Installing
- Notes
- Place the hood in the service position
- Engine assembly with transmission, installing
- Manual transmissions: Installing the gear selector mechanism cables
- Automatic transmission: Installing the gear selector mechanism cables
- Engine mounting on transmission side, installing
- Hoses and wiring, routing and connecting
- Fuel hose, routing and connecting
- Charge air hose from the turbocharger (TC), upper hose, installing
- Air conditioning (A/C) compressor on engine, installing
- Connectors, connecting
- Drive shaft right-hand in transmission, installing
- Engine mounting rear, installing
- Engine mounting front, installing
- Front-rear member, installing
- Front exhaust pipe on exhaust manifold, installing
- Automatic transmission: Installing the oil pipes
- Drive shaft left-hand side, installing
- Lateral strut, installing
- Engine splash guards, installing
- Front wheel, installing
- Wiring, installing
- Coolant hoses, installing
- Heater Hoses, Installing
- Air Cleaner (ACL), Installing
- Battery, installing
- Throttle cable and the air intake hose on the throttle body (TB), securing
- Power steering pump, installing
- Poly V-belts, installing
- Coolant, filling
- VVT-unit, replacing/adjusting
- VVT-Unit, Replacing/Adjusting
- Camshaft seals, replacing
- Notes
- Preparations
- Removing timing gear covers
- Installing the lifting beam and the lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Replacing the camshaft seal
- Secure the crankshaft position
- Installing camshafts' timing gear pulleys
- Installing the timing belt
- Tightening timing gear pulley
- Check
- Installing the timing covers
- Installing the right-hand engine mounting
- Finishing
- Checking work
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Notes
- Preparation
- Coolant, draining
- Exhaust manifold, removing
- Starter motor, removing
- Fuel line, draining
- Fuel line, removing
- Components, removing
- Cable harness, exposing
- Inlet pipe, removing
- Timing belt pulley, removing
- Coolant pump's inlet pipe, disconnecting
- Camshaft cover and cylinder head, removing
- When replacing or working on the cylinder head
- Gasket face, cleaning
- Installing the cylinder head
- Notes
- Aligning the crankshaft
- When replacing or working on the cylinder head
- 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
- Installing engine mounting
- Right engine mount, installing
- Finishing
- Installing components
- Inlet pipe, installing
- Components, installing
- Fuel line, installing
- Exhaust manifold, installing
- Starter motor, installing
- Checking performed work
- Replace the Engine Mountings
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Notes
- Removing the auxiliaries belt
- Removing the timing covers
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Tensioning the tensioner pulley and the idler pulley
- Removing the splash guards under the engine
- Removing the timing belt (at the bottom)
- Installing the timing belt
- Check
- Installing timing covers
- Installing the right engine mounting
- Finishing
- Checking work
- Engine replacement, transferring components
- Replacing Components (B4204T3; 2004)
- Camshaft seals, replacing
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Engine replacement, transferring components
- Removing turbocharged engines with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Turbocharged engine assembly with the transmission, installing
- VVT-unit, replacing/adjusting
- Replacing Components (B4204T3 (Ca) (Us); 2001-2003)
- Camshaft seals, replacing
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Engine replacement, transferring components
- Removing turbocharged engines with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Turbocharged engine assembly with the transmission, installing
- VVT-unit, replacing/adjusting
- Replacing Components (B4204T4; 2003-2004)
- Camshaft seals, replacing
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Engine replacement, transferring components
- Removing turbocharged engines with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Turbocharged engine assembly with the transmission, installing
- VVT-unit, replacing/adjusting
- Replacing Piston Cooling Valves (B4204T3; 2004)
- Replacing The Dual Mass Flywheel (B4204T2 CVVT; 2000)
- Replacing The Dual Mass Flywheel (B4204T3; 2004)
- Replacing The Dual Mass Flywheel (B4204T3 (Ca) (Us); 2001-2003)
- Replacing The Dual Mass Flywheel (B4204T4; 2003-2004)
- Replacing The Piston Cooling Valves (B4204T2 CVVT; 2000)
- Replacing The Piston Cooling Valves (B4204T3 (Ca) (Us); 2001-2003)
- Replacing The Piston Cooling Valves (B4204T4; 2003-2004)