Installing the flywheel

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.

Fig 1: 3 Flywheel Studs

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use tool 9995678 , with 3 studs and nuts.

Ensure that the crankshaft flange and flywheel mating surfaces are completely clean.
Install the 3 studs as shown. Turn the short thread length towards the crankshaft.
Install the flywheel.
NOTE: Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel. There is a marking to show the position of the guide hole.
Align gear sector 9995112 .
Pull the flywheel towards the crankshaft with the three nuts on special tool 9995678 .
The turned section of the nut must be turned towards the flywheel.
NOTE: It is important that the flywheel bears on the crankshaft flange before the other screws are installed.
Install the other screws. Use new screws. Tighten the screws crosswise to 45 Nm .
Remove special tool 9995678 . Install three new screws. Tighten the screws to 45 Nm .
Angle-tighten all the screws crosswise to 65 degrees .
Install the engine speed (RPM) sensor assembly with the bracket. Tighten the screws to 10 Nm .