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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volvo S40 / V40 (from 1996 to 2000, the year of issue)

general info. full specifications. diagnostics. hints. tips. tricks
Volvo S40 / V40
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Volvo
S40 / V40
General Information
Operation and maintenance of car
Design and specifications Engine
Engine repair
Removing the cylinder head
Installing the cylinder head
Removing and installing engine mounts
Removing Engine
Dismantling and assessment of the state of the engine parts
Assembly and engine installation
Transmission
Brakes
Front suspension and steering
Rear suspension
Engine Management System Fenix 5.1
Electric. Wiring and components
Body
Diagrams
 


Hit Counter by Digits


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Removing Engine



To remove the motor, do the following:
1) Remove the battery
2) Drain the engine cooling system;
3) remove the radiator, as follows:
- Disconnect the connector, remove the two bolts from the radiator fan shroud and remove elektrovenilyator engine cooling;

Places mounting the radiator pipes
Fig. 4.22. Places mounting the radiator pipes


- Disconnect the upper and lower pipes from the radiator (Fig. 4.22);
- Disconnect the two hoses from the surge tank;
- Disconnect the hose of an automatic transmission;
- Remove the four screws on the radiator;
- Remove the radiator;

Front desk with removed wheel
Fig. 4.23. Front desk with removed wheel


4) Remove both front wheels (Fig. 4.23);
5) on cars equipped with automatic transmission:
- Remove the ball joints from the steering gear mounts knuckles, brake pipe clamps, wire staples ABS;
- Remove the shock absorber bolts to the steering knuckle on both sides;

Removing the half-line
Fig. 4.24. Removing the half-line


- Remove the left axle shaft, use Remove the plug 999 5462 (Fig. 4.24);
- Remove the heat shield and the front exhaust pipe;
- Remove the mounting bolts of the engine in front and behind;
- Remove the engine support on the part of the distributor;
- Remove the lower beam of the engine;
- Disconnect the speedometer;
6) on vehicles equipped with manual transmission:
- Remove the oil pan Transmission;
- Drain the oil and put the drain plug with a new sealing ring;
- Remove the shield under the spar Transmission;
- Remove the three screws, remove the left axle and hang it on the stabilizer bar;
- Remove the spring clip from the flexible shaft and disconnect a cable of a speedometer;
- Remove the bolts gearbox and engine in front and behind;
- Remove the right axle (remove the locking pins) and hang it on the stabilizer bar;
- Remove the gear lever Transmission;
7) Lower the vehicle;
8) Remove the battery tray;

Places mounting air intake hose to the air filter and a temperature sensor (indicated by arrows)
Fig. 4.25. Places mounting air intake hose to the air filter and a temperature sensor (indicated by arrows)


9) disconnect the air intake hose from the air filter / air pump (Fig. 4.25);
10) Disconnect the inlet air temperature sensor;

NOTE
If the car is equipped with speed maintenance, disconnect the vacuum hose and the wires from the vacuum pump.


Places hose attachment (indicated by arrows)
Fig. 4.26. Places hose attachment (indicated by arrows)


11) Disconnect the inlet hose of the air valve (Fig. 4.26);
12) Disconnect the hose of the air valve of idling;
13) Disconnect the hose from the pump air supply to the inlet air hose;
14) disconnect the hose from the arrester inlet air hose;
15) disconnect a hose vent valve;
16) remove the hose pre-heating;
17) Remove the bolts of the air filter housing;
18) Lift the air filter and remove it;
19) Remove the throttle cable to the cam;
20) disconnect the two heater hoses and radiator hose on the side of the engine;

Brake servo
Fig. 4.27. Brake servo


21) disconnect the hose from the engine brake booster (Fig. 4.27);
22) disconnect the vacuum hose from the pump system EVAP;
23) remove an arm of a cable of a gear change;
24) on cars equipped with automatic transmission:
- Disconnect the connector;

Shift cable
Fig. 4.28. Shift cable


- Disconnect the shift cable from gearbox (Fig. 4.28);
- With pliers Seeger, or similar instrument, remove two oil cooler hoses from the transmission;
25) Remove the retaining bracket from the tube to the clutch slave cylinder;
26) Remove the clutch slave cylinder;
27) Remove the earth wire from the battery to the gearbox;
28) Remove the accessory drive belt;
29) Remove the five screws power steering pump and move the pump aside;
30) Remove the air conditioning compressor, for that:

Securing air conditioner compressor
Fig. 4.29. Securing air conditioner compressor


- Remove the wiring from the engine mount (Fig. 4.29);
- Remove the four screws on the air conditioning compressor;
- Remove the compressor and tilt it forward as far as possible;
- Remove the mounting pipe of the air conditioner above the support of the engine;
31) Remove the engine wiring harness;

Places harness attachment points
Fig. 4.30. Places harness attachment points: 1 - the gauge of pressure and oil temperature;
2 - air-conditioning compressor; 3 - the generator; 4 - temperature sensor; 5 - knock sensor; 6 - the air valve of idling; 7 - injectors; 8 - coil; 9 - the camshaft position sensor; 10 - the gauge of frequency of rotation of the crankshaft; 11 - automatic transmission;
12 - terminal "masses"; 13 - the throttle potentiometer


32) Disconnect all the connectors from the engine;

NOTE
Mark the position of the attachment points harness shown in Fig. 4.30.

33) disconnect the vacuum hose of the air pressure sensor;
34) disconnect the vacuum hose from the solenoid valve of the air pump;

Built from the positive battery terminal
Fig. 4.31. Built from the positive battery terminal


35) Disconnect the wires and the connector on the positive battery terminal (Fig. 4.31);
36) Remove the nut with a plastic holder wiring;
37) Remove the distributor;
38) Replace the nozzle holder 999 5533.
39) lift and place the side of the power distribution and fuel injectors;
40) disconnect the vacuum hose from the pressure regulator;
41) Remove the bracket from the power distribution of the fuel;
42) close the nozzle openings;

A WARNING
Do not damage the injector nozzles and spray needle.


Installation of lifting lugs 999 5185, 999 5186 and 999 2810 lifting beams
Fig. 4.32. Installation of lifting lugs 999 5185, 999 5186 and 999 2810 lifting beams


43) Install the lifting lugs 999 5185 and 999 5186 (Fig. 4.32);
44) Lift the engine to offload support;
45) remove the axle bolts of the engine mounts;
46) the air conditioning compressor put on a stretcher;
47) Remove the motor mount Transmission;
48) Remove the bolt on the engine side of the distributor;
49) Lift the motor using the lifting beams 999 in 2810;

NOTE
Pay close attention to the power unit has not touched the body or other equipment.

50) Remove the automatic transmission:
- Remove the bolts fastening the torque converter;
- Remove the bolts the engine / gearbox, remove the box;
51) Remove the manual gearbox:
- Remove the bolts of the engine / transmission;
- Carefully remove the gearbox, taking care that it is not hanging on a splined connection, remove the primary shaft of a check point and the clutch disc;
52) Remove the drive plate and flywheel for this:
- Use a serrated lock 999 5112 for fixing the flywheel from turning;
- Remove the bolts fastening the drive plate;
- Remove the drive plate;
- Remove the flywheel bolts;
- Remove the flywheel;
53) set the engine on the stand. Use a floor stand and retainer 999 2520 999 5297;
54) Remove the lifting equipment;
55), remove the engine from the gearbox:

Location of some equipment
Fig. 4.33. Location of some equipment: 1 - coolant hose;
2 - the gauge of frequency of rotation of the crankshaft;
3 - the ignition coil (2 pcs.) And spark plug wires; 4 - the camshaft position sensor; 5 - the lower radiator hose


- The ignition coil (2 pcs.) (Fig. 4.33) and the spark plug wires;
- The camshaft position sensor;
- The lower radiator hose;
- The coolant hose;
- Speed sensor crankshaft;
56), remove the engine from the exhaust manifold (Fig. 4.33):
- Lifting lugs;
- Heat shield plate and pre-heater;
- an exhaust manifold;
- The coolant tube;
- Securing the fuel;
- The right engine support.
57), remove the engine from the intake manifold:
- Bracket accessory and a generator;
- A temperature sensor;
- The inlet manifold, the knock sensor (torque 20 Nm);
- Oil catch tank and hose;
- The dipstick with a tube;
- starter;
- The front engine support.




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Removing and installing the rear engine mounts
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Dismantling and assessment of the state of the engine parts

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