Genuine Volvo S40 Valve Cover

Volvo S40 Valve Cover Parts and Q&A

• Valve Cover
  9207618
  Q: How to remove and refit the valve cover that is integral with the intake manifold for 2.0 litre 4-cylinder diesel engine on Volvo S40?

  A:

  To remove the cylinder head cover, which is integral with the intake manifold, start by taking off the plastic cover from the top of the engine. Release the clips to detach the wiring harness and fuel pipes from the timing belt upper cover. Next, undo the bolt to remove the wiring bracket from the right-hand rear corner of the cylinder head, and also undo the bolt to take off the pipe support bracket in front of the brake vacuum pump. Disconnect the wiring plug, undo the retaining bolt, and remove the camshaft position sensor from the right-hand end of the cylinder head cover. Then, undo the bolts, slacken the nut, and remove the timing belt upper cover. Disconnect the injectors' wiring plugs, detach the harness duct from the intake manifold/cover, and position it aside. Disconnect the crankcase ventilation hoses from the intake manifold/cover, release the clamp, and disconnect the EGR pipe from the intake manifold, also sliding out the clip to disconnect the breather hose from the rear of the cylinder head cover. Release the glow plugs' wiring harness from the clips on the manifold, undo the screws to disconnect the intake hose from the intake manifold, and unclip the fuel temperature sensor located on the underside of the intake manifold. Undo the retaining bolts for the manifold/cover in reverse order and discard the gaskets, as new ones must be fitted. For refitting, clean the sealing surfaces of the manifold/cover and the head, fit the new seals to the intake manifold/cover, and then attach it to the cylinder head, using a little petroleum jelly on the manifold O-rings to ease assembly. Tighten the bolts to the specified torque in sequence, and ensure that all fasteners are tightened to their specified torque where applicable. The camshaft position sensor must be refitted correctly to ensure proper functionality.