Genuine Volvo S40 Intake Manifold

Volvo S40 Intake Manifold Parts and Q&A

• Intake Manifold
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  Q: How to remove the Intake Manifold and Valve Cover for 2.0 and 2.4 litre 5-cylinder diesel engine on Volvo S40?

  A:

  To remove the intake manifold, begin by removing the plastic cover on top of the engine, then remove the high pressure fuel pipes and fuel injectors, as the fuel pipes will have to be discarded as new ones will be needed for reinstallation. Next, remove the air inlet pipe in the front of the engine by loosening the clamps at both ends as well as that for the breather hose, and undo the bolt for the support bracket. After this, loosen the clamps and remove the air inlet hose from the bottom of the intake manifold and EGR assembly and the breather hose on the intake manifold. Proceed by undoing the three bolts and removing the oil filler neck and the wiring plug for the camshaft position sensor. Finally, undo the eighteen securing bolts, and very carefully pick the manifold off. For refitting: Reverse the removal procedure and make sure to leave the rubber sealing gasket in place at the bottom of the intake manifold and tighten the retaining nuts with the specified torque, beginning at the center and working outward.
• Intake Manifold
  31338645
  Q: What precautions should be observed before working on the Intake Manifold in the fuel system for petrol engines on Volvo S40?

  A:

  Prior to working on any component in the fuel system, take the precautions. For 1.8 and 2.0 litre models you should start by removing your electronic throttle module, having noted where the piece fits in before disconnecting the EVAP canister and brake servo vacuum hoses from the manifold. Unplug the wiring plug from the pressure sensor in the lower left-hand corner of the manifold. Undo the fuel rail mounting bolts and relocate the fuel rail and injectors out of the way, being sure to plug or cover the holes in the cylinder head to avoid contamination. Take out the two screws that hold the oil level dipstick tube in place, inspecting the condition of the O-ring seal at the base and renewing it if needed. The intake manifold is held by 7 bolts, one on the top and one on the bottom, undo these bolts and disconnect the vacuum hoses from the control valves on the intake manifold, and the crankcase breather hose then remove the intake manifold and dispose of the seals. It is better to change the actuator vacuum hose at the solenoid. For refitting, reverse the removal operations via use of a new manifold gasket and new seals and o-rings for injectors if needed, making sure that you find the manifold seals in the right position and tightening the bolts snugly. For 2.4 litre models, remove the fuel injectors first, then slacken the lower row of manifold retaining bolts, remove the top and outer bolts and then lift the manifold off position and disconnect the hose from the manifold and oil separator as it is withdrawn, discarding the gasket. Refitting is a process of reversing the disassembly, with new gaskets and seals as required, and tightening the fasteners back to their specified torque.