Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2000 Volvo S40FACTORY OEM SERVICE PROCEDURE
Engine - Inspection And Adjustment (644 Body)
- Checking And Adjusting Components (B4204T2 CVVT; 2000)
- Checking the canister purge (CP) valve
- Compression test
- Cylinder leakage test
- Pressurizing the fuel tank system, check
- Valve clearance, checking
- Valve Clearance, Setting/Adjusting
- Notes
- Preparation
- Removing the starter motor
- Removing components
- Exposing the cable harness
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Removing the camshaft cover and cylinder head
- Cleaning
- Preparations
- Installing the valve lifters and camshaft
- Installing the camshaft press
- Measuring the valve clearance
- Correcting the measured clearance
- When the correct valve clearance is reached
- Installing the valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the front camshaft seal
- Aligning the crankshaft
- Installing the camshaft timing gear pulley
- Installing the timing belt
- Tightening the timing gear pulley
- Check
- Installing the right engine mounting
- Finishing
- Installing components
- Installing the starter motor
- VVT-unit, replacing/adjusting
- Checking And Adjusting Components (B4204T3; 2004)
- Checking the canister purge (CP) valve
- Compression test
- Cylinder leakage test
- Pressurizing the fuel tank system, check
- Valve clearance, checking
- Valve clearance, setting/adjusting
- Notes
- Preparation
- Removing the starter motor
- Removing components
- Exposing the cable harness
- Installing the lifting beam and the lifting hook
- Removing the right-hand engine mounting
- Marking the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing the camshaft cover and valve lifters
- Cleaning
- Preparations
- Installing the camshaft and valve lifter
- Installing the camshaft press
- Checking the valve clearance
- Correcting measured clearance
- Measuring the correct valve clearance
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the front camshaft seal
- Aligning the crankshaft
- Installing the timing gear pulley for the camshafts
- Installing the timing belt
- Timing gear pulley, tightening
- Check
- Installing the right-hand engine mounting
- Finishing
- Installing components
- Installing the starter motor
- VVT-unit, replacing/adjusting
- Checking And Adjusting Components (B4204T3 (Ca) (Us); 2001)
- Checking the canister purge (CP) valve
- Compression test
- Cylinder leakage test
- Pressurizing the fuel tank system, check
- Valve clearance, checking
- Valve clearance, setting/adjusting
- Notes
- Preparation
- Removing the starter motor
- Removing components
- Exposing the cable harness
- Installing the lifting beam and the lifting hook
- Removing the right-hand engine mounting
- Marking the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing the camshaft cover and valve lifters
- Cleaning
- Preparations
- Installing the camshaft and valve lifter
- Installing the camshaft press
- Checking the valve clearance
- Correcting measured clearance
- Measuring the correct valve clearance
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the front camshaft seal
- Aligning the crankshaft
- Installing the timing gear pulley for the camshafts
- Installing the timing belt
- Timing gear pulley, tightening
- Check
- Installing the right-hand engine mounting
- Finishing
- Installing components
- Installing the starter motor
- VVT-unit, replacing/adjusting
- Checking And Adjusting Components (B4204T3 (Ca) (Us); 2003)
- Checking And Adjusting Components (B4204T4; 2003-2004)
- Crank Mechanism (2000-2004)
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.