Genuine 2004 Volvo S40 Turbocharger

2004 Volvo S40 Turbocharger Parts and Q&A

• Q: How to remove the turbocharger on 2004 Volvo S40?

  A: To remove the turbocharger from models with 1.6 litre (80kw) engine, start by removing the catalytic converter, then remove the clamp at the throttle body, unbolt the turbocharger and remove the air outlet pipe. Next, unscrew the oil pressure pipe, disconnect the vacuum pipes and remove the bottom bolts that connect the turbocharger to the exhaust manifold. After that, remove the heatshield and the upper mounting bolt and nuts to release the turbocharger. For the 1.6 litre (85kw) engine, remove the particulate filter, and unbolt the air outlet pipe and the support bracket. Remove the dipstick guide tube, heatshield bracket and the heatshield above the exhaust manifold. Disconnect the air pipe from the cleaner housing to the turbocharger and disconnect the wiring plug and vacuum pipe from the actuator. Unscrew the oil pressure pipe, and remove the turbocharger by unbolting it from the exhaust manifold. For the 2.0 litre 5-cylinder engine start by removing the particulate filter and the air pipe at the front of the engine. Slacken various clamps and bolts, then raise the vehicle high and dry and remove the undershield on the engine. After that, disconnect the oil pressure pipe and the oil return pipe, and unbolt the turbocharger from the exhaust manifold. If there is a need for refitting, make sure that all the mating surfaces are clean and dry, replace all the O-rings, seals, and gaskets, tighten all the fasteners to the specified torque, and when starting the engine remove fuel pump relay and start the engine until the oil pressure light is off.