Crankshaft seal rear, replacing

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.

Special tools:

9995112

9995651

NOTE: As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removing the flywheel and carrier plate

Fig 1: Checking Flywheel

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the gearbox:

M3P see Gearbox, fitting .
M5P see Gearbox, fitting .
AW42-50 see Removing/Installing the transmission .

Remove the flywheel/carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Removing the seal

Fig 2: Identifying Old Seal And Special Tool Extractor 999 5651

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Fig 3: Cleaning Around Crankshaft Flange

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: When cleaning work around the flange, not in and out. No grinding tools or similar may be used. It is extremely important that there is no thread sealant residue or other dirt. This could cause leakage.

NOTE: To clean the crankshaft, use cloth 9511024.

Installing the sealing ring

CAUTION: Only Volvo approved engine oil may be used. Grease must not be used at all. It attracts dirt and results in the build up of coke.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Fig 4: Identifying Sealing Ring

Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool 9997174 . Discard the old screws for the flywheel.

Installing flywheel and carrier plate

Fig 5: 3 Flywheel Studs

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: Ensure that the surface of the crankshaft and the mating surfaces for the flywheel/carrier plate are clean. Ensure that there is no thread sealant residue in the screw holes.

Install:

the flywheel and carrier plate
the 3 studs 9995678 distributed as shown. Turn the short thread length towards the crankshaft.

NOTE: Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel/carrier plate. The position of the guide hole is marked.

Fig 6: Checking Flywheel

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: It is important that the flywheel and carrier plate bear on the crankshaft flange before the other screws are installed. Always use new screws. Ensure that the thread sealant on the new screws is intact. If not apply a few drops of sealant 1161056 to the thread.

Align gear sector: 9995112 .
Pull the flywheel/carrier plate towards the crankshaft using the 3 nuts on special tool 9995678 . The turned section of the nut must be turned towards the flywheel/carrier plate.

Install the other screws. Tighten crosswise to 45 Nm .
Replace the 3 x special screws with new standard screws. Tighten crosswise to 45 Nm .
Then angle-tighten all 10 x screws crosswise. Use 9512050 . Flywheel: 65° . Carrier plate 50° .
Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Installing the gearbox

Install the gearbox:

M3P see Gearbox, fitting .
M5P see Gearbox, fitting .
AW42-50 see Removing/installing the transmission .

Checking the engine:

Test drive the car to check the function of the engine and the gearbox.