Genuine 2009 Volvo S40 Cylinder Head

2009 Volvo S40 Cylinder Head Parts and Q&A

• Q: How to remove and refit a cylinder head for 2.4 litre petrol engine on 2009 Volvo S40?

  A: To remove the cylinder head, first disconnect the battery negative lead and drain the engine coolant and remove the intake and exhaust manifolds. Then remove the camshafts and tappets, and the bolts that hold the engine mounting bracket to the right-hand end of the cylinder head/block, and the bolt for the timing belt rear cover, if applicable. Remove the earth lead(s) at the rear of the cylinder head, then slacken the clips to remove the radiator top hose and the expansion tank hose from the thermostat housing. Disconnect the coolant hose from the left-hand end of the cylinder head, and then slacken and remove the cylinder head bolts, noting that new bolts will be required for refitting. Carefully loosen and remove the cylinder head and set on wooden blocks to protect the valves, recovering the old head gasket, if the head is to be overhauled. For prep before refitting, make sure that the faces of the cylinder head and block are mating faces and are clean, (use a plastic scraper to remove any gasket and carbon, but be careful not to damage the aluminium alloy). Seal the water, oil and bolt holes in the cylinder block to stop carbon contamination as well as clean the pistons thoroughly. Inspect mating surfaces for damage, minor imperfections repaired with a file and check for warpage with a straight-edge. Ensure that the cylinder head bolt holes are clean and dry, using a tap or modified head bolt to clean them out if needed. For refitting, install a new head gasket on the cylinder block, making sure it's the proper way up, and then lower the head into place and lightly oil the threads of the new bolts. Tighten the bolts in the given order up to the Stage 1 torque and then the Stage 2 torque and finally up to the given angle for Stage 3 using an angle-tightening gage. Re-attach the coolant pipe flange using a new gasket, reconnect the radiator top hose and tighten the timing belt cover and rear earth lead. Reinstall the right hand engine mounting, camshaft and tappets without reconnecting the battery yet, followed by intake and exhaust manifolds and refill the engine cooling system.