Ignition, Engine Control (b4204t2 CVVT 2000)

2001 Volvo V40
ENGINE Engine - Removal, Replacement & Installation
ENGINE
Engine - Removal, Replacement & Installation
IGNITION, ENGINE CONTROL (B4204T2 CVVT; 2000)

IGNITION COIL(S), REPLACEMENT
Special tools:
9995702
Removing the ignition coil(s)
Fig. 1: Removing Spark Plugs

Courtesy of VOLVO CARS OF NORTH AMERICA.
 Remove both engine covers.

 Detach the connectors.
 Disconnect the high voltage cable.
 Remove the retaining screws.
 Pull out the ignition coils.
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05:24:45 p.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2001 Volvo V40
Installing the rubber and spring from the ignition coil
Fig. 2: Installing Rubber And Spring From Ignition Coil

If necessary, remove the rubber and the spring from the spark plug or from the spark plug hole.
Check and clean the spark plug if necessary.
Clean the ignition coil.
Fit the new spring (1) with the countersink outwards. Guide in the new spring (1) with a small screwdriver by
pressing down the lower part of the spring in the coil.
NOTE: Check that the spring (1) is raised out of the coil by approx. 5 mm.
Fit the new rubber in the groove on the ignition coil (2).
Installing the ignition coil(s)
martes, 20 de febrero de 2018 05:24:45 p.m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
2001 Volvo V40
Fig. 3: Ignition Coil Connectors

 Check the rubber and spring inside. Replace if necessary.

 Fit the ignition coils in place and press them in.
 Tighten the screw. Tightening torque 10 Nm .
 Connect the high voltage cables.
 Reattach the connector.
NOTE: The grey connector is for the left-hand coil (cylinder 2 and 3), the blue
connector is for the right-hand coil (cylinder 1 and 4).
 Check the function.

 Fit both engine covers.
REPLACING SPARK PLUGS
Special tools:
9995702
Removing
2001 Volvo V40
Fig. 4: Removing Spark Plugs

 Remove both engine covers.

 Disconnect the connectors.
 Disconnect the HT lead.
 Remove the mounting screws.
 Pull off the ignition coils.
 Remove the spark plug with special tool 9995702 .
Installing
2001 Volvo V40
Fig. 5: Ignition Coil Connectors

 Check the rubber and the spring inside. Replace if necessary.

 Check the spark gap: 0.7-0.8 mm.
 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 .
 Position the ignition coils. Press the ignition coils into place.
 Tighten the screw. Tightening torque 10 Nm .
 Connect the high tension cables.
 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).

 Install both engine covers.
REPLACING THE IDLE AIR CONTROL (IAC) VALVE
2001 Volvo V40
Removing
Fig. 6: Removing/Installing Idle Air Control (IAC) Valve

Remove:
 the cover over the throttle cable.

 the idle air control (IAC) valve connector.
 the two screws.
 the idle air control (IAC) valve and the gasket from the intake manifold.
Installing
2001 Volvo V40
Fig. 7: Removing/Installing Idle Air Control (IAC) Valve

Always use a new gasket.
 Locate the new gasket. The tab must be pointing downwards to the right.
 Tighten the idle air control (IAC) valve. Tightening torque 10 Nm .
 Reconnect the connector.
 Reinstall the cover over the throttle cable.
Start the engine. Read off any diagnostic trouble codes (DTCs).
REPLACING THE MASS AIR FLOW (MAF) SENSOR
Removing
2001 Volvo V40
Fig. 8: Replacing/Installing Mass Air Flow (MAF) Sensor

 Remove the clamp and the air intake hose. Use a twisting movement.
 Disconnect the connector.
 Remove the two Tx 25 screws.
 Remove the mass air flow (MAF) sensor.
 Remove the O-ring.
Installing
 Install a new O-ring.

 Position the mass air flow (MAF) sensor with the connector upward.
 Tighten the screws.
 Connect the connector.
 Clean the air intake hose. Press the air intake hose firmly into place on the mass air flow (MAF) sensor.
 Tighten the clamp.
REPLACING THE TURBOCHARGER (TC) CONTROL VALVE
2001 Volvo V40
Removing
Fig. 9: Removing/Installing Turbocharger (TC) Control Valve

Removing/disconnecting
 The connector.
 The turbocharger (TC) control valve from the air cleaner (ACL) housing.
 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
Installing/reconnecting
 The hoses in their original positions. The clamps.

1. Red (on the intake pressure side)
2. Yellow (to the boost pressure control (BPC) valve)
2001 Volvo V40
3. White (to the by-pass valve)

 The valve to the air cleaner (ACL) housing
 The connector.
REPLACING THE VARIABLE VALVE TIMING (VVT) CONTROL VALVE
Preparations
Fig. 10: Removing Upper Timing Cover

Remove:
 the upper timing cover.
Remove the valve housing assembly
2001 Volvo V40
Fig. 11: Removing/Installing Valve Housing Assembly

Remove:
 the connector
 the screws
 the valve
 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.
Install the valve housing assembly
2001 Volvo V40
Fig. 12: Removing/Installing Valve Housing Assembly

Install:
 a new gasket
 the valve
 the screws. Tighten to 10 Nm
 the connector
REPLACING THE VARIABLE VALVE TIMING SOLENOID
Remove the cover from the timing gear
See Removing the cover on top of the engine.
Removing the variable valve timing system
2001 Volvo V40
Fig. 13: Removing Connector And Wiring Beside Connector

 Remove the connector and the wiring beside the connector

 Remove the screw
 Carefully pull the device off
 Remove the o-ring.
Install the variable valve timing system
2001 Volvo V40
Fig. 14: Installing Variable Valve Timing System

 Wipe up any spilled oil. Clean the mating surfaces

 Install a new O-ring
 Position the system. Turn the system into the correct position
 Install the bolt. Tighten to 8 Nm
 Connect the wiring.
Install the cover on the timing gear
See Installing the cover on top of the engine.
Start the engine. Check for leakage.
ENGINE MECHANICAL (B4204T2 CVVT; 2000)

CAMSHAFT SEALS, REPLACING
Special tools:
9995006
2001 Volvo V40
9995383
9995460
9995452
9995651
9995451
9995199
9995718
9995719
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 in
the graphics is always correct.
NOTE: Crankshaft and camshafts must not be turned more than is stated in the method
description. If the shafts are turned in any other way, the valves may be
damaged.
Preparations
Remove:
 the cable from the battery's negative terminal. First read Note when disconnecting and connecting the
battery lead .
 the inlet hose between air filter and throttle housing. Put it aside.
2001 Volvo V40
Fig. 15: Removing Brake Servo Vacuum Hose From Connection In Throttle Housing
Remove:
 the brake servo's vacuum hose from its connection in the throttle housing. Loosen the hose by pressing
down the plastic ring at the same time as the hose is pulled upwards. Move the hose aside.
 the fuel line and cabling from its clips in the cylinder head's trailing edge.
2001 Volvo V40
Fig. 16: Cable Channel Screws

Remove:
 the cable channel's screws.

 camshaft's rear cover.
 the camshaft position (CMP) sensor housing
 the trigger wheel.
 right engine protection cover (only turbo).
 the auxiliaries belt
Removing timing gear covers
2001 Volvo V40
Fig. 17: Removing/Installing Timing Covers

Remove:

 the front timing cover.
Installing the lifting beam and the lifting hook
2001 Volvo V40
Fig. 18: Removing/Installing Metal Bracket For Servo Hose

Loosen the servo hose's plate bracket from the auxiliary unit's rotation guard.
2001 Volvo V40
Fig. 19: Installing Lifting Beam And Lifting Hook

Place lift tool 9995006 slightly in front of the engine's front lifting eye. Use lift arm 9995383 and lift hook
9995460 to lift the engine a few mm at the leading edge.
Removing the right-hand engine mounting
2001 Volvo V40
Fig. 20: Installing Right Engine Mounting

Remove:
 the servo reservoir's screws.

 the engine mount's screws.
 the engine mounting.
 the lower timing cover.
Position the engine according to the marking
2001 Volvo V40
Fig. 21: Removing/Installing Timing Covers & Positioning Engine According To Marking
Remove the right front wheel.
Position the upper timing cover.
Turn the crankshaft until the markings on the crankshaft and camshaft gear match.
Turn another 1/4 turns clockwise on the crankshaft and then back until the markings match. Markings are
shown. Remove the upper timing gear cover.
Removing the timing belt
2001 Volvo V40
Fig. 22: Removing Timing Belt

Slacken off the center screw for the belt tensioner slightly.
Hold and fixate the centre screw. Turn the tensioner's eccentric clockwise using a 6 mm Allen key to 10 o'clock.
Remove the timing belt from the camshaft gears.
Removing the timing gear pulley
2001 Volvo V40
Fig. 23: Camshaft Adjustment Tool 999 5452 Installed

Timing gear pulleys with variable valve timing unit
 Install camshaft adjustment tool 9995452 at the rear of the camshafts.
Fig. 24: Removing/Installing Plug And Center Screw At Variable Valve Timing Unit
Timing gear pulleys with variable valve timing unit:
 Remove the plug at the front edge of the variable valve timing unit (TORX 55).
 Remove the centre screw in the VVT-unit (TORX 55).
Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may
run out. Place paper underneath.
2001 Volvo V40
Fig. 25: Removing Screws For Timing Gear Pulley Using Counterhold 999 5199
Timing gear pulleys without variable valve timing units:
 Remove the timing gear pulley's screws. Use counterhold 9995199 .

 Remove timing gear pulley.
 Remove tool 9995452 .
 Remove the screw that holds the inner timing gear cover to the cylinder head.
Replacing the camshaft seal
2001 Volvo V40
Fig. 26: Identifying Seal And Special Tool 999 5651

Carefully press in tool 9995651 between the sealing ring and the camshaft.
Carefully pry out the seal.
Oil the new seal.
Fig. 27: Installing Front Camshaft Seal
2001 Volvo V40
Install the new seal for the camshaft with VVT using drift 9995718 .
Install the new seal for the camshaft without VVT using drift 9995719 .
Install the screw holding the inner timing cover to the cylinder head.
Secure the crankshaft position
Install the adjustment tool.
Remove:
 front air baffle.

 the support between the cylinder block and the intake manifold.
 the starter motor mounting screws.
Place the starter motor to one side.
Remove the blind cover plug and the sealing washer.
Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.
Fig. 28: Identifying Adjustment Special Tool 999 5451

Install gauge 9995451 . Make sure that the gauge bottoms against the engine block.
Turn the crankshaft back counter-clockwise until it stops against the drift.
2001 Volvo V40
Fig. 29: Checking Marking On Crankshaft Timing Gear Pulley Corresponds With Marking On Oil
Pump
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing camshaft timing gear pulleys
2001 Volvo V40
Fig. 30: Installing Timing Gear Pulley

Timing gear pulley without VVT:
 install upper timing cover.

 install timing gear pulley without VVT on the camshaft. Use two screws positioned so that the markings
on the timing belt gears/upper timing gear cover match. Do not tighten.
2001 Volvo V40
Timing gear pulley VVT:
 Install the timing gear pulley with the center screw on the camshaft. Make sure that the markings on the
timing gear pulleys/upper timing gear cover match, but do not tighten.
Installing the timing belt
2001 Volvo V40
Fig. 32: Timing Belt Routing Sequence

Install the timing belt on the timing gear pulleys.
NOTE: Adjust so that the screws in the timing gear pulley without variable valve timing
do not reach the limit position in the oval holes.
Tension the timing belt
2001 Volvo V40
Fig. 33: Identifying Needle Position At Varying Temperatures

NOTE: This adjustment is to be made with a cold engine. Suitable temperature is

approximately 20°C/67°F. At a higher temperature, for example with a warm
engine or a higher ambient temperature, the needle is further to the right.
The image shows the indicator position at different engine temperatures.
2001 Volvo V40
Fig. 34: Belt Is Tensioned Between Intake Camshaft Pulley, Idler Pulley And Crankshaft
 The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft.
 Fix the belt tensioner centre screw in position and turn the belt tensioner eccentric counter clockwise until
the tensioner indicator passes the marked position.
Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
 Hold the eccentric secure and tighten the center screw. Torque tighten to 20 Nm .
Tightening timing gear pulley
Tighten the centre screw on the timing gear pulley with VVT. Tighten to 90 Nm .
Install the plug. Tighten to 35 Nm .
Install the third screw on the camshaft without VVT. Tighten to 20 Nm .
Remove the adjustment tools.
Check
2001 Volvo V40
Fig. 35: Checking Markings On Crankshaft And Camshaft Pulley Correspond

 Press the belt to check that the indicator on the tensioner moves easily.
 Position the upper timing cover.
 Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond
NOTE: Check that the indicator on the belt tensioner is within the marked area.
 Remove the upper timing cover.
Installing the timing covers
2001 Volvo V40

Install:
 lower timing gear cover.

 the front timing gear cover. Tightening torque 12 Nm .
Installing the right-hand engine mounting
2001 Volvo V40

Screw down the engine mount against the engine. Tightening torque 67 Nm .
Install:
 the screws on the body frame's console. Tighten with 50 Nm .
Finishing
2001 Volvo V40

Remove lifting beam and lifting hook.
Install:
 the servo reservoir.

 servo hose's metal console on the auxiliary unit belt's rotation guard.
 turbo engines: right engine protection cover as well as the cover over right headlight unit.
 rear camshaft cover.
 blinder. Tightening torque 17 Nm .
 camshaft sensor housing. Tightening torque 5 Nm .
 cable channel.
 brake servo's vacuum hose.
 hose between inlet pipe and air filter housing.
 the blind cover plug.
2001 Volvo V40

 the cable from the battery's negative terminal. First read Note when disconnecting and connecting the
battery lead .
Checking work
Function test:
 Carry out a road test.
CRANKSHAFT SEAL REAR, REPLACING
Special tools:
9995112
9995651
9991801
9995678
9997174
9512050
and/or models, some variation may occur. However, the essential information is
always correct.
Removing the flywheel and carrier plate
Fig. 39: Checking Flywheel
2001 Volvo V40
Remove the gearbox:
 See Removal .
Remove the flywheel/carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.
Removing the seal
Fig. 40: Identifying Old Seal And Special Tool Extractor 999 5651
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.
2001 Volvo V40
Fig. 41: Cleaning Around Crankshaft Flange

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.
2001 Volvo V40
Fig. 42: Identifying Sealing Ring

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. 43: 3 Flywheel Studs

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
2001 Volvo V40
 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.

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 3x special screws with new standard screws. Tighten crosswise to 45 Nm .
 Then angle-tighten all 10x 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 transmission
 See Installation .
Checking the engine:
Test drive the car to check the function of the engine and the gearbox.
2001 Volvo V40
Gearbox, fitting
Special tools:
9512661
9995460
9995972
9995383
CAUTION: If the gearbox is not changed, the right-hand seal and O-ring should be
changed, see Change the seal .
Position the gearbox against the engine
Fig. 45: Identifying Support Special Tool 9995972

Position the gearbox in the assembly position on support 9995972 and secure it with the brackets.
Apply a little grease, part number 1161246-2, to the clutch shaft.
2001 Volvo V40
Grease the splines (RH drive shaft) on the gearbox using part number 1161035-9.
Press the gearbox towards the engine along the clutch plate splines, and press on the right-hand drive shaft onto
the splines.
CAUTION: Fit the drive shaft so that the drilled holes for the locking pins are aligned.
NOTE: Position the starter motor on the adjustment bushing.
Secure the gearbox to the engine
Fig. 46: Identifying Gearbox Retaining Bolts

Thread the four retaining bolts and tighten to 50 Nm .
Remove the support 9995972 .
D4192T.
Press on the gearbox/engine mounting and secure with four bolts. Tightening torque 27 Nm .
2001 Volvo V40
Attach the gearbox mounting to the side of the body.
Fig. 47: Identifying Gearbox Mounting Bolts

Fit the mounting to the gearbox and secure with three bolts.
Use lifting hook 9995460 to lift the engine and fit the bolt to the chassis support.
Fit the three bolts and tighten to 45 Nm .
Lower the engine until the lifting brace no longer supports it.
Tighten the bolt on the side of the body to 98 Nm .
NOTE: Be careful of the hydraulic pipe to the clutch.
Diesel cars: Fit the fuel filter
2001 Volvo V40
Fig. 48: Identifying Fuel Filter Nuts

Position the fuel filter.
Fit the two nuts and tighten to 21 Nm .
Remove the lifting brace
2001 Volvo V40
Fig. 49: Identifying Lifting Brace

Remove the lifting hooks 9995460 , lifting brace 9995006 and support 9995383 .
Fit the retaining bolts to the top side of the gearbox
2001 Volvo V40
Fig. 50: Identifying Gearbox Retaining Bolts

Thread the bolts and tighten to 50 Nm .
Diesel cars:
Position the cable harness support on the gearbox and fit the bolt.
Tighten to 50 Nm .
Fit the starter motor
2001 Volvo V40
Fig. 51: Identifying Starter Motor Bolts

Position the starter motor and thread the three bolts.
Tighten the bolts to 50 Nm .
Fit the left-hand drive shaft
2001 Volvo V40
Fig. 52: Identifying Left-Hand Drive Shaft Bolts

Raise the car
Remove the protector from the tripod and opening in the gearbox.
Turn the steering wheel to the right to full lock.
Carefully fit the drive shaft into the differential.
Turn the steering wheel to the left and fit the lower adjustment bolt to the attachment point for the shock
absorber/wheel axle.
Position the bellows.
Fit the three bolts and tighten to 25 Nm .
Secure the wheel axle to the shock absorber.
2001 Volvo V40
Fig. 53: Identifying Wheel Axle And Shock Absorber

Fit the upper bolt.
Tighten the two bolts to 90 Nm .
Insert the brake pipe into the support and fit the lock clip.
Fit the ABS line to the support.
Connect the lead to the reversing light switch
2001 Volvo V40
Fig. 54: Identifying Reversing Light Switch And Connector

Clean the connector first.
Connect the gearbox ground cable
2001 Volvo V40
Fig. 55: Identifying Gearbox Ground Cable

Clean the contact surfaces thoroughly.
Fit the cable and tighten to 40 Nm .
Diesel cars: Fit the intercooler
2001 Volvo V40
Fig. 56: Identifying Intercooler Bolts

Position the intercooler and thread the three bolts.
Fit the right-hand drive shaft and speedometer cable to the gearbox
2001 Volvo V40
Fig. 57: Removing Right Hand Drive Shaft From Transmission (MT)
If the drilled hole in the end pointing towards the gearbox is at the bottom (down in the space between two
splines), the equivalent hole in the half-shaft must be at the top (crown), and vice versa.
Fit the two new locking pins to the drive shaft.
CAUTION: Seal the holes for the locking pins with sealant, part number 1161058-1.
Fit a new O-ring to the speedometer cable and tighten.
Insert the wire fully into the housing and fit a circlip.
Fit the wheel
2001 Volvo V40
Fig. 58: Identifying Wheel Installation

Check that the contact surfaces of the brake disc and brake pads are clean.
Grease the central hub guide pin in front of the brake pad with corrosion inhibitor, part number 1161038-3.
Position the wheel and loosely tighten the bolts.
Then tighten diagonally opposite bolts alternately to 110 Nm .
When tightening with a percussion wrench, torque socket 9512661 must be used.
Retighten by hand.
CAUTION: Tighten in crosswise sequence to the correct tightening torque to avoid

stresses in the brake disc.
Fit the hub cap.
Fit the gear selector rod
2001 Volvo V40
Fig. 59: Identifying Gear Selector Rod And Bolt With Torque Specifications
Grease moving parts with Volvo grease, part number 1161241-3.
Check the rubber parts.
Position the gear selector rod and thread the bolt.
Tighten the bolt to 16 Nm .
Fit the central longitudinal member
2001 Volvo V40
Fig. 60: Central Front-Rear Member

Fit the engine mounting to the engine support point.
Fit the two bolts (correct size).
Fit the four bolts:
 front: long bolts

 rear: short bolts.
Tighten the bolts to:
 on body side, 69 Nm
 on engine side, 52 Nm .
First, tighten the rear bolts and then the front bolts.
Fit the heat shield
2001 Volvo V40
Fig. 61: Identifying Heat Shield Bolts

Position the heat shield and thread the first bolt (A).
Fit the two other bolts.
Fill the gearbox with oil
2001 Volvo V40
Fig. 62: Removing Filler/Level Plug And Fitting New Seal To Filler/Level Plug
Position a receptacle to catch any spills.
Remove the filler/level plug.
Fill the gearbox with oil, part number 1161681, up to the edge of the filler orifice.
Fit a new seal to the filler/level plug
Fit the filler/level plug and tighten to 1.75 Nm .
Fit the left-hand engine cover
2001 Volvo V40
Fig. 63: Identifying Left-Hand Engine Cover Bolts

Position the engine cover.
Fit the three bolts in order as shown.
Gas engine cars: Fit the front engine protector
2001 Volvo V40
Fig. 64: Mudflap And Screw

Position the engine cover.
Secure the engine protector with bolts and screws. Tighten to 10 Nm .
Fit the pulse sensor
2001 Volvo V40
Fig. 65: Identifying Pulse Sensor Bolts

Position the sensor and fit the two bolts.
Fit the hydraulic clutch cylinder to the gearbox
2001 Volvo V40
Fig. 66: Identifying Hydraulic Clutch Cylinder

Position the hydraulic clutch cylinder and pipe.
NOTE: Depress the piston as far as possible.
Fit the bolt to the support.
Remove the lock clip from the clutch cylinder.
Fit the two bolts.
Insert the hose into the support and fit the lock clip.
Diesel cars: Fit the intercooler hoses
2001 Volvo V40
Fig. 67: Identifying Intercooler Hoses

Fit the two hoses and tighten the hose clips.
Fit the air filter
2001 Volvo V40
Fig. 68: Identifying Air Filter Box

Fit the air filter in a twisting movement and press the guide pin into the support.
Thread the two bolts and tighten to 10 Nm .
Check the hatch for the gearbox in the front wing.
Fit the inlet air hose
2001 Volvo V40
Fig. 69: Identifying Ventilation Hoses And Connector

CAUTION: Check that the throttle plate moves freely of the strip clamp.
Gas engine cars:
Connect the hose and secure with two hose clips.
Connect hose (D) at the rear.
Plug in the connector (C).
Connect the crankcase ventilation hose (B).
Fit the crankcase ventilation hose by (A).
Fit the preheater hose.
Diesel cars:
Fit the air hose and secure it with hose clips.
2001 Volvo V40
Connect the air temperature sensor.
Attach the ventilation hose (B) to the crankcase.
Fit
 Cable to the negative battery terminal

 Engine protection plate, tightening torque 11 Nm .
 Diesel cars: engine protection plate on underside.
Check:
 Start the engine and check the function of the clutch.
CYLINDER HEAD/GASKET, REPLACING
Special tools:
9995454
9512666
9995670
9995451
9512050
9512767
9995452
9995718
9995719
9995450
and / or models, some variation may occur. However, the essential information
in the graphics is always correct.
Preparation
Remove the cable from the battery negative terminal. First read Note when disconnecting and connecting the
battery lead .
2001 Volvo V40
Coolant, draining
Fig. 70: Drain Valve And Coolant Reservoir Cap

 Remove the front air baffle.

 Open the engine nipple.
 Drain the coolant into a container.
 Close the nipple.
 Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.
Exhaust manifold, removing
Turbo US
Remove the exhaust manifold acc. to Exhaust manifold, replacing .
Starter motor, removing
Remove:
 lower hose to the charge-air cooler.

 inlet pipe's support console.
2001 Volvo V40
 connector for oil pressure switch.

 plastic charge-air pipe from the turbo.
 starter motor's screws.
 unhook the starter motor and let hang.
Fuel line, draining
Drain the fuel line. See Draining the fuel injection system .
Fuel line, removing
Fig. 71: Removing/Installing Fuel Line From Engine

Loosen the fuel line at the quick-coupling on the fuel rail.
Components, removing
2001 Volvo V40

Remove:
 the cover over the injectors

 the cover over the throttle housing.
 the upper timing cover
 the cover over the ignition coils.
 the throttle cable from the throttle housing's console.
2001 Volvo V40
Remove:
 the brake servo's vacuum hose. Pull on the hose while pressing down the plastic ring.
 the turbo control valve from the air filter housing.
 the mass air flow sensor's connector.
 EVAP-valve's connection to mass air flow sensor's hose.
 air filter housing's top part complete with hose.
 the pipe screw for the water-heated crankcase ventilation.
Cable harness, exposing
2001 Volvo V40
Fig. 74: Removing/Installing Cable Harness

Remove:
 the screw from the ignition coils' ground.

 the camshaft position sensor.
Remove:
 the ignition coils' connectors.
Place the cable harness to the side.
Screw loose the cable channel from the cylinder head's trailing edge and the throttle housing's console.
Disconnect cables and hoses from the cylinder head's trailing edge.
Remove:
 water temperature sensor's connector.

 injectors' connectors.
Lay the cable channel and cable harness to the side.
2001 Volvo V40
Mark up and remove ignition coils and ignition cables.
Remove:
 camshaft's rear cover.

Inlet pipe, removing
Fig. 75: Removing/Installing Inlet Pipe

Remove:
 upper radiator hose with thermostat housing's cover.

 the screw holding the dip stick pipe to the intake manifold
 connectors from air assistance valve and throttle position sensor.
 crankcase ventilation's hose from camshaft cover.
 vacuum hoses from inlet pipe, mark up location.
 console between servo pump/inlet pipe.
 screws that hold inlet pipe to the cylinder head.
2001 Volvo V40
 the intake manifold
Timing belt pulley, removing
Remove the timing belt pulley acc. to Camshaft seals, replacing.
Remove the engine mount front for cylinder head.
Coolant pump's inlet pipe, disconnecting
Fig. 76: Coolant Pump Intake Pipe

Remove the two screws at the coolant pipe connection to the bypass channel.
Carefully turn the pipe to remove it from the cylinder block.
Camshaft cover and cylinder head, removing
2001 Volvo V40
Fig. 77: Removing/Installing Camshaft Cover And Cylinder Head

Remove:
 VVT-valve.
 spark plugs from cylinder 1 and 4.
Install tool 9995454 (2 pcs.) with 2-3 mm clearance to camshaft cover. Make sure that the screws in the spark
plug thread is tightened all the way in.
Remove all the screws securing the camshaft cover to the cylinder head.
2001 Volvo V40
Fig. 78: Removing Screws Securing Camshaft Cover To Cylinder Head

Use pliers 9995670 to lift the cover from the cylinder head. Use the pliers at the pry lugs. Begin at cylinder and
move alternately backwards.
Loosen the wing nuts a few turns and repeat the procedure.
Carefully press out the front and rear camshaft seals.
CAUTION: Be very careful so that the sealing faces on the camshafts are not
damaged.
Remove:
 tools 9995454 .
 the camshaft cover
 the camshafts
Lift out the depressors. Use suction cup. Not magnet.
CAUTION: Mark up and position the lifters so that their original positions can be
2001 Volvo V40
established.
Fig. 79: Removing Screws Holding Cylinder Head On Cylinder Block

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately
towards the center.
Get help to lift off the cylinder head.
CAUTION: Do not damage the mating surfaces.
When replacing or working on the cylinder head
2001 Volvo V40
Fig. 80: Removing Thermostat Housing & Gaskets

Remove:
 the thermostat housing

 all parts that shall be transferred to the new cylinder head.
 gaskets.
Gasket face, cleaning
2001 Volvo V40
Fig. 81: Cleaning Camshaft Cover

Clean the gasket faces for:
 the coolant bypass channel

 the cylinder block
 camshaft cover.
When replacing/reworking of the cylinder head, clean the gasket faces for:
 the manifold. Check that the studs are tightened

Blow the oil ducts clean.
CAUTION: Do not use a metal scraper. Use a soft putty scraper or gasket dissolver
1161440-1. The surfaces must be completely clean to seal tightly.
WARNING: Use a fume hood or extractor when using gasket solvent
2001 Volvo V40
Installing the cylinder head
NOTE: For tightening torques not in the text, see Tightening torques for 4-cylinder
gasoline engines .
NOTE: To ensure that there is no exhaust leakage, see Flanged joint, assembling .
Aligning the crankshaft
Fig. 82: Installing Gauge 999 5451

Remove the blind cover plug.
2001 Volvo V40
Pump
Check that the marking on the crankshaft timing belt pulley matches with the marking on the oil pump.
2001 Volvo V40
Fig. 84: Installing Thermostat Housing & Manifold

Install:
 thermostat housing. Use a new gasket.

 the manifold. Use new gaskets. Lubricate the studs using paste 116 1408
Install a new cylinder head gasket.
Install the cylinder head.
Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.
2001 Volvo V40
Fig. 85: Installing Cylinder Head

Use new screws. Lubricate and install all the screws.
Tighten the screws as shown.
Tighten the screws in the following order:
1. Tightening torque 20 Nm .
2. Tightening torque 60 Nm .
3. Angle tighten 130° . Use protractor 9512050 .
Valve depressors and camshafts, installing
NOTE: When installing a new cylinder head, the valve clearance must be set. See Valve
clearance, setting/adjusting .
Lubricate the valve guide wells.
Install all the tappets.
NOTE: Make sure that the depressors end up in the same place as before. If needed,
2001 Volvo V40
replace valve depressors to achieve correct valve clearance.
Fig. 86: Identifying Intake And Exhaust Camshafts

Lubricate the camshaft bearing seats.
Install the intake camshaft. Make sure that the groove at the back of the camshaft is above an imaginary center
line.
Install the exhaust camshaft. Make sure that the groove at the back of the camshaft is below an imaginary center
line.
2001 Volvo V40
Fig. 87: Applying Liquid Gasket On Camshaft Cover

Applying liquid gasket.
Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells on the cylinder head.
Apply liquid gasket 116 1059 on the camshaft cover.
Use roller 9512767 .
The surface must be completely covered without any excess.
CAUTION: Make sure that liquid gasket does not end up in coolant or oil channels.
Only a thin layer of liquid gasket is needed.
Camshaft cover, installing
2001 Volvo V40

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.
Install the camshaft cover.
Install press tool 9995454 (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install all screws and tighten from the middle and out towards the edges. Tighten with 17 Nm .
Remove the press tools.
Install the spark plugs. Tighten to 30 Nm .
Coolant pump's inlet pipe, installing
Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.
NOTE: Apply thread sealant, 116 1056 on the screws' threads.
2001 Volvo V40
Fig. 89: Installing Camshaft Covers

Fit the camshaft gauge 9995452 on the rear edge of the camshafts. Make sure the screws holding the gauge to
the camshafts and the screw holding the gauges together as a unit are well tightened.
Front camshaft seal, installing
2001 Volvo V40

Lubricate the surfaces on the seal that the camshaft rotates against.
Install the new seal for the camshaft without VVT using drift 9995719 .
Install the new seal for the camshaft with VVT using drift 9995718 .
Camshafts' timing belt pulley, installing
Install the camshafts' timing belt pulley acc. to Camshaft seals, replacing.
Installing engine mounting
2001 Volvo V40
Fig. 91: Installing Engine Mounting

Place engine mount on cylinder head. Screw down the engine mount against the cylinder head. Tighten with 35
Nm and then tighten through an angle of 75° , one movement without interruption.
Right engine mount, installing
2001 Volvo V40

Install the lower timing cover.
Screw down the engine mount against the engine. Tightening torque 67 Nm .
Install:
 screws on the body's console. M10 screw tighten with 50 Nm

 Install the upper timing cover.
Finishing
2001 Volvo V40

Remove lifting beam and lifting hook.
Install:

 servo hose's metal console on the auxiliary unit belt's rotation guard.
 rear camshaft cover.
Installing components
Install:
 blinder. Tightening torque 17 Nm .

 camshaft sensor housing. Tightening torque 5 Nm .
 cable channel.
Inlet pipe, installing
2001 Volvo V40

Install:
1. inlet pipe. Use new gasket. Tightening torque 17 Nm .

2. vacuum hoses from inlet pipe acc. to marking.
3. crankcase ventilation's hose on camshaft cover.
4. connectors from air assistance valve and throttle position sensor.
5. oil dipstick tube.
6. upper radiator hose with thermostat housing's cover.
Components, installing
2001 Volvo V40

Install:
 the ignition coils and ignition cables according to earlier markings.

 the ignition coils' ground cable.
 the camshaft position sensor.
Lay the cable channel and cable harness in place.
Install:
 the cable channel's screws on the cylinder head's trailing edge and the throttle housing's console.
 console between inlet pipe and servo pump.
 injectors' connectors.
 water temperature sensor's connector.
 air preheating hose between air filter and exhaust manifold's heat shield plate.
 the pipe screw for the water-heated crankcase ventilation.
 air filter housing's top part complete with hose.
2001 Volvo V40
 EVAP-valve's connection to mass air flow sensor's hose.

 the mass air flow sensor's connector.
 the turbo control valve on the air filter housing.
 brake servo's vacuum hose.
 throttle cable.
 the inlet hose between mass air flow sensor and throttle housing.
 the cover over the ignition coils.
 the cover over the throttle housing.
 the cover over the injectors
Fuel line, installing
Fig. 96: Pressing Fuel Line Into Its Quick-Coupling On Fuel Rail
Press the fuel line into its quick-coupling on the fuel rail.
Exhaust manifold, installing
2001 Volvo V40
Turbo US
Install the exhaust manifold acc. to Exhaust manifold, replacing .
Starter motor, installing
Install:
 the blind cover plug.

 the starter motor
 plastic charge-air pipe to the turbo.
 inlet pipe's support console.
 connector for oil pressure switch.
 lower hose to the charge-air cooler.
 right front wheel acc. to Installing wheels .
 the negative battery cable. First read Note when disconnecting and connecting the battery lead .
Checking performed work
Change oil and oil filter, and fill coolant.
Check:
 the engine oil level

 the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.
ENGINE REPLACEMENT, TRANSFERRING COMPONENTS
See Engine replacement, transferring components
REMOVING TURBOCHARGED ENGINES WITH THE TRANSMISSION
See Removing turbocharged engines with the transmission
REPLACE THE ENGINE MOUNTINGS
Special tools:
2001 Volvo V40
9995006
9995383
9995460
Conditions
Remove both the screws. Move the bracket for the A/C hose to one side.
Replacing the right-hand engine mounting
Installing the lifting beam and lifting hook

Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt.
Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lifting arm 9995383
and lifting hook 9995460 to raise the front of the engine a few millimeters.
2001 Volvo V40

Remove:
 the screws for the servo holder

 the engine mounting screws
Installing the right engine mounting
2001 Volvo V40

Screw the engine mounting onto the engine. Tighten to 67 Nm .
Install the screws on the bracket for the bodywork. Tighten to 50 Nm .
Finishing
Remove the lifting beam and lifting hook.
Install:
 the power steering reservoir

 the metal bracket for the servo hose.
Replacing the left-hand engine mounting
Removing the left-hand engine mounting
2001 Volvo V40
Fig. 100: Removing/Installing Left-Hand Engine Mounting

Remove:
 the air cleaner assembly. See Removing the air cleaner (ACL) housing
 the nut for the engine mounting in the bodywork.
Position lifting beam 9995006 and lifting hook 9995460 in the rear eyelet for the engine. Lift the engine until
the screws can be removed.
Remove:
 the three nuts for the engine mounting on the transmission bracket
Installing the left-hand engine mounting
2001 Volvo V40

Install:
 the engine mounting. Correctly position the rubber guard

 the nuts on the transmission bracket. Tighten to 45 Nm
 the screw and nut. Tighten by hand.
Tighten to 98 Nm .
Install the air cleaner. See Installing the air cleaner (ACL) housing.
Replacing the front engine mounting
Removing the front engine mounting
2001 Volvo V40
Fig. 102: Removing Front Engine Mounting

Remove:
 the screw and nut (B) from the engine mounting

 the screws (A)
Installing the front engine mounting
Install:
 the engine mounting. Position the hole against the front of the car
 the screws in the front-rear strut. Tighten to 35 Nm
 the screw and the nut in the engine mounting. Tighten to 55 Nm .
Replacing the rear engine mounting
Removing the rear engine mounting
2001 Volvo V40
Fig. 103: Removing/Installing Rear Engine Mounting

Remove:
 the parallel strut for the front suspension

 the heat deflector plate
 the screws (A) from the mounting in the car body
 the nut and screw (B). Slowly pull the engine mounting downwards
 the screws (C)
Installing the rear engine mounting
2001 Volvo V40

Install:
 the engine mounting with the hole pointing backwards

 the screws (C). Tighten to 35 Nm
 the screw and the nut (B). Tighten by hand
 the screws (A). Tighten to 69 Nm .
NOTE: Ensure that the bushings are correctly positioned as shown.
Remove the screw (B) for the front engine mounting.
Tighten the rear screw first, then the front screw. Tighten to 55 Nm .
Install:

 the parallel strut for the front suspension.
Replacing the air cleaner (ACL)
2001 Volvo V40
NOTE: The graphics are used for different model years and/or models. Some variation
may occur. However, the essential information in the graphics always
corresponds to the text.
Preparations
Remove:
 the cable from the battery negative terminal. First read Note when disconnecting and connecting the
battery lead
 the cable from the battery positive terminal
 the battery.
Removing the air cleaner (ACL) housing
Fig. 105: Disconnecting Connectors, Vacuum Hoses And Wiring From Air Cleaner (ACL) Housing
Remove:
 the connectors from the mass air flow (MAF) sensor and the assisted air control valve. Disconnect the
connectors, vacuum hoses and wiring from the air cleaner (ACL) housing
 the assisted air control valve from the air cleaner (ACL) housing
2001 Volvo V40
 the inlet hose from the terminal on the mass air flow (MAF) sensor
 the preheating hose.
Fig. 106: Releasing Clip Holding Fresh Air Intake On Air Cleaner (ACL) Housing And Lifting Off Air
Cleaner (ACL) Housing Assembly
Remove:
 the screws for the relay box. Move the box to one side
 the screws for the air cleaner (ACL) housing.
Release the clip holding the fresh air intake on the air cleaner (ACL) housing. Lift off the air cleaner (ACL)
housing assembly.
Installing the air cleaner (ACL) housing
2001 Volvo V40
Fig. 107: Installing Air Cleaner (ACL) Housing

Position the air cleaner (ACL) housing.
Install:
 the screws for the air cleaner (ACL) housing

 the screws for the relay box
 the preheating hose
 the inlet hose
 the assisted air control valve.
Reconnect the vacuum hoses, connectors and wiring.
Installing the battery
Install:
 the battery
 the cable on the battery positive terminal
 the cable on the battery negative terminal. First read Note when disconnecting and connecting the
2001 Volvo V40
battery lead .
REPLACING THE COVER ON TOP OF THE ENGINE
See Replacing the cover on top of the engine
REPLACING THE OIL PUMP AND FRONT CRANKSHAFT SEAL
Special tools:
9995433
9986187
9995919
9995455
9512050
Remove the timing belt, see Removing the timing belt.
Removing the vibration damper
Fig. 108: Identifying Vibration Damper & Counterhold 9995433

 Install counterhold 9995433

 Counterhold and remove the crankshaft center nut
 Work the vibration damper loose and remove by hand
 Remove the timing belt.
2001 Volvo V40
Removing the crankshaft timing gear pulley
Fig. 109: Identifying Crankshaft Belt Pulley Removal

 Use universal puller 9986187 and two of the vibration damper screws
 Tighten both the screws by hand to stop in the pulley
 Install the puller so that the claws engage in the screws, not in the camshaft pulley.
NOTE: Ensure that the tool claws do not damage the pulley teeth.
When only replacing the front crankshaft seal
2001 Volvo V40
Fig. 110: Identifying Seal Installation Using Tool 9995455

 Remove the old seal using a groove-cut chisel or: 9995919

 Clean the mating surface
 Grease and install a new seal.
Use tool 9995455
 Press in the seal using a drift and the crankshaft center nut as shown.
NOTE: Ensure that the crankshaft does not rotate when pressing in the
crankshaft seal.
Removing the oil pump
Fig. 111: Identifying Oil Pump Stop Lugs

 Remove the four oil pump screws
2001 Volvo V40
 Remove the oil pump.
Use a groove-cut chisel and carefully break at the stop lugs
 Clean the gasket face and the mating surfaces.
Installing the oil pump
Fig. 112: Identifying Oil Pump And Special Tool 999 5455
Install the new oil pump.
 Install a new gasket

 Carefully insert the oil pump over the end of the crankshaft.
NOTE: Do not damage the sealing ring in the oil pump during installation.
 Install 4 new screws as guides

 Pull in the oil pump with drift 9995455 and the crankshaft center nut.
NOTE: Ensure that the crankshaft does not rotate when drawing in the pump.
 Tighten the screws crosswise. Tighten to 10 Nm

 Install the crankshaft timing gear pulley.
Carefully tap alternately around the pulley until end position is reached.
NOTE: The timing gear pulley can only be in one position on the splines on the
end of the crankshaft.
Installing the vibration damper
2001 Volvo V40
Fig. 113: Identifying Vibration Damper & Counterhold 9995433

Install the vibration damper.
Tighten the center nut to 180 Nm .
Use counterhold 9995433 .
Remove the counterhold. Tighten the screws. Tighten to 25 Nm .
Angle-tighten 30° . Use bevel protractor 9512050 .
Install the timing belt according to Installing the timing belt.
REPLACING THE TIMING BELT
Special tools:
9995006
9995383
9995460
Removing the auxiliaries belt
2001 Volvo V40
Fig. 114: Removing/Installing Auxiliaries Belt

 Turbocharged engines: remove the right hand engine cover and the cover over the right headlamp.
 Slacken off the auxiliaries belt by turning the screw on the tension pulley clockwise
 Remove the auxiliaries belt.
Removing the timing covers
2001 Volvo V40
Remove:

2001 Volvo V40

2001 Volvo V40

Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lifting arm 9995383
and lifting hook 9995460 to raise the front of the engine a few millimeters.
2001 Volvo V40


 the engine mounting
2001 Volvo V40
Fig. 119: Positioning Engine According To Marking

Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond.
Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The
markings are shown. Remove the upper timing cover.
2001 Volvo V40

Hold the center screw still. Turn the tensioner eccentric clockwise using a 6 mm Allen key to 10 o'clock.
Remove the timing belt from the tension pulley, camshaft pulley and water pump.
Tensioning the tensioner pulley and the idler pulley
Spin the idler pulley and listen for noise. When replacing with a new idler pulley, tighten to 24 Nm .
Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center
screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block rib.
Ensure that the Allen hole on the eccentric is at "10 o'clock".
Removing the splash guards under the engine
2001 Volvo V40
Fig. 121: Removing/Installing Front/Rear Splash Guards Under Engine

Remove:
 the front air baffle

 the rear air baffle.
Removing the timing belt (at the bottom)
2001 Volvo V40
Fig. 122: Removing/Installing Lower Belt Cover

Remove:
 the two screws from the lower belt cover

 the lower belt guard
 the timing belt using a twisting movement
 clean the surrounding area.
Install the timing belt over the pulley on the crankshaft.
Install:
 the lower belt guard

 the rear air baffle.
2001 Volvo V40

Install the new belt in the following order:
 crankshaft
 the idler pulley
 intake camshaft
 exhaust camshaft
 water pump
 belt tensioner.
2001 Volvo V40


approximately 20°C/67°F. At higher temperatures (with the engine at operating
temperature or a high outside temperature for example) the indicator is further
to the right.
The graphic shows the position of the indicator at different engine temperatures.
2001 Volvo V40
 Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned
between the intake camshaft pulley, the idler pulley and the crankshaft
 Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the
tensioner indicator passes the marked position.
Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
 Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm .
Check that the indicator is in the correct position.
Check
2001 Volvo V40
Fig. 126: Checking Markings On Crankshaft And Camshaft Pulley

 Press the belt to check that the indicator on the tensioner moves easily
 Install the upper timing cover
 Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond.
Installing timing covers
2001 Volvo V40
Install:
 the lower timing cover

 the front timing cover. Tighten to 12 Nm
 the auxiliaries belt.
2001 Volvo V40

Screw the engine mounting into place on the engine. Tighten to 67 Nm .
Install:
 the screws on the bracket for the bodywork. Tighten to 50 Nm

Finishing
2001 Volvo V40

Install:
 the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt
 the front wheel according to Installing the wheels
 turbocharged engines: the right hand engine cover and the cover over the right headlamp unit.
Checking work
Function test:
 Test drive the engine.
TURBOCHARGED ENGINE ASSEMBLY WITH THE TRANSMISSION, INSTALLING
See Turbocharged engine assembly with the transmission, installing
VVT-UNIT, REPLACING/ADJUSTING
2001 Volvo V40
See VVT-unit, replacing/adjusting
ENGINE MECHANICAL (B4204T2 CVVT; 2000)

Special tools:
9985972
9992520
9992810
9995112
9995297
9995186
9995642
9995463
Starter motor, removing
2001 Volvo V40
Fig. 130: Starter Motor Mounting Screws

 Pull off the cover

 Remove the support bracket from the intake manifold.
 Remove the wiring from the starter motor.
 Remove the mounting screws. Remove the starter motor.
Transmission, removing
2001 Volvo V40
Fig. 131: Removing Transmission Using Mobile Jack 999 5972

Remove the torque converter screws. Remove the screwed joint between the transmission and the engine where
the flywheel cover is secured to the cylinder block.
WARNING: When removing the transmission, use mobile jack 9995972 with fixture
9995463 to support the transmission and prevent damage.
Carrier plate, removing
2001 Volvo V40
Fig. 132: Removing Carrier Plate

See Remove flange plate.
Engine on mounting stand, installing
2001 Volvo V40
Fig. 133: Installing Engine On Mounting Stand

Use engine stand 999 2520 and support 999 5297.
Remove the lifting tools.
Install an appropriate number of washers to compensate for the transmission guide pins.
Engine components left-hand side, transferring
2001 Volvo V40
Fig. 134: Transferring Engine Components Left-Hand Side

1. The upper cover

2. The ignition coils and wiring
3. Camshaft position (CMP) sensor
4. The lifting eyelet.
Engine components exhaust side, transferring
2001 Volvo V40
Fig. 135: Transferring Engine Components Exhaust Side

1. The pre-heater plate

2. Exhaust manifold
3. The engine mounting on the timing belt side
4. The thermostat housing and the oil cooler and hoses
5. The bracket for the drive shaft bearing
6. The coolant pipe.
Engine components air intake side, transferring
2001 Volvo V40
Fig. 136: Transferring Engine Components Air Intake Side

1. Oil pressure sensor

2. Oil dipstick and pipe
3. Generator (GEN)
4. The intake manifold assembly with the radiator hose connection
5. The thermostat assembly
6. Knock sensor (KS)
7. The flame trap and hoses
8. The engine mountings and the lifting eyelet
9. The starter motor wiring.
Carrier plate, installing
See Install flange plate.
Transmission, installing
2001 Volvo V40
Fig. 137: Installing Transmission

The torque converter. Tighten to 50 Nm .
Plug the old engine in the same way as the new engine.
Install the exhaust side cover plate.
Install the speed sensor. Tighten to 20 Nm .
Install the cable mounting. Tighten the cable mounting.
Starter motor, Installing
2001 Volvo V40
Fig. 138: Starter Motor Mounting Screws

 Install the starter motor. Tighten the screws.
Tighten to 50 Nm
 Install the bracket. Finger-tighten the bracket to the intake manifold

 Connect the wiring
 Install the protective cover.
Special tools:
9992810
9995185
9995462
9995474
2001 Volvo V40
9995488
9995533
9995642
9995666
Radiator and engine, draining coolant
 See Draining the coolant from the radiator and the engine .
Removing the left-hand side drive shaft nut
Remove the hub cap. Remove the nut.
Remove the air conditioning (A/C) hose from the fan shroud.
Removing the front and rear splash guards under the engine

Removing the lateral strut
2001 Volvo V40
Fig. 140: Removing/Installing Cross Stay Member

Removing the front-rear member
2001 Volvo V40
Fig. 141: Removing/Installing Longitudinal Member

Remove:

 the nuts for the engine pads
 the front and rear screws
 the two screws from the engine pads. Lift the front-rear member down from the car.
Removing the down pipe from the exhaust manifold
2001 Volvo V40
Fig. 142: Removing/Installing Down Pipe From Exhaust Manifold

 Remove the nuts

 Pull the front exhaust pipe downwards
 Remove the gasket.
Removing the rear engine mounting
2001 Volvo V40

Remove the four screws. Remove the engine bracket.
Removing the front engine mounting
2001 Volvo V40
Fig. 144: Removing/Installing Front Engine Mounting

Remove the clamps from the charge air cooler (CAC) hose.
Remove the three screws and the engine mounting.
Removing the poly V-belts
2001 Volvo V40

 Relieve the load on the belts by turning the belt tensioner counter-clockwise
 Remove the poly V-belts. Move it upwards.
Removing the air conditioning (A/C) compressor
2001 Volvo V40
Fig. 146: Removing Air Conditioning (A/C) Compressor

Unscrew the upper screw from the mounting for the power steering pump.
Remove:
 the connector (A)

 the four mounting screws
 the compressor. Turn the compressor upwards as far as possible
 Move the mounting to one side.
Tie the front edge of the compressor to the car body.
NOTE: Do not damage the A/C hoses and pipes.
Removing the oil pressure sensor and generator (GEN) connectors
2001 Volvo V40
Fig. 147: Checking Engine Oil Pressure Sensor

Remove:
 the connector from the oil pressure sensor

 the cable clamp from the bracket
 the connector in the middle.
Removing the right-hand drive shaft from the transmission
2001 Volvo V40
Fig. 148: Removing Stub Axle From Spring Strut (Removing On Right-Hand Side)
Remove:
 The drive shaft bearing cap on the engine side

 Both the front wheels
 The brake hose clips. Lift out the hoses from their mountings
 The ABS lines from its mountings
 The two nuts and the upper screw from the spring strut
 The wheel spindle from the spring strut (turn it)
 The drive shaft from the transmission
 The lower screw. Move the drive shaft to one side.
Insert special tool 9995488 into the transmission.
Secure the wheel spindle using the lower spring strut screw.
Tie the drive shaft to the wheel arm.
Removing the left-hand side cover
2001 Volvo V40
Remove the screws. Lift off the cover.
Removing the left-hand side drive shaft assembly
Fig. 149: Removing Left-Hand Side Drive Shaft Assembly

Remove:
 The brake hose clips. Lift out the hoses from their mountings
 The ABS lines from its mountings
 The center nut from the drive shaft
 The two nuts and the upper screw from the spring strut
 Detach the drive shaft from the transmission. Use special tool 9995462
 The drive shaft assembly
 Insert special tool 9995488 into the transmission
 Secure the wheel spindle using the lower spring strut screw.
Automatic transmission: Disconnect the transmission oil pipes
2001 Volvo V40
Fig. 150: Disconnecting/Installing Transmission Oil Pipes

Disconnect the oil pipe terminals from the transmission. Move the pipes to one side.
Ensure that no dirt gets into the transmission and hoses.
Seal all openings using plastic plugs.
NOTE: Do not remove the hoses from the pipes.
Draining the fuel injection system
See Draining the fuel injection system .
Removing the battery and battery shelf
2001 Volvo V40
Fig. 151: Battery And Shelf

Remove the battery.
NOTE: If the car has cruise control, remove the vacuum hose and the connector before
the vacuum pump is detached.
Remove the screws from the battery shelf.
Release the cable harness from the clamp.
Remove the hose clamp from the battery shelf.
Removing the air cleaner (ACL)
Remove the air cleaner (ACL). See Removing the air cleaner (ACL) housing .
Disconnect the battery positive and negative leads
2001 Volvo V40
Fig. 152: Disconnect/Installing Battery Positive And Negative Leads

Disconnect the connector (A).
Remove:
 The nut and the battery positive lead

 The ground lead from the transmission.
Removing the gear selector mechanism cables
2001 Volvo V40
Fig. 153: Installing Gear Selector Mechanism Cables (Automatic Transmission)

Automatic transmission
Remove: the gear selector cable mountings.
Disconnect the connector.
Remove the gear selector cable from the gear selector bevel arm on the transmission.
Remove the connectors from the transmission:
 Remove the gear selector cable from the transmission

 The ground lead from the transmission
 Remove the bracket for the connector from the transmission
 Separate the connector.
Removing the vacuum hose from the canister purge (CP) valve
2001 Volvo V40
Fig. 154: Removing Vacuum Hose From Canister Purge (CP) Valve
Removing hoses from the turbocharger (TC)
2001 Volvo V40
Fig. 155: Removing/Installing Hoses From Turbocharger (TC)

Remove:
 The charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
 The hose for the idle air control (IAC) valve at the charge air cooler (CAC)
 The hose at the pipe
 The screw for the bracket. Remove the pipe assembly together with the hose.
Removing the throttle cable
2001 Volvo V40
Fig. 156: Removing/Installing Throttle Cable

Remove:
 the cover by removing one screw and two plugs

 the cable with the throttle in the wide open position
 the retaining clip. Remove the cable sleeve.
Removing the cover, the mounting and the connectors
2001 Volvo V40
Fig. 157: Removing Cover, Mounting And Connectors

Remove the connectors for:
 the engine speed (RPM) sensor

 the camshaft position (CMP) sensor
 the knock sensor (KS)
 the cable harness.
Remove:
 the protective tube from the 3 clips

 the brake servo hose from the power brake booster (press in the snap-ring and pull out the hose)
 the hose from the valve for the air cleaner (ACL).
Removing the fuel line from the engine
2001 Volvo V40

 Press the lock facing together. Pull out the fuel line
 Disconnect the pipe from the clamps. Move the pipe to one side.
Removing the cable harness
2001 Volvo V40
Fig. 159: Engine Cable Harness

Disconnect the connectors from the engine.
NOTE: Note the position of all the mounting points for the cable harness.
Remove:
 the engine coolant temperature (ECT) sensor

 the cable from the bracket
 the cover over the injectors (pull the cover off)
 the injectors
 the throttle position (TP) sensor
 idle air control (IAC) valve
 the cable guide by slackening off one screw and a nut
 the switch for the tail lamp
 move the entire cable harness to one side.
Removing the coolant hoses
2001 Volvo V40
Fig. 160: Removing Coolant Hoses

Remove:
 the clamps
 the upper radiator hose
 the lower radiator hose on the engine side.
Removing the heater hoses from the engine connection
2001 Volvo V40
Fig. 161: Removing Heater Hoses From Engine Connection

Remove:
 slacken off the hose clamps (make a note of how the hoses are routed)
 pull off the heater hoses.
Removing the power steering pump from the engine
2001 Volvo V40
Fig. 162: Removing Power Steering Pump

 Remove the brackets between the power steering pump and the intake manifold and the lower bracket
 Remove the Poly V-belt
 Remove the mounting screws between the spokes on the pulley
 Remove the oil reservoir from the bodywork. Release the hose from the clips
 Remove the power steering pump. Place the pump to one side.
Place the hood in the service position
2001 Volvo V40
Fig. 163: Placing Hood In Service Position

Remove the two screws.
Remove the support on the body side.
Support the hood.
Removing the engine with the transmission
2001 Volvo V40
Fig. 164: Installing Engine Assembly With Transmission

Hang lifting hooks 9995185 and 9995642 on 9992810 .
Raise the lifting equipment until it takes the strain off the engine.
Remove the engine mounting on the transmission side:
 Remove the nut and the screw

 Remove the three screws. Remove the transmission bracket.
Remove the engine mounting from the upper timing belt cover.
NOTE: Check carefully that the driveline is clear of the bodywork and other optional
equipment. Turn the clamp at the oil cooler if necessary.
Lift out the engine.
Adjust the lifting equipment continuously throughout the lift.
Return the hood to the normal position.
2001 Volvo V40
REPLACING CAMSHAFT SEAL (RETAINING RING) FRONT SIDE
Special tools:
9995719
9995718
9995919
Remove
Remove camshaft seal at VVT unit side
 Remove toothed belt, see Remove auxiliaries belt

 Remove the gear pulley at the side to be replaced, see Removing the timing gear pulley.
Remove camshaft retaining ring
Fig. 165: Identifying Special Tool 9995919

 Remove the retaining ring with help of special tool 9995919

 Clean the surfaces.
2001 Volvo V40
Install
Install camshaft retaining ring

 Grease the new retaining ring

 Install the ring by using special tool 9995718 at VVT side and 9995719 at other side.
 Remove the tools and check proper fitting.
 Install gear pulley, see Installing the camshaft timing gear pulley.
 Install toothed belt, see Install auxiliaries belt.
Check for leakage.
REPLACING ENGINE MOUNTING BOLSTERS
Special tools:
9995006
9995383
2001 Volvo V40
9995460
Prerequisites
 Remove the right engine bay cover

 Remove the two bolts and move the AC hose support to one side.
Replace engine mounting bolster at distributor side
Fig. 167: Identifying Engine Mounting Bolts

Remove the engine bolster nut.
Position the lifting beam 9995006 and the support 9995383 over the engine and locate the lifting lug 9995460 at
the front lifting eye.
Lift the engine up until the engine bolster bolt can be removed.
Remove the three bolts and remove the support (pushing power steering hose to one side).
Install the support on the engine and tighten the bolts. Torque setting 76 Nm .
2001 Volvo V40
Install the engine bolster. Finger-tighten.
Remove the lifting beam.
Tighten the bolster nut. Torque setting 98 Nm .
Install the hose support. Torque setting 10 Nm .
Install the engine cover.
Install the right engine bay cover.
Replacing engine mounting bolster at transmission side

Remove the complete air cleaner (ACL), see Removing the air cleaner (ACL) housing .
Remove the engine bolster nut.
Lift the engine/transmission up until the engine bolster bolt can be removed.
When lifting the engine/transmission, use a block of wood to protect the transmission.
2001 Volvo V40
Remove the cable harness clip from the wire end.
Remove the three nuts and remove the mounting bolster.
Install the mounting bolster and place the 2 rubber protecting flaps in the correct position.
Install the 3 nuts. Torque setting 45 Nm .
Install the bolt and the nut in the bolster. Finger-tighten.
Remove the lifting beam.
Tighten the bolster nut. Torque setting 98 Nm .
Install the complete air cleaner (ACL), see Installing the air cleaner (ACL) housing .
Install the inlet air-preheater hose.
Replace front engine mounting bolster
Fig. 169: Removing Front Engine Mounting

Remove the nut and the bolt from the engine mounting bolster.
2001 Volvo V40
Remove the two mounting bolts and remove the mounting bolster.
Install the new engine mounting bolster (Position the hole towards the front of the car).
Tighten the:
 Two bolts (A) on the longitudinal member to 35 Nm .

 Central bolt (B) in the bolster to 55 Nm .
Replace rear engine mounting bolster

Remove the splash guards from the underside.
Remove the drive shaft heat-shield.
Remove the two bolts (A) from the mounting on the body side.
Remove the bolt (B) of the mounting and pull the engine mounting down slightly.
Remove the two mounting bolts (C) and remove the mounting.
2001 Volvo V40
Install the mounting with the two bolts (C).
Position the hole (D) towards the rear of the car. Torque setting 35 Nm .
Replace the bolt (B). Finger-tighten.
Fig. 171: Installing Front-Rear Member

Install the two bolts (A). Torque setting 69 Nm .
NOTE: Position the rubbers in the correct position as shown. (The rear and the front of
the center member must be in similar positions).
Loosen the front mounting-bolster bolt (B). First tighten the rear mounting-bolster bolt (torque setting 55 Nm ),
then tighten the front mounting bolt again (torque setting 55 Nm ).
Install the heat shield and the splash guard.
REPLACING FLANGE PLATE
Special tools:
2001 Volvo V40
9995112
Remove flange plate
Fig. 172: Checking Carrier Plate

Use gear selector 9995112 to block the flange plate.
Remove the bolts and take the flange plate off.
Install flange plate
Clean the surfaces from flange plate and crankshaft fixation.
Fit the bolts finger tighten.
Tighten the bolts to in two stages diagonally.
Stage 1: 45 Nm .
Stage 2: angle tighten 45° turn.
REPLACING REARMOST CRANKSHAFT RETAINING RING
Special tools:
9991801
9995112
9995676
NOTE: This method assumes the transmission has been removed.
2001 Volvo V40
Removing flange plate
See Remove flange plate.
Replacing retaining ring
Fig. 173: Replacing Retaining Ring

Remove the retaining ring with a screwdriver.
NOTE: Do not damage the contact faces. Note the position of the retaining ring relative
to the retaining ring holder.
Oil the retaining ring mating lips.
Install the retaining ring using the installation kit 9995676 and the universal handgrip 9991801 .
Tap the retaining ring in until the die touches the crankshaft.
Installing flange plate
See Install flange plate.
2001 Volvo V40
REPLACING THE CAMSHAFT SEALS
Special tools:
9995006
9995383
9995460
9995452
9995451
9995199
9995718
9995719
9995651
NOTE: The crankshaft and the camshafts must not be turned more than is stated in the
method description. If the shafts are turned in any other way the valves may be
damaged.
Preparations
Remove:
battery lead
 the inlet hose between the air cleaner (ACL) and throttle body (TB). Place it to one side.
2001 Volvo V40
Remove:
 the brake servo vacuum hose from the terminal in the throttle body (TB). Disconnect the hose by pressing
the plastic ring down. At the same time pull the hose upwards. Move the hose to one side
 the fuel line and wiring from the clips at the rear edge of the cylinder head.
2001 Volvo V40
Fig. 175: Cable Channel Screws

Remove:
 the screws for the cable duct

 the rear cover for the camshaft
 the trigger wheel
 the right-hand engine splash guard
Removing the timing covers
2001 Volvo V40

Remove:

2001 Volvo V40

Remove the nut for the engine mounting.
Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lift arm 9995383
and lifting hook 9995460 to lift the front edge of the engine a few mm until the engine mounting screw can be
taken out.
2001 Volvo V40
Fig. 178: Removing Engine Mounting On Timing Gear Side

Remove:

2001 Volvo V40
Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond.
Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The
markings are shown. Remove the upper timing cover.
2001 Volvo V40

Hold the center screw still and turn the tensioner eccentric clockwise to the "10 o'clock" position using a 6 mm
Allen key.
Remove the timing belt from the camshaft pulleys.
2001 Volvo V40

Timing gear pulleys with variable valve timing unit
 Install camshaft adjustment tool 9995452 at the rear of the camshafts.
2001 Volvo V40
Timing gear pulleys with variable valve timing units:
 Remove the plug at the front edge of the variable valve timing unit (TORX 55)
 Remove the center screw from the VVT unit (TORX 55).
Timing gear pulleys without variable valve timing units:
 Remove the screws for the timing gear pulley. Use counterhold 9995199
 Remove the timing gear pulley
 Remove tool 9995452
 Remove the screw holding the inner timing cover to the cylinder head.
Replacing the camshaft seal
2001 Volvo V40
Fig. 184: Identifying Seal And Special Tool 999 5651

Carefully press in tool 9995651 between the sealing ring and the camshaft.
Carefully pry out the seal.
Oil the new seal.
Fig. 185: Camshafts And Special Tools 995718 And 995719
2001 Volvo V40
Install the new seal for the camshaft with variable valve timing. Use drift 9995718 .
Install the new seal for the camshaft without variable valve timing. Use drift 9995719 .
Remove:

 the support between the cylinder block and the intake manifold
 the mounting screws for the starter motor
Remove the blind cover plug and the blind cover washer

Install adjustment tool 9995451 . Ensure that the adjustment tool bottoms out against the cylinder block.
2001 Volvo V40
Pump
Installing the camshaft timing gear pulley
2001 Volvo V40

Timing gear pulleys without variable valve timing (VVT):
 install the upper timing cover

 install the timing gear pulley without variable valve timing on the camshaft. Use the two screws
positioned so that the markings on the timing gear pulleys and upper timing cover correspond. Do not
tighten.
2001 Volvo V40
Timing gear pulleys with variable valve timing (VVT):
 Install the timing gear pulley using the center screw on the camshaft. Ensure that the markings on the
timing gear pulleys/upper timing cover correspond. Do not tighten.
2001 Volvo V40

2001 Volvo V40


approximately 20°C/67°F. At higher temperatures (with the engine at operating
temperature or a high outside temperature for example) the indicator is further
to the right.
The graphic shows the position of the indicator at different engine temperatures.
2001 Volvo V40
 The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft.
 Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the
tensioner indicator passes the marked position.
Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
 Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm .
Tightening the timing gear pulley
Tighten the center screw on the timing belt tensioner with variable valve timing. Tighten to 90 Nm .
Install the third screw on the camshaft without variable valve timing. Tighten to 20 Nm .
Check
2001 Volvo V40
Fig. 193: Checking Markings On Crankshaft And Camshaft Pulley

 Install the upper timing cover
Installing timing covers
2001 Volvo V40

Install:
 the lower timing cover

 the front timing cover. Tighten to 12 Nm
2001 Volvo V40

Install the engine mounting screw and nut in the bodywork bracket. Tighten by hand.
Finishing
2001 Volvo V40

Tighten the engine mounting nut. Tighten to 98 Nm .
Install:

 the rear camshaft cover
 the trigger wheel. Tighten to 17 Nm
 the camshaft position (CMP) sensor housing. Tighten to 5 Nm
 the cable duct
 the brake servo vacuum hose
 the hose between the intake manifold and air cleaner (ACL) housing
 the blind cover plug
 the mounting screws for the starter motor
 the support between the cylinder block and the intake manifold
2001 Volvo V40

battery lead .
Checking work
Function test:
 Test drive the car.
Special tools:
9995702
Removing the cover on top of the engine
Fig. 197: Engine Top Cover Screws

 Remove the screws from the rear of the cover

 Remove the two screws from the timing gear side
2001 Volvo V40
 Undo the clips on the timing gear side. Remove the cover(s).
Installing the cover on top of the engine
Fig. 198: Engine Top Cover Screws

 Position the cover(s)

 Secure the clips on the timing gear side
 Install the screws. Tighten to 10 Nm .
REPLACING THE CYLINDER HEAD AND GASKET
Special tools:
9995454
9512666
9995670
9995451
2001 Volvo V40
9512050
9512767
9995452
9995718
9995719
Preparation
Disconnect the battery negative lead. First read Note when disconnecting and connecting the battery lead .
Draining the coolant
Fig. 199: Drain Valve And Coolant Reservoir Cap

 Remove the front air baffle
2001 Volvo V40
 Open the nipple on the engine

 Drain the coolant into a container
 Close the nipple
 Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.
Separating the exhaust system
Remove the nuts where the three-way catalytic converter (TWC) and the front exhaust pipe divide.
Unhook the exhaust system and allow it to hang.
Removing the manifold and turbocharger (TC)
Remove the manifold. See Exhaust manifold, replacing .
Removing the starter motor
Remove:
 the lower hose for the charge air cooler (CAC)

 the support bracket for the intake manifold
 the connector for the oil pressure switch
 the plastic charge air pipe from the turbocharger (TC)
 the screws for the starter motor
 unhook the starter motor and allow it to hang.
Draining the fuel line
Drain the fuel line. See Draining the fuel injection system .
Removing the fuel line
2001 Volvo V40

Disconnect the quick-release connector between the fuel line and the fuel rail.
Use tool 9512666 .
Removing components
2001 Volvo V40

Remove:
 the cover over the injector

 the cover over the throttle body (TB)
 the cover over the ignition coils
 the front timing cover
 the throttle cable from the bracket for the throttle body (TB).
2001 Volvo V40
Remove:
 the vacuum hose for the brake servo. Pull the hose while pressing the plastic ring down
 the turbocharger (TC) control valve from the air cleaner (ACL) housing
 the connector for the mass air flow (MAF) sensor
 the EVAP hose connection to the mass air flow (MAF) sensor hose
 the upper section of the air cleaner (ACL) housing and hose
 the pipe screw for the water-heated crankcase ventilation
Exposing the cable harness
2001 Volvo V40

Remove:
 the screw from the ignition coil ground

 the camshaft position (CMP) sensor.
Remove:
 the variable valve timing valve connector

 the ignition coil connectors.
Place the cable harness to one side.
Unscrew the cable duct from the rear edge of the cylinder head and the throttle body (TB) bracket. Release the
rear edge of the cylinder head from the cables and hoses.
Remove:
 the connector for the engine coolant temperature sensor

 the injector connectors.
2001 Volvo V40
Place the cable duct and cable harness to one side.
Mark up and remove the ignition coils and ignition cables.
Remove:
 the rear cover for the camshaft

Removing the intake manifold

Remove:
1. the upper radiator hose together with the cover for the thermostat housing
2. the screw holding the dip stick pipe to the intake manifold
3. the connectors from the assisted air control valve and the throttle position (TP) sensor
4. the hose for the crankcase ventilation from the camshaft cover
5. the vacuum hoses from the intake manifold, mark up the position
2001 Volvo V40
6. the bracket between the servo pump and intake manifold

7. the screws holding the intake manifold to the cylinder head
8. the intake manifold.
Install the lifting beam and the lifting hook. See Installing the lifting beam and lifting hook.
Remove the right engine mounting. See Removing the right-hand engine mounting.
See Position the engine according to the marking.
Remove the timing belt according to Removing the timing belt.
Remove the timing gear pulley. See Removing the timing gear pulley.
Releasing the intake pipe for the coolant pump
2001 Volvo V40
Fig. 205: Coolant Pump Intake Pipe

Remove the two screws at the coolant pipe connection to the bypass channel.
Carefully turn the pipe to remove it from the cylinder block.
Removing the camshaft cover and cylinder head
2001 Volvo V40

Remove:
 the variable valve timing valve

 the spark plugs from cylinders 1 and 4.
Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well
is fully tightened.
Remove all the screws securing the camshaft cover to the cylinder head.
2001 Volvo V40
Fig. 207: Removing Screws Securing Camshaft Cover To Cylinder Head

Use pliers 9995670 to lift the cover from the cylinder head. Install the pliers at the stop lugs. Start at the
cylinder and work alternately backward.
Slacken off the wing nuts a few turns. Repeat the procedure.
Carefully press out the front and rear camshaft seals.
CAUTION: Do not damage the sealing surfaces on the camshafts.
Remove:
 tools 9995454
 the camshaft cover
 the camshafts.
Lift out the valve lifters. Use suction pads. Do not use magnets.
CAUTION: Mark up and position the lifters so that their original positions can be
2001 Volvo V40
established.
Fig. 208: Removing Screws Holding Cylinder Head On Cylinder Block

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately
towards the center.
Get help to lift off the cylinder head.
2001 Volvo V40
Fig. 209: Identifying Gauge 9995451

Remove:

 the heat deflector plate above the manifold
 the manifold and gaskets.
Cleaning the gasket face
2001 Volvo V40
Fig. 210: Cleaning Camshaft Cover

Clean the gasket faces for:
 the coolant bypass channel

 the cylinder block
 camshaft cover.
When replacing or machining the cylinder head, clean the gasket faces for:
 the manifold. Check that the studs are tightened

 thermostat housing.
Blow the oil ducts clean.
CAUTION: Do not use a metal scraper. Use a soft putty knife and gasket solvent
1161340-3 if necessary. The surfaces must be completely clean in order to
form a complete seal.
WARNING: Use a fume hood or extractor when using gasket solvent.
2001 Volvo V40
NOTE: For tightening torques not in the text, see Tightening torques for 4-cylinder
gasoline engines .
Aligning the crankshaft
Fig. 211: Installing Gauge 999 5451

Remove the blind cover plug.
Install adjustment tool 9995451 . Ensure that the adjustment tool bottoms out against the cylinder block.
2001 Volvo V40
Install:
 the thermostat housing. Use a new gasket

 the manifold. Use new gaskets. Lubricate the studs with paste 1161408
 the heat deflector plate above the manifold.
Install a new cylinder head gasket.
Install the cylinder head.
Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.
2001 Volvo V40
Fig. 213: Identifying Cylinder Head

Use new screws. Lubricate and install all the screws.
Tighten the screws as shown.
Tighten the screws in the following order:
1. Tighten to 20 Nm
2. Tighten to 60 Nm
3. Angle-tighten 130°. Use protractor 9512050 .
Installing the valve lifters and camshafts
NOTE: When installing a new cylinder head, the valve clearance must be set. See Valve
clearance, setting/adjusting .
Lubricate the valve guide wells.
Install all the valve lifters.
NOTE: Make sure that the lifters are in the same position as before.
2001 Volvo V40
Fig. 214: Identifying Intake And Exhaust Camshafts

Lubricate the camshaft bearing seats.
Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center
line.
Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary
center line.
2001 Volvo V40
Fig. 215: Applying Liquid Gasket On Camshaft Cover

Applying liquid gasket.
Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells on the cylinder head.
Apply liquid gasket 116 1059 to the camshaft cover.
Use roller 9512767 .
The surface must be completely covered without any excess.
CAUTION: Ensure that no liquid gasket gets into the coolant or oil ducts. Only a thin
layer of liquid gasket is required.
Installing the camshaft cover
2001 Volvo V40

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.
Install the camshaft cover.
Install 2 press tools 9995454 .
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install the intake manifold and lifting eyes, tighten screws from the middle and outwards.
Remove the press tools.
Install:
 the variable valve timing (VVT) solenoid. Use a new gasket.

 the spark plugs. Tighten to 30 Nm .
Installing the intake pipe for the coolant pump
Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.
2001 Volvo V40
NOTE: Apply thread sealant 116 156 to the screw threads.
Fig. 217: Installing Camshaft Covers

Install camshaft adjustment tool 9995452 at the rear of the camshafts. Check that the screws securing the
adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seal
2001 Volvo V40

Lubricate the surfaces of the seal that the camshaft rotates against.
Install the new seal for the camshaft with variable valve timing. Use drift 9995718 .
Install the new seal for the camshaft without variable valve timing. Use drift 9995719 .
Installing the camshaft timing gear pulley
Install the camshaft timing gear pulley. See Installing camshafts' timing gear pulleys.
Install the timing belt. See Installing the timing belt.
Tightening the timing gear pulley
See Tightening timing gear pulley.
Check
2001 Volvo V40
Fig. 219: Checking Indicator On Tensioner Moves Easily

2001 Volvo V40
2001 Volvo V40

Install the engine mounting screw and nut in the bodywork bracket. Tighten by hand.
Finishing
2001 Volvo V40

Tighten the engine mounting nut. Tighten to 98 Nm .
Install:

 the rear camshaft cover
 the trigger wheel. Tighten to 17 Nm
 the camshaft position (CMP) sensor housing. Tighten to 5 Nm
 the cable duct.
Installing the intake manifold
2001 Volvo V40

Remove:
1. the intake manifold. Use a new gasket. Tighten to 17 Nm

2. the vacuum hoses from the intake manifold according to the markings
3. the hose for the crankcase ventilation from the camshaft cover
4. the connectors from the assisted air control valve and the throttle position (TP) sensor
5. the dip stick pipe
6. the upper radiator hose together with the thermostat housing cover.
2001 Volvo V40

Install:
 the ignition coils and ignition cables according to earlier markings

 the connectors on the variable valve timing valve and ignition coils
 the ground lead for the ignition coils
 the camshaft position (CMP) sensor.
Place the cable duct and cable harness in position.
Install:
 the screws for the cable duct on the rear edge of the cylinder head and throttle body (TB) bracket.
 the bracket between the intake manifold and the power steering pump
 the connectors for the injectors
 the connector for the engine coolant temperature sensor
 the air preheating hose between the air cleaner (ACL) and the heat deflector plate for the exhaust
manifold
2001 Volvo V40
 the pipe screw for the water-heated crankcase ventilation

 the upper section of the air cleaner (ACL) housing and hose
 the EVAP hose connection to the mass air flow (MAF) sensor hose
 the connector for the mass air flow (MAF) sensor
 the turbocharger (TC) control valve on the air cleaner (ACL) housing
 the brake servo vacuum hose
 the throttle cable
 the inlet hose between the mass air flow (MAF) sensor and throttle body (TB)
 the front timing cover
 the cover over the ignition coils
 the cover over the throttle body (TB)
 the cover over the injectors.
Installing the fuel line
Fig. 225: Pressing Fuel Line Into Its Quick-Coupling On Fuel Rail
Press the fuel line into the quick-release connector on the fuel rail.
2001 Volvo V40
Installing the exhaust manifold
Install the manifold and turbocharger (TC) according to Exhaust manifold, replacing .
Assembling the exhaust system
Fig. 226: Installing Front Wheel

Install a new gasket where the front exhaust system and three-way catalytic converter (TWC) separate.
Lift up and align the front exhaust system against the manifold.
Install a new gasket and new nuts. Tighten.
Installing the starter motor
Install:
 the blind cover plug

 the starter motor
 the plastic charge air pipe for the turbocharger (TC)
 the support bracket for the intake manifold
2001 Volvo V40
 the connector for the oil pressure switch

 the lower hose for the charge air cooler (CAC)
 the right front wheel. See Installing the wheels
 the cable to the battery negative terminal. First read Note when disconnecting and connecting the
battery lead .
Checking work
Change the oil. Replace the oil filter. Top up the coolant.
Check:
 the engine oil level

 the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.
REPLACING TOOTHED (TIMING) BELT
Special tools:
9512661
9995433
9995006
9995383
9995460
NOTE: Service interval for timing belt and tensioner pulley: 165,000 km/105,000 miles .
Remove auxiliaries belt
2001 Volvo V40

 Remove the right engine compartment cover and the cover above the right headlight unit
 Release the auxiliaries belt by turning the pulley screw clockwise
 Remove the auxiliaries belt
 Release the belt tensioner (counterclockwise).
Remove upper timing gear covers
2001 Volvo V40

 Remove two screws and remove upper cover by undoing the two clips at the side
 Remove the screw and take the cover off.
Install lifting beam and lifting lug
2001 Volvo V40
Fig. 229: Installing Lifting Beam And Lifting Lug

NOTE: Remove the nut from the body support.
Position the lifting beam 9995006 centrally above the engine and install the lifting lugs 9995460 in the lifting
eyes.
Install the extra support 9995383 (if necessary).
Lift the engine up a few mm at the front.
Remove engine mounting on timing gear side
2001 Volvo V40

 Remove three bolts and the screw from the mounting at body side and pull out the mounting with the
rubber.
Remove lower timing gear cover
2001 Volvo V40
Fig. 231: Removing Lower Timing Gear Cover

 Undo bottom cover and move backwards.
Remove engine bracket
2001 Volvo V40
Fig. 232: Installing Engine Bracket

 Remove the four bolts and pull bracket from engine.
Lift engine if necessary.
Turn wheel to the right.
Open lid in side cover.
Align timing gear and crankshaft according to the markings
2001 Volvo V40
Place the upper cover in position.
Turn the crankshaft clockwise until the markings, camshaft gear, inner timing gear cover and the
crankshaft/gear wheel align with the oil pump housing.
Remove upper rear timing cover.
Remove timing belt at the top side
2001 Volvo V40
Fig. 234: Removing Timing Belt At Top Side

 Remove bolt (A) and take tensioner off

 Remove timing belt and move it downwards
 Clean and check the gears.
Check idler pulley
2001 Volvo V40
Fig. 235: Checking Idler Pulley

Rotate the pulley rapidly and listen for abnormal noise from the bearing.
When replacing: torque setting idler pulley 25 Nm .
Check that all pulley contact surfaces for the belt are clean and smooth.
Remove the engine splashguards
2001 Volvo V40

Remove:
 rear
 front.
Remove timing belt at lower side
2001 Volvo V40

 Remove the two bolts from the snow cap

 Remove the timing belt and take it out with a turning movement
 Clean surrounding.
Install timing belt at lower side
Place the timing belt between damper and engine block.
Route belt upwards.
Install cover plates
2001 Volvo V40

 Place the lower snow cover and fit the two bolts
 Place the front and rear engine splashguards.
Install new timing belt and tensioner pulley
2001 Volvo V40
Fig. 239: Installing Timing Belt And Tensioner Pulley

 Check timing marks

 Position the new tensioner, and finger tighten bolt (A)
 Turn excenter from tensioner in lowest position as shown.
 Route the belt around the crankshaft (1) and the idler pulley (2)
 Route the belt over both timing gears (3.4)
 Route the belt over the water pump (5) and around the tension pulley (6)
 Install upper rear timing cover on engine (do not tighten)
 Check alignment.
Adjusting timing belt tension
2001 Volvo V40
Fig. 240: Adjusting Timing Belt Tension

 Tighten bolt (B) to 3 Nm

 Place a 6 mm hex tool in the tensioner and turn tensioner anti clockwise until the toothed belt is
tensioned .
 Move the adjuster until the indicator pin is in the middle (A)
 Tighten the bolt (B) to 20 Nm without moving the tensioner.
 Re-adjust if necessary.
 Press pin (A) clockwise and anti-clockwise to check.
Check timing belt tension
2001 Volvo V40

 Rotate the crankshaft two revolutions and check that the markings on the crankshaft pulley and timing
gears align with the marks on the timing gear cover.
 Check the adjustment of the tensioner (indicator pin (A) in the middle)
 Adjust again if necessary, see Adjusting timing belt tension
NOTE: After adjustment always turn crankshaft twice.
 Remove upper timing cover.
Install engine bracket
2001 Volvo V40
Fig. 242: Installing Engine Bracket

Clean mounting pin, position bracket and install bolts. Tightening torque 35 Nm + 75° .
Install timing gear covers
2001 Volvo V40

Install:
 lower timing gear cover. Check lower cover and water hose fittings.
 the top cover (1x screw) (B), torque setting 10 Nm
 the top timing cover and tighten.
NOTE: Close lid in side cover move front wheels straight.
Install auxiliaries belt
2001 Volvo V40

 Clean the pulley grooves

 Turn the tensioning device clockwise
 Install the auxiliaries belt as shown.
 Release the belt tensioner (counterclockwise)
 Tighten the bracket. Torque to 10 Nm
 Install power steering hose. Torque 10 Nm .
Install engine suspension on timing gear side
2001 Volvo V40
Fig. 245: Installing Engine Suspension On Timing Gear Side

 Position the support on the engine and tighten the bolts (A) to 67 Nm
 Loosely install the bolts in the body support.
 Remove the lifting beam 9995006
 Tighten the body support (B) nut to 98 Nm .
Test drive engine
Start the engine and check function.
 Install the right engine compartment cover and headlight unit cover.
Special tools:
9512834
9992810
9995186
2001 Volvo V40
9995642
9995488
Place the hood in the service position
See Place hood in service position .
Engine assembly with transmission, installing
Fig. 246: Installing Engine Assembly With Transmission

Install lifting yoke 9992810 and lifting hooks 9995642 and 9995186 .
 Adjust the lifting yoke so that the engine is balanced

 Adjust the lifting hooks continuously throughout the lift
 Install the screw and the nut on the engine mounting on the timing side.
Manual transmissions: Installing the gear selector mechanism cables
2001 Volvo V40
Fig. 247: Installing Gear Selector Mechanism Cables (Manual Transmissions)

Check the gear selector mechanism cables.
Install:
 the mechanical cables using clips on the brackets

 the mechanical cables with washer and clips on the levers. Lubricate using grease 116 1241-3 .
Automatic transmission: Installing the gear selector mechanism cables
2001 Volvo V40
Fig. 248: Installing Gear Selector Mechanism Cables (Automatic Transmission)

Check the gear selector mechanism cables.
Install:
 The connectors and the mounting

 Ground lead
 Gear selector cables.
Engine mounting on transmission side, installing
2001 Volvo V40
Fig. 249: Installing Engine Mounting On Transmission Side

 Install the mounting on the transmission. Tighten to 45 Nm .
NOTE: Ensure that the rubber protectors are correctly positioned.
 Install the screw and the nut on the engine mounting in the body
 Remove the lifting equipment
 Tighten the screws for the engine mountings on the left and right-hand sides. Tighten to 98 Nm .
Return the hood to the normal position.
Hoses and wiring, routing and connecting
2001 Volvo V40
Fig. 250: Engine Hoses/Wiring, Routing And Connecting

Connect:
 The injectors. Secure the wiring

 The wiring for the ignition coil and the ground lead
 The cable mounting on the engine. Tighten the mounting. Tighten to 10 Nm
 The positive crankcase ventilation (PCV) valve.
 The throttle position (TP) sensor and the idle air control (IAC) valve.
Fuel hose, routing and connecting
2001 Volvo V40

Connect the fuel hose(s). Pull the hose(s) to check that they are secure.
Charge air hose from the turbocharger (TC), upper hose, installing
2001 Volvo V40
Fig. 252: Removing/Installing Hoses From Turbocharger (TC)

 Install the pipe and insert in the upper hose.

 Install the clamp. Connect to the engine via the intermediate pipe. Tighten the hose clamps.
Air conditioning (A/C) compressor on engine, installing
2001 Volvo V40
Fig. 253: Air Conditioning (A/C) Compressor On Engine, Installing

Install the air conditioning (A/C) compressor. Install the bracket on screw (B). Do not tighten the screw (B).
Tighten the other screws. Tighten to 25 Nm .
Connectors, connecting
2001 Volvo V40
Fig. 254: Connecting Generator (GEN), Sensor On A/C Compressor & Oil Pressure Sensor
Connect the connectors for:
 Generator (GEN)
 The sensor on the A/C compressor
 The oil pressure sensor.
Drive shaft right-hand in transmission, installing
2001 Volvo V40
Fig. 255: Drive Shaft Right-Hand In Transmission, Installing

Remove special tool 9995488 from the transmission.
Install the drive shaft in the transmission and the bearing.
Finger tighten the bearing cap.
Secure the wheel spindle on the spring strut. Install the screws and nuts.
Tighten the bearing cap screws. Tighten to 25 Nm .
Engine mounting rear, installing
2001 Volvo V40

Install the mounting. Tighten the 4 screws.
Tighten to 40 Nm .
Engine mounting front, installing
2001 Volvo V40
Fig. 257: Engine Mounting Front, Installing

Connect the inlet hose to the charge air cooler (CAC). Tighten the hose.
Secure the hose on the engine mounting. Tighten on the engine with three screws. Tighten to 50 Nm .
Tighten the nut for the clamp.
Tighten to 6 Nm .
Install the air conditioning (A/C) pipe in the engine mounting.
Front-rear member, installing
2001 Volvo V40
Fig. 258: Installing Front-Rear Member

Install heat shield.
Install the front-rear member. Insert the two screws (B) through the engine pads. Tighten the two screws.
Install the front and rear engine screws (A). Tighten the screws. Tighten to 69 Nm .
NOTE: Position the rubber elements in the correct positions as shown. The position of
the mounting points for the front-rear member must be the same at both the
front and the rear.
Slacken off the screw (B) for the front engine pad. First tighten the screw for the rear engine pad. (Tighten to 55
Nm .) Then tighten the screw for the front engine pad. (Tighten to 55 Nm .).
Front exhaust pipe on exhaust manifold, installing
2001 Volvo V40
Fig. 259: Installing Front Exhaust Pipe On Exhaust Manifold

Install a new gasket.
Tighten the nuts. Tighten to 25 Nm .
Automatic transmission: Installing the oil pipes
2001 Volvo V40
Fig. 260: Disconnecting/Installing Transmission Oil Pipes

Install the lower pipe. Use a new O-ring.
Install the upper pipe (the return line) with the mounting in the control system cover. Install the connection
loosely.
The pipe cap nut is tightened later.
Drive shaft left-hand side, installing
2001 Volvo V40
Fig. 261: Installing Drive Shaft Left-Hand Side

 Clean the drive shaft and the splines

 Remove special tool 9995488 from the transmission
 Remove the screw from the wheel spindle/spring strut.
 Insert the drive shaft into the transmission. Press the drive shaft in as far as it will go.
 Position the hub over the drive shaft splines. Install the nut.
 Install the two screws on the wheel spindle/spring strut.
Lateral strut, installing
2001 Volvo V40
Fig. 262: Removing/Installing Cross Stay Member

 Install the lateral strut. Use screws

 Tighten the screws. Tighten to 50 Nm .
Engine splash guards, installing
2001 Volvo V40
Fig. 263: Installing Engine Splash Guards

Install:
 Tighten the two screws on the wheel spindle/spring strut. Tighten to 90 Nm

 Secure the ABS lines in their mountings
 Install the brake hose in the mounting. Secure using a clamp.
Front wheel, installing
2001 Volvo V40
Fig. 264: Installing Front Wheel

 Install the wheels. Tighten the nuts slightly

 Then tighten crosswise. Tighten to 110 Nm .
 Torque tighten the wheel nuts one more time.
 Lower the car.
NOTE: When tightening using a pneumatic impact wrench, only use torque socket
9512834 .
NOTE: Tightening crosswise to the correct torque is important to prevent stresses in

the brake disc.
Tighten the center nut (A). Tighten to 120 Nm + 60° .
Wiring, installing
2001 Volvo V40
Fig. 265: Disconnect/Installing Battery Positive And Negative Leads

 The ground lead to the transmission

 The brake servo hose to the power brake booster
 The wiring for the starter motor
 The battery positive terminal
 Route the wiring
 Connect the connectors. Clamp the wiring into place.
Coolant hoses, installing
2001 Volvo V40
Fig. 266: Installing Coolant Hoses

 Install the expansion tank. Tighten the clamp.

 Tighten the cap nut on the oil cooler pipe connector on the transmission. Tighten to 30 Nm .
Heater hoses, installing
2001 Volvo V40
Fig. 267: Installing Heater Hoses

 Install and tighten the two heater hoses. Check that the hoses are correctly connected.
 Install the heat shield on the firewall.
Air cleaner (ACL), installing
See Installing the air cleaner (ACL) housing .
Battery, installing
2001 Volvo V40
Fig. 268: Battery And Shelf

 Install the battery shelf. Tighten to 16 Nm

 Install and secure the battery with the clamp.
NOTE: Cars with cruise control: The vacuum hose and vacuum motor wiring must
be connected before the battery shelf is screwed into place.
Throttle cable and the air intake hose on the throttle body (TB), securing
2001 Volvo V40
Fig. 269: Securing Throttle Cable And Air Intake Hose On Throttle Body (TB)
 Clean the air intake hose and the throttle body (TB)
 Install the hose. Tighten the clamp
NOTE: Ensure that the clamp never comes into contact with the throttle pulley in
the idling or wide open throttle (WOT) positions.
 Connect the idle hose to the idle air control (IAC) valve. Use a new hose clamp.
Power steering pump, installing
2001 Volvo V40
Fig. 270: Installing Power Steering Pump

 Install the power steering pump and the screws.

 Loosely install the support bracket between the generator (GEN) and the intake manifold. Install the
lower bracket.
 Tighten the screws. Tighten to 25 Nm .
 Secure the cable in the bracket.
 Tighten the support bracket between the generator (GEN) and the intake manifold. Tighten to 25 Nm .
 Tighten the lower screw on the support bracket. Tighten to 25 Nm .
Poly V-belts, installing
2001 Volvo V40

 Clean the belt pulley track

 Turn the belt tensioner unit clockwise
 Install the auxiliaries belt as shown.
 Release the belt tensioner equipment (counter-clockwise)
 Tighten the bracket. Tighten to 10 Nm
 Install the power steering hose. Tighten to 10 Nm .
Coolant, filling
See Filling with coolant
Install all covers.
Check the oil level in the automatic transmission. See Checking Oil Level .
Special tools:
2001 Volvo V40
9995452
9995199
NOTE: Since the graphics in this service information are used for different model years
NOTE: Crankshaft and camshafts must not be turned more than is stated in the method
description. If the shafts are turned in any other way the valves may be
damaged.
Preparations
Prepare the car according to Preparations.
Removing the variable valve timing (VVT) unit

Install camshaft adjustment tool 9995452 at the rear of the camshafts.
2001 Volvo V40
Remove:
 the plug at the front edge of the variable valve timing (VVT) unit (TORX 55).
 the center screw in the variable valve timing unit (TORX 55).
2001 Volvo V40
Remove:
 timing belt pulley's screws. Use counterhold 9995199 .

 the timing gear pulley
 tool 9995452 .
 the screw holding the inner timing cover to the cylinder head.
Timing belt pulley without VVT-unit: -Remove - Timing belt pulley, removing. - Remove 9995452 .
Install the adjustment tool.
Remove:

2001 Volvo V40
Remove the blind cover plug and the sealing washer.

2001 Volvo V40
Pump
Installing VVT-unit
2001 Volvo V40
Install the timing gear pulley using the center screw on the camshaft.
Ensure that the markings on the timing gear pulleys/upper timing cover correspond. Do not tighten.
Installing the timing gear pulley
2001 Volvo V40

Install:

 timing belt pulley without VVT on the camshaft. Use two screws positioned so that the markings on the
timing belt gears/upper timing gear cover match. Do not tighten.
2001 Volvo V40

2001 Volvo V40


approximately 20°C/67°F. At a higher temperature, for example with a warm
engine or a higher ambient temperature, the needle is further to the right.
The image shows the indicator position at different engine temperatures.
2001 Volvo V40
 The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft.
 Fix the belt tensioner center screw in position and turn the belt tensioner eccentric counter clockwise until
the tensioner indicator passes the marked position.
Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
 Hold the eccentric secure and tighten the center screw. Torque tighten to 20 Nm .
VVT unit/timing gear pulley, tightening
2001 Volvo V40
Fig. 282: Identifying VVT Unit/Timing Gear Pulley

Tighten the centre screw on the timing gear pulley with VVT. Tighten to 90 Nm .
Install the third screw on the timing belt pulley without VVT. Tighten with 20 Nm .
Check
2001 Volvo V40

 Press the belt to check that the indicator on the tensioner moves easily.
 Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond
Finishing
Reset the car. See Installing the timing covers.
IGNITION, ENGINE CONTROL (B4204T3 (CA) (US); 2001-2003)

See Ignition coil(s), replacement
2001 Volvo V40
See Replacing spark plugs
See Replacing the idle air control (IAC) valve
See Replacing the mass air flow (MAF) sensor
See Replacing the turbocharger (TC) control valve
See Replacing the variable valve timing (VVT) control valve
See Replacing the variable valve timing solenoid
ENGINE MECHANICAL (B4204T3 (CA) (US); 2001-2003)

See Camshaft seals, replacing
See Crankshaft seal rear, replacing
See Cylinder head/gasket, replacing
See Replace the engine mountings
2001 Volvo V40
See Replacing the oil pump and front crankshaft seal
See Replacing the timing belt
IGNITION, ENGINE CONTROL (B4204T4; 2003-2004)

See Ignition coil(s), replacement
See Replacing spark plugs
See Replacing the idle air control (IAC) valve
See Replacing the mass air flow (MAF) sensor
See Replacing the turbocharger (TC) control valve
See Replacing the variable valve timing (VVT) control valve
2001 Volvo V40
See Replacing the variable valve timing solenoid
ENGINE MECHANICAL (B4204T4; 2003-2004)

See Camshaft seals, replacing
See Crankshaft seal rear, replacing
See Cylinder head/gasket, replacing
See Replace the engine mountings
See Replacing the oil pump and front crankshaft seal
See Replacing the timing belt
2001 Volvo V40
OIL PAN (B4204T2 CVVT; 2000)

REPLACE THE OIL PAN
Special tools:
9511205
Preparations
Remove the oil dip stick and pipe. Raise the car.
Drain the engine oil. See Engine oil, draining .
Remove the support brace between the control arms.
Removing the front-rear member

Remove:
 the front and rear splash guards under the engine
2001 Volvo V40
 the heat deflector plate in front of the output shaft

 the nuts from the engine mountings at the front and rear edges
 four screws (two long and two short)
 the two screws from the engine mountings. Remove the front-rear member.
Removing the oil cooler
Fig. 285: Oil Cooler Screws

Applies to 98- model year only
Remove the four screws from the oil cooler.
Detach the oil cooler from the oil pan. Leave the oil cooler hanging from the coolant hoses.
Removing the oil pan
Slacken off all the screws holding the oil pan.
Remove all but four screws. It is recommended that the four screws in the corners of the pan are left in place.
Carefully tap the oil pan until the joint and its liquid gasket releases. Use a rubber mallet.
2001 Volvo V40
Remove:
 the four remaining screws

 the oil pan.
Cleaning
Clean the gasket surfaces on the oil pan and cylinder block. Use a razor blade or a gasket scraper and gasket
solvent 116 1440 .
WARNING: Use a fume hood or extractor when using gasket solvent.
Installing the oil pan
Fig. 286: Applying Liquid Gasket To Oil Pan

Apply liquid gasket 116 1059-9 to the oil pan. Use roller 9511205 .
Install:
 new O-rings
2001 Volvo V40
 the oil pan. Secure the oil pan loosely using a few screws
 remaining screws.
Fig. 287: Pressing Oil Pan Against Transmission

Press the oil pan against the transmission. Tighten the screws (1), (2), (3) and (4). Tighten to 3 Nm . Tighten the
screws (5). First tighten to 25 Nm . Then tighten to 48 Nm . Tighten all screws in the oil pan joint. Tighten to
17 Nm . Start at the transmission and continue forwards in pairs.
Applies to 98- model year only
Connect the oil cooler to the oil pan. Use four screws. Tighten to 17 Nm . Use new O-rings.
Installing the front-rear member
2001 Volvo V40

Install the front-rear member on the front engine mounting.
Press the engine forward. Secure the front-rear member on the rear engine mounting.
Install the front-rear member to the body. Use four screws. Tighten to 69 Nm .
Tighten the screws in the engine mountings. Tighten to 55 Nm .
Install:
 the heat deflector plate in front of the output shaft. Tighten to 10 Nm

 the support strut between the suspension turrets. Tighten to 55 Nm .
Install new oil filter. See:
 model year -97 , Installing the oil filter, model year -97
 model year 98- , Installing the oil filter, model year 98- .
Install:
2001 Volvo V40
 the oil plug with a new gasket. Tighten to 35 Nm

 dip stick with pipe. Use a new O-ring.
NOTE: Check that the O-ring is correctly positioned.
Fill with engine oil. Run the engine to operating temperature.
Check for oil leaks from the oil pan or oil cooler.
Install the front and rear splash guards under the engine.
Check the oil level. Top up as necessary.
Replacing the oil and oil filter
Special tools:
9995458
9995679
Warning
WARNING: Avoid prolonged skin exposure to oil.
 Extended and repeated contact with oil can cause skin to dry out. This can result in itchiness, dry skin,
eczema and other skin complaints.
 Used oil is more dangerous than new oil
 Used oil may contain contaminants that are a health risk
 Avoid skin contact, especially with engine oil
 Use protective gloves if necessary.
 Avoid oil soaked rags and cloths
 Wash thoroughly after skin contact with oil, especially before meals
 Use a skin cream to prevent the skin drying.
Draining engine oil
 Remove the drain plug

 Replace the copper washer
 Install the drain plug and tighten to 35 Nm .
Removing the oil filter, model year -97
2001 Volvo V40
Fig. 289: Removing Oil Filter, Model Year -97

Remove the rear engine splashguard
Use oil filter wrench 9995458 .
Wipe up any spilled oil (use kitchen paper for example).
Clean the engine contact surface.
Removing the oil filter, model year 98-
2001 Volvo V40
Fig. 290: Installing Oil Filter, Model Year 98-

Remove the rear engine splashguard.
Use oil filter wrench 9995679 .
Wipe up any spilled oil (use kitchen paper for example).
Remove the oil filter from the housing.
Clean the housing and the engine.
Installing the oil filter, model year -97
2001 Volvo V40
Fig. 291: Installing Oil Filter, Model Year -97

Brush oil on the gasket.
Screw the filter on by hand until the gasket touches the gasket surface. Tighten a further 1/2-3/4 turn.
Fill oil.
Install the rear engine splash cover.
Installing the oil filter, model year 98-
2001 Volvo V40
Fig. 292: Installing Oil Filter, Model Year 98-

Install the filter in the housing.
Install the housing on the oil sump. Use oil filter wrench 9995679 .
Tighten with 25 Nm .
Install the engine splash cover.
Filling with oil
Top up oil. See Lubricants, engine .
Start the engine and check for leakage.
Stop the engine and give the oil time to run down into the sump. Then check the oil level. Top up if so required,
but do not overfill.
Wipe the engine compartment clean. Make sure that the steering wheel and gear lever are clean.
OIL PAN (B4204T3 (CA) (US); 2001-2003)
2001 Volvo V40
REPLACE THE OIL PAN
See Replace the oil pan
OIL PAN (B4204T4; 2003-2004)

REPLACE THE OIL PAN
See Replace the oil pan
REPLACING DUAL MASS FLYWHEEL (B4204T2 CVVT; 2000)

REPLACING THE DUAL MASS FLYWHEEL
Special tools:
9995112
9995678
Preparatory work
 To remove the transmission from turbocharged engines, see Removing . For engine B4204S2, see
Removing the transmission .
 Remove clutch driven plate B4204S2, see Removal .
Removing the flywheel

 Remove the engine speed (RPM) sensor assembly with the bracket.
 Turbocharged engines: to replace the oil seal for the crankshaft, see Replacing rearmost
2001 Volvo V40
crankshaft retaining ring.

 B4204S2 engines: to replace the oil seal for the crankshaft, see Crankshaft seal rear, replacing.
 Slacken off the 10 screws for the flywheel crosswise. Lift out the flywheel.
 Check the rear oil seal on the crankshaft for leakage. Clean if necessary.
Installing the flywheel
Fig. 294: Three Flywheel Studs

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
2001 Volvo V40
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° .
 Install the engine speed (RPM) sensor assembly with the bracket. Tighten the screws to 10 Nm .
Reinstall the transmission
NOTE: To install the transmission on turbocharged engines, see Installing . For engine
B4204S2, see Transmission, installing .
Test driving and checking
 Clean and check that everything is in position.

 Start the car. Check first with the gear in neutral.
 Rapidly depress and release the clutch a couple of times.
Then test drive car without putting any pressure on the clutch at first.
Once the engine has reached operating temperature and the clutch feels normal, try a few test starts with rapid
gear changes.
There should be no jerking or vibrations.
CAUTION: Inform the customer that a new flywheel has been installed.
Crankshaft seal rear, replacing
Special tools:
9995112
9995651
9991801
9995678
9997174
9512050
2001 Volvo V40
and/or models, some variation may occur. However, the essential information is
always correct.
Removing the flywheel and carrier plate

Remove the gearbox:
 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
2001 Volvo V40
Fig. 296: Identifying Old Seal And Special Tool Extractor 9995651
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.
2001 Volvo V40
Fig. 297: Cleaning Around Crankshaft Flange

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.
2001 Volvo V40
Fig. 298: Identifying Sealing Ring

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. 299: Three Flywheel Studs

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
2001 Volvo V40
 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.

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 3x special screws with new standard screws. Tighten crosswise to 45 Nm .
 Then angle-tighten all 10x 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:
 See Removing/installing the transmission .
Checking the engine:
Test drive the car to check the function of the engine and the gearbox.
2001 Volvo V40
Checking/replacing the clutch driven plate and self-adjusting clutch
Special tools:
9995112
9995662
9995663
9995677
NOTE: Remove the transmission from turbocharged engines, see Removing . For
engine B4204S2, see Removing the transmission .
Removal
Block the flywheel
Fig. 301: Blocking The Flywheel Using Gear Sector 999 5112
Align gear sector 9995112 .
Set the clutch automatic adjustment
Use counterhold 9995677 .
Align the counterhold. See Aligning the counterhold for automatic clutch adjustment.
Aligning the counterhold for automatic clutch adjustment
2001 Volvo V40
Fig. 302: Aligning Counterhold For Automatic Clutch Adjustment

The three pins on the counterhold lock the automatic adjustment.
Position the tool as shown.
Ensure that all the three pins as shown enter the groove in front of the tension springs for the automatic adjuster.
Press the ring against the pressure plate. Pull out the counterhold springs. Secure the three hooks in the center
holes of the outer edge. See Removal .
Installing the compression tool
2001 Volvo V40
Fig. 303: Compression Tool 9995662 Installed

Install compression tool 9995662 , together with the conversion kit on the clutch.
Ensure that the hooks engage correctly. Ensure that the hooks do not trap the adjuster springs.
Center the compression tool.
Screw in the compression tool, at the same time checking that the tool hooks are in place.
Compress the clutch so that the automatic adjuster is not under load.
If the clutch is worn, turn the counterhold for automatic adjustment to the original position marking. The
marking consists of two stamped arrows.
Then continue to screw in the compression tool until the diaphragm spring has pressed the pressure plate to a
free position.
A click can be heard when the clutch pressure plate snaps out.
Removing the clutch and the clutch driven plate
Relieve the load from the diaphragm spring
2001 Volvo V40
Fig. 304: Identifying Clutch Diaphragm Spring

NOTE: Do not allow the diaphragm spring to be under load for a long period of time.
Remove the load as soon as possible. Leave the compression tool in position.
NOTE: Keep fingers away from the three clutch rivets when relieving a load or
removing the compression tool. There is a risk of clamping injuries.
Checking the clutch
Fig. 305: Identifying Clutch

Leave the compression tool and fixing ring on the clutch if the clutch is to be reinstalled.
Wipe the clutch with a dry cloth.
Check carefully for damage through over heating, cracks, scoring or other damage to the friction surface.
2001 Volvo V40
Check that spring is not damaged or broken.
Check the pressure plate for out-of-true
Fig. 306: Checking Pressure Plate For Out-Of-True

Wipe the pressure plate friction area clean.
Check any out-of-true carefully. Use a ruler and a feeler gauge. Out-of-true is permitted in one direction only.
Out-of-true must not exceed 0.2 mm . If out-of-true is greater, replace the clutch.
The clutch must be replaced as a complete unit.
Checking the clutch driven plate
Fig. 307: Checking Clutch Driven Plate

Wipe off clutch driven plate using a dry cloth. The cloth must be free of oil and contaminants.
2001 Volvo V40
Check the clutch carefully for signs of wear, damage through overheating, cracking or other damage.
NOTE: The clutch driven plate must always be replaced if there are radial ripples on the
friction coating. The clutch driven plate must also be changed if there is oil or
grease on it.
Check that there are no cracks or large scratches on the flywheel

Replace the flywheel according to Replacing the dual mass flywheel.
Installation
Install the clutch driven plate centering tool
Fig. 309: Centering Tool Installed On Clutch Driven Plate

Use centering tool 9995663 . The conversion kit is included.
2001 Volvo V40
Remove the cone from the centering tool.
Install the centering tool in the flywheel center as far in as possible.
Use a ring spanner as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.
Ensure by touch that the centering tool is secured in the crankshaft.
Clutch driven plate, installing
Fig. 310: Clutch Driven Plate

CAUTION: Turn the slightly longer section of the clutch driven plate hub in, towards
the flywheel. There is a marking on the clutch driven plate .
Install the cone on the centering tool. Tighten the cone by hand . Secure the clutch driven plate.
NOTE: Tightening tools must not be used on the cone or damage may be caused to the
clutch driven plate.
Install the tools on the clutch
2001 Volvo V40
Fig. 311: Identifying Clutch Diaphragm Spring

Install counterhold 9995677 . See Aligning the counterhold for automatic clutch adjustment.
Install compression tool 9995662 . See Installing the compression tool.
First tighten the center screw on the compression tool to contact, then compress the clutch.
NOTE: When the center screw comes into contact with the diaphragm spring, the
screw should, for a loose clutch, be tightened 4.5 - 5 turns or until a clear click
is heard .
Installing the clutch
Fig. 312: Clutch Automatic Adjustment Using Counterhold 9995677

Check that the clutch automatic adjustment is secured with counterhold: 9995677 .
Install the clutch and locate on the guide pins. The compression tool center screw is hollow so that it can be
2001 Volvo V40
threaded onto the centering drift.
Check that the clutch is in contact with the flywheel all around its circumference.
Carefully tighten the six screws crosswise so that the clutch is guided up onto the guide pins and is in contact all
around the circumference of the flywheel.
Tighten the screws crosswise to 25 Nm .
Remove the tools
Fig. 313: Clutch Assembly

Screw out the center screw. Remove the compression tool.
NOTE: Keep fingers away from the three clutch rivets when relieving a load or
removing the compression tool. There is a risk of clamping injuries.
Remove the clutch driven plate centering cone.
Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a
rubber mallet so that the threads are not damaged. Remove the centering tool.
Remove the hooks. Remove the counterhold.
Remove the flywheel gear sector.
NOTE: To install the transmission on turbocharged engines, see Transmission,

installing . For engine B4204S2, see Transmission, installing .
REPLACING DUAL MASS FLYWHEEL (B4204T3 (CA) (US); 2001-2003)
2001 Volvo V40
See Replacing the dual mass flywheel
REPLACING DUAL MASS FLYWHEEL (B4204T4; 2003-2004)

See Replacing the dual mass flywheel
REPLACING PISTON COOLING VALVES (B4204T2 CVVT; 2000)

REPLACING PISTON COOLING VALVES
Removing the timing belt and mechanical timing belt tensioner
Remove the timing belt according to Remove timing belt at the top side.
Remove the timing belt tensioner. Remove the idler pulley. Remove the screw securing the inner timing cover
to the cylinder head.
Raise the car.
Remove the vibration damper.
Removing components
2001 Volvo V40
Fig. 314: Identifying Piston Cooling Valve And Inner Timing Cover Screws
Remove:
 the two screws (1) securing the inner timing cover to the cylinder block
 the lower belt guard at the oil pump housing.
Press the inner timing cover off the flange around the coolant pump. Start at the lower edge of the pump.
Hold the cover out of the way. Remove the piston cooling valve (2) and the seal washer.
2001 Volvo V40
Fig. 315: Identifying Piston Cooling Valve And Inner Timing Cover Screws
Install:
 a new piston cooling valve (2) with a new seal washer. Tighten to 35 Nm
 the inner timing cover. First press the cover into place over the flange at the top of the coolant pump.
Then press the remaining section of the cover into place over the flange around the pump. Check that the
cover is correctly positioned
 the two screws (1) securing the inner timing cover to the cylinder block
 the lower belt guard.
Install:
 the screw securing the inner timing cover to the cylinder head
 idler pulley. Tighten to 25 Nm
 the timing belt tensioner. Screw in the center screw by hand. Ensure that the fork on the tensioner centers
above the cylinder block rib. Check that the Allen hole on the eccentric is at "10 O'CLOCK"
 the vibration damper.
2001 Volvo V40
Install the timing belt according to Installing the timing belt.
REPLACING PISTON COOLING VALVES (B4204T3 (CA) (US); 2001-2003)

See Replacing piston cooling valves
REPLACING PISTON COOLING VALVES (B4204T4; 2003-2004)

See Replacing piston cooling valves

Ignition, Engine Control (b4204t2 CVVT 2000)

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Ignition, Engine Control (b4204t2 CVVT 2000)

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What are the steps to remove and replace ignition coils?

What are the steps to remove and replace ignition coils?

What are the steps to remove and replace spark plugs?

What are the steps to remove and replace spark plugs?

2001 Volvo V40

ENGINE Engine - Removal, Replacement & Installation

Engine - Removal, Replacement & Installation

IGNITION, ENGINE CONTROL (B4204T2 CVVT; 2000)

Removing the ignition coil(s)

Fig. 1: Removing Spark Plugs

 Remove both engine covers.

martes, 20 de febrero de 2018 05:25:01

Installing the rubber and spring from the ignition coil

Fig. 2: Installing Rubber And Spring From Ignition Coil

Check and clean the spark plug if necessary.

Clean the ignition coil.

Installing the ignition coil(s)

Fig. 3: Ignition Coil Connectors

 Check the rubber and spring inside. Replace if necessary.

 Check the function.

REPLACING SPARK PLUGS

Fig. 4: Removing Spark Plugs

 Remove both engine covers.

Fig. 5: Ignition Coil Connectors

 Check the rubber and the spring inside. Replace if necessary.

Tightening torque 25 Nm . Use special tool 9995702 .

 Check the function.

REPLACING THE IDLE AIR CONTROL (IAC) VALVE

Fig. 6: Removing/Installing Idle Air Control (IAC) Valve

 the cover over the throttle cable.

Fig. 7: Removing/Installing Idle Air Control (IAC) Valve

Always use a new gasket.

REPLACING THE MASS AIR FLOW (MAF) SENSOR

Fig. 8: Replacing/Installing Mass Air Flow (MAF) Sensor

 Install a new O-ring.

REPLACING THE TURBOCHARGER (TC) CONTROL VALVE

Fig. 9: Removing/Installing Turbocharger (TC) Control Valve

NOTE: Note how the hoses are connected.

 The hoses in their original positions. The clamps.

3. White (to the by-pass valve)

REPLACING THE VARIABLE VALVE TIMING (VVT) CONTROL VALVE

Fig. 10: Removing Upper Timing Cover

 the upper timing cover.

Remove the valve housing assembly

Fig. 11: Removing/Installing Valve Housing Assembly

Install the valve housing assembly

Fig. 12: Removing/Installing Valve Housing Assembly

REPLACING THE VARIABLE VALVE TIMING SOLENOID

Remove the cover from the timing gear

See Removing the cover on top of the engine.

Removing the variable valve timing system

Fig. 13: Removing Connector And Wiring Beside Connector

 Remove the connector and the wiring beside the connector

Install the variable valve timing system

Fig. 14: Installing Variable Valve Timing System

 Wipe up any spilled oil. Clean the mating surfaces

Install the cover on the timing gear

See Installing the cover on top of the engine.

Start the engine. Check for leakage.