Cylinder Head Assembly: Service and Repair Replacing the Cylinder Head and Gasket

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 1 Cylinder Head Assembly: Service and Repair Replacing the Cylinder Head and Gasket Cylinder Head/Gasket, Replacing Special Tools: 999 5454, 951 2666, 999 5670, 999 5451, 951 2050, 951 2767, 999 5452, 999 5718, 999 5719, 999 5450 NOTE: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct. Preparation Disconnect the battery negative lead. Coolant, draining - Remove the front air baffle - 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 to the cylinder block. xhaust manifold, removing urbo US emove the exhaust manifold. tarter motor, removing emove: - 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. uel line, draining rain the fuel line. uel line, removing

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 2 Disconnect the quick-release connector between the fuel line and the fuel rail. Components, removing Remove: - the cover over the injector - the cover over the throttle body (TB) - the upper timing cover - the cover over the ignition coils - the front timing cover - the throttle cable from the bracket for the throttle body (TB). emove:

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 3 - 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 - the auxiliaries belt. able harness, exposing emove: - the screw from the ignition coil ground - the camshaft position (CMP) sensor. - 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. - the connector for the engine coolant temperature sensor - the injector connectors.

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 4 Place the cable duct and cable harness to one side. Mark up and remove the ignition coils and ignition cables. - the rear cover for the camshaft - the camshaft position (CMP) sensor housing - the trigger wheel. ntake manifold, removing Remove: - the upper radiator hose together with the cover for the thermostat housing - the screw holding the dip stick pipe to the intake manifold - the connectors from the assisted air control valve and the throttle position (TP) sensor - the hose for the crankcase ventilation from the camshaft cover - the vacuum hoses from the intake manifold, mark up the position - the bracket between the servo pump and intake manifold - the screws holding the intake manifold to the cylinder head - the intake manifold. iming gear pulley, removing - Remove the timing gear pulley. - Remove the engine mounting at the front of the cylinder head. oolant pump inlet pipe, releasing

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 5 - Remove the two screws at the coolant pipe connection to the bypass channel. - Carefully turn the pipe to remove it from the cylinder block. amshaft cover and cylinder head, removing - Remove: - the variable valve timing valve - the spark plugs from cylinders 1 and 4. - Install 2 tools 999 5454. 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.

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 6 - Use pliers 999 5670 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 999 5454 - 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 established. - 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

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 7 Remove: - the thermostat housing - all components which will be transferred to the new cylinder - gaskets. CAUTION: Do not damage the mating surfaces. Gasket face, cleaning Clean the gasket faces for: - the coolant bypass channel - the intake manifold - 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.

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 8 CAUTION: Do not use a metal scraper. Use a soft putty knife and gasket solvent 1161440-1 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. Cylinder head, installing NOTE: Ensure that there is no exhaust leakage. Aligning the crankshaft - Remove the blind cover plug. - Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position. - Install adjustment tool 999 5451. Ensure that the adjustment tool bottoms out against the cylinder block. - Turn the crankshaft back counter-clockwise until it stops against the drift. - Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump. hen replacing or working on the cylinder head nstall:

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 9 - the thermostat housing. Use a new gasket - the manifold. Use new gaskets. Lubricate the studs using paste 116 1408. CAUTION: Do not damage the mating surfaces. Cylinder head, installing - 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. - Use new screws. Lubricate and install all the screws. - Tighten the screws as shown in the below figure. Tighten the screws in the following order: 1. Tighten to 20 Nm 2. Tighten to 60 Nm 3. Angle-tighten 130 degrees. Use protractor 951 2050. alve lifters and camshafts, installing OTE: When installing a new cylinder head, the valve clearance must be set.

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 10 Lubricate the valve guide wells. Install all the valve lifters. NOTE: Make sure that the lifters are in the same position as before. If necessary, replace the valve lifter to obtain the correct valve clearance. - 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. - 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 951 2767. - 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. amshaft cover, installing

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 11 - Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters. - Install the camshaft cover. - Install 2 press tools 999 5454. - Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools. - Install all the screws. Tighten the screws from the middle and outwards. Tighten to 17 Nm. - Remove the press tools. - Install the spark plugs. Tighten to 30 Nm. oolant pump intake pipe, installing - Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket. NOTE: Apply thread sealant 116 1056 to the screw threads. - Install camshaft adjustment tool 999 5452 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. ront camshaft seal, installing

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 12 - Lubricate the surfaces of the seal that the camshaft rotates against. - Install the new seal for the camshaft without variable valve timing. Use drift 999 5719. - Install the new seal for the camshaft with variable valve timing. Use drift 999 5718. - Install the screw holding the inner timing cover to the cylinder head. amshaft timing gear pulley, installing nstall the camshaft timing gear pulley. nstalling engine mounting Position the engine mounting on the cylinder head. Screw the engine mounting into place on the cylinder head. Tighten to 35 Nm. Then angle-tighten 75 degrees in a single uninterrupted movement. ight engine mounting, installing

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 13 - Install the lower timing cover. - Screw the engine mounting into place on the engine. Tighten to 67 Nm. Install: - the screws on the bracket for the bodywork. The M10 screw. Tighten to 50 Nm - Install the upper timing cover. Finishing - Remove the lifting beam and lifting hook. Install: - the power steering reservoir - the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt - the auxiliaries belt - the rear camshaft cover. nstalling components nstall: - the trigger wheel. Tighten to 17 Nm - the camshaft position (CMP) sensor housing. Tighten to 5 Nm - the cable duct.

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 14 Intake manifold, installing Install: 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. Components, installing Install: - the ignition coils and ignition cables according to the earlier markings - the ground lead for the ignition coils - the camshaft position (CMP) sensor. Place the cable duct and cable harness in position. - 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

2002 Volvo V40 L4-1.9L Turbo VIN 29 B4204T3 Copyright 2009, ALLDATA 10.10 Page 15 - the connectors for the injectors - the connector for the engine coolant temperature (ECT) sensor - the air preheating hose between the air cleaner (ACL) and the heat deflector plate for the exhaust manifold - the auxiliaries belt - 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 upper timing cover - the cover over the throttle body (TB) - the cover over the injectors. Fuel line, installing Press the fuel line into the quick-release connector on the fuel rail. Exhaust manifold, installing Turbo US Install the exhaust manifold. Starter motor, Installing Install: - the blind cover plug - the starter motor - the plastic charge air pipe for the turbocharger (TC) - the support bracket for the intake manifold - the connector for the oil pressure switch - the lower hose for the charge air cooler (CAC) - the front air baffle - the right front wheel. - the cable to the battery negative terminal. hecking work Change the oil. Replace the oil filter. Top up the coolant. Check: - the engine oil level - the coolant level.