S40/V40
1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
5. Transmission
5.1. General information
5.2. Technical characteristics
5.3. Design, check and replacement of coupling
5.4. Filling and pumping of hydraulic system of coupling
5.5. Adjustment of a pedal of coupling
5.6. Replacement of the working cylinder of coupling
5.7. Design and replacement of elements of the transmission
5.7.1. Device and operation of the transmission
5.7.2. Removal of the transmission
5.7.3. Installation of the transmission
5.7.4. Replacement of an epiploon of a main shaft on the removed transmission
5.7.5. Replacement of an epiploon of the right half shaft of KP
5.8. Gear shifting mechanism
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
12. Schemes of electric equipment
 



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5-7-3-ustanovka-korobki-peredach.html

5.7.3. Installation of the transmission

       PREVENTION
According to the identification plate be convinced that the new transmission of the same type, as old.

For the KP installation it is necessary to execute:
a) preparatory operations:

Fig. 5.33. Installation of a support under the transmission


— install the transmission on a support 999 5979 in assembly situation and fix by arms (see fig. 5.33);
— apply a small amount of jellied lubricant 1161246-2 on vents of a main shaft;
— apply lubricant 1161035-9 on vents (the right half shaft) on the transmission;
— move up the transmission to the engine so that the shaft entered vents of the conducted clutch plate and establish the right half shaft on vents;
b) attach the transmission to the engine:

Fig. 5.35. Bolts of fastening of KP to the engine (two bolts are not shown)


— put and tighten four fixing bolts (fig. 5.35) the moment of an inhaling of 50 N · m;
— remove a support 999 5972;
c) connect a transmission support to a body:

Fig. 5.24. Bolts of fastening of the left mudguard (are shown by shooters)


— mount a transmission support by means of three bolts (fig. 5.24);
— adjust position of the engine by means of the lifting device and establish a bolt in a support on a body;
— put three bolts and tighten the moment 45 N · m;
— lower the engine so that the lifting beam ceased to hold it;

       NOTE
You watch to damaging a tube of hydraulic system of coupling.

— wrap a bolt from a body, tighten the moment 98 N · m;
— exempt the engine from the lifting device;

Fig. 5.20. Bolts of fastening of KP (are specified by shooters)


d) establish bolts of fastening of the transmission from above and tighten their moment 50 N · m (fig. 5.20);

Fig. 5.19. Bolts of fastening of a starter (are shown by shooters)


e) establish a starter on the place and put three fixing bolts (fig. 5.19) and tighten their moment 50 N · m;
— lift the car;
— remove protection from a trekhshipovik and take out a cap from a transmission opening;
— turn a steering wheel against the stop to the right;
— carefully establish the left half shaft in differential (see fig. 5.33);
— turn a steering wheel against the stop to the left and install the lower bolt in the shock-absorber/fastener of a rotary fist;
— establish protective covers;
— put three bolts and tighten the moment 25 N · m;
g) attach a rotary fist to the shock-absorber:
— put the top bolt;
— tighten both bolts the moment of 90 N · m;
— install the pipeline of the brake system in an arm and record a bracket;
— fix an ABS system wire in arms;
— clear the socket and connect a backing lamp switch wire;

Fig. 5.25. A bolt of fastening of a mass wire to KP (it is shown by an arrow)


— connect a wire of connection with "mass" of the transmission (see fig. 5.25), having carefully cleared contact surfaces;
— fix a wire by the moment of 40 N · m;
h) install the right half shaft and a flexible shaft of a speedometer on the transmission;
— fill an opening under the fixing pins with sealant 1161058-1;
If the opening from the transmission is from below (the space basis between teeths) between two vents, then the corresponding opening has to be in a half shaft from above (top) and vice versa;
— establish two new lock pins in a half shaft;
— establish a new sealing ring on a flexible shaft of a speedometer and fix it;

Fig. 5.31. Detachment of the right half shaft:
1 — a mandrel


— with a force press a flexible shaft in the case and put a lock ring (see fig. 5.31);
— establish wheels;
i) establish a gear shifting bar;
— grease details of hinged connections with jellied Volvo 1161241-3 lubricant;
— check rubber elements;

Fig. 5.28. Fastening of a bar of gear shifting to KP: 1 — a bar; 2 — a bolt; 3 — a nut


— establish a bar of gear shifting on the place and insert a bolt (fig. 5.28) tighten a bolt the moment of 16 N · m;
j) establish the central longitudinal beam:

Fig. 5.27. Details of fastening of support of the engine and the central longitudinal beam (are shown by shooters)


— mount support on arms of the engine (fig. 5.27);
— put bolts in support and acquire them;
— put four bolts of fastening of a longitudinal beam to a body: in front — long bolts; behind — short bolts;
— tighten bolts the moments: four bolts of fastening of a beam of 69 N · m; two bolts of support of the engine of 52 N · m;
— at first tighten a back bolt, and then forward;

Fig. 5.26. Bolts of fastening of the heat-insulating screen (are shown by shooters)


— install the heat-insulating screen, and at first put a bolt And (fig. 5.26); then other two bolts, moment of an inhaling of 10 N · m;
k) fill in oil in the transmission:
— substitute a stopper of a jellied (control) opening;
— fill the transmission with oil 3345534-6 to the lower edge of a jellied opening;
— put a new sealing ring on a stopper of a jellied (control) opening;
— put and tighten a stopper of a filling (control) opening, the moment of 22 N · m;
l) establish engine mudguards:
— wrap three bolts of fastening of the left mudguard and tighten their moment 17 N · m (fig. 5.24);

Fig. 5.23. Removal of a forward mudguard of the engine


— establish a forward mudguard, fix it by bolts and screws the moment of 10 N · m (fig. 5.23);
— install the sensor of a flywheel and fix it by two screws, tighten screws the moment of 20 N · m;

Fig. 5.14. Fastening of the working cylinder of coupling: 1 — the union; 2 — bolts


m) install the working cylinder of coupling on the transmission (fig. 5.14):
— press the piston as it is possible more deeply in the cylinder;
— remove a collar from the coupling cylinder;
— insert a rod into a clutch release fork lever;
— put two bolts of fastening of the cylinder;
— tighten bolts the moment of 30 N · m;
— establish a tube with the Banzho union, tighten the union the moment of 25 N · m;

Fig. 5.18. Screws of fastening of the air filter (are shown by shooters)


o) install the air filter by rotary motion (fig. 5.18) and tighten their moment 10 N · m;
— check installation of an air inlet;

Fig. 5.13. Fastening of an inlet hose of the air filter: 1 and 3 — places of fastening of a hose of ventilation of a case of the engine; 2 and 6 — collars; 4 — the socket of the air sensor; 5 — a hose of the air pump; 7 — a hose of the air filter


— establish an inlet air hose (fig. 5.13).

       PREVENTION
You watch that the cam of a butterfly valve was not hooked for a collar.

— connect a hose and record two collars;
Establish a hose of preliminary heating.
o) establish:
— negative wire of the rechargeable battery; engine cover moment of an inhaling of 11 N · m;
p) start the engine and check coupling work.

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5.7.2. Removal of the transmission
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5.7.4. Replacement of an epiploon of a main shaft on the removed transmission