Volvo Vehicle Models Volvo S40 1995-2004 Torque Specifications
Volvo Vehicle Models Volvo S40 1995-2004

Volvo Vehicle Models Volvo S40 1995-2004 Torque Specifications

Complete Volvo Vehicle Models Volvo S40 1995-2004 torque specifications guide. Includes factory-specified torque values, torque sequences, and technical specifications for all components including body, brakes, drivetrain, electrical, emissions sensors, fuel, exhaust, HVAC, and suspension. Essential information for proper assembly and maintenance.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

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Torque Calculator

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1.6l I4 Engine

Torque specifications for 1.6L-I4 Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.25
Torque Specification
1. 18 ft-lbs (25 N·m) 2. 90°
Important Notes
Follow the manufacturer's torque sequence for the cylinder head bolts. Failure to do so may result in head gasket failure.
2

Valve Cover Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the valve cover gasket is properly seated before tightening.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.5
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Follow the manufacturer's torque sequence for main bearing bolts. Improper torque can lead to crankshaft misalignment.
2

Connecting Rod Nuts

M8 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the connecting rod bearings are properly installed before tightening.

Timing System

1

Camshaft Sprocket Bolt

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the timing marks are aligned before tightening.
2

Timing Belt Tensioner Bolt

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the timing belt is properly tensioned before tightening.

Intake And Exhaust

1

Intake Manifold Bolts

M8 x 1.25
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Follow the manufacturer's torque sequence for intake manifold bolts.
2

Exhaust Manifold Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the exhaust manifold gasket is properly seated before tightening.

Accessories

1

Alternator Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the alternator is properly aligned before tightening.
2

Water Pump Bolts

M8 x 1.25
Torque Specification
11 ft-lbs (15 N·m)
Important Notes
Follow the manufacturer's torque sequence for water pump bolts.

1.8l I4 Engine

Torque specifications for 1.8L-I4 Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.25
Torque Specification
1. 18 ft-lbs (25 N·m) 2. 90°
Important Notes
Follow the manufacturer's specified torque sequence to ensure even clamping force.

Crankshaft Main Bearings

1

Main Bearing Bolts

M12 x 1.5
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Ensure the crankshaft is properly seated before tightening.

Connecting Rods

1

Connecting Rod Nuts

M8 x 1.0
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure proper alignment of the connecting rod caps before tightening.

Flywheel

1

Flywheel Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Use thread locker on the bolt threads as specified by the manufacturer.

Oil Pan

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.

Valve Cover

1

Valve Cover Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.

Timing System

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the tensioner is properly aligned before tightening.
2

Camshaft Sprocket Bolt

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the camshaft is properly aligned before tightening.

Crankshaft Pulley

1

Crankshaft Pulley/Harmonic Balancer Bolt

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Use thread locker on the bolt threads as specified by the manufacturer.

Intake Manifold

1

Intake Manifold Bolts

M8 x 1.25
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.

Exhaust Manifold

1

Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.

Fuel System

1

Fuel Rail Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuel rail is properly aligned before tightening.
2

Fuel Injector Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuel injectors are properly seated before tightening.

Ignition System

1

Spark Plugs

M14 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the spark plugs are properly seated before tightening.
2

Ignition Coil Bolt

M6 x 1.0
Torque Specification
8 ft-lbs (11 N·m)
Important Notes
Ensure the ignition coil is properly seated before tightening.

Cooling System

1

Water Pump Bolts

M6 x 1.0
Torque Specification
11 ft-lbs (15 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.
2

Thermostat Housing Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.

Accessory Drive

1

Serpentine/Accessory Drive Belt Tensioner Bolt

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the tensioner is properly aligned before tightening.
2

Drive Belt Idler Pulley Bolt

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the idler pulley is properly aligned before tightening.

Starter Motor

1

Starter Motor Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the starter motor is properly aligned before tightening.

Alternator

1

Alternator Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the alternator is properly aligned before tightening.

Oil System

1

Oil Filter Housing Bolt

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the oil filter housing is properly aligned before tightening.
2

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Use a new crush washer and ensure the sealing surface is clean.

Fuel Filter

1

Fuel Filter Bolt/Nut

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the fuel filter is properly aligned before tightening.

Power Steering Pump

1

Power Steering Pump Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the power steering pump is properly aligned before tightening.

2.0l Engine

Torque specifications for 2.0L Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.5
Torque Specification
1. 18 ft-lbs (25 N·m) 2. 90°
Important Notes
Follow the manufacturer's specified torque sequence for the cylinder head bolts.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.75
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Ensure the crankshaft is properly seated before tightening.
2

Connecting Rod Nuts

M8 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the connecting rods are properly aligned with the crankshaft.

Flywheel

1

Flywheel Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Use thread locker on the flywheel bolts.

Oil System

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.
2

Oil Filter Housing Bolt

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the O-ring is properly seated.
3

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Use a new crush washer.

Turbocharger

1

Turbocharger Mounting Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the turbocharger is properly aligned before tightening.
2

Turbocharger Oil Feed Line Bolts

M6 x 1.0
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the oil feed line is properly aligned.

2.0l I4 Engine

Torque specifications for 2.0L-I4 Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.25
Torque Specification
1. 18 ft-lbs (25 N·m) 2. 90°
Important Notes
Follow the manufacturer's specified torque sequence for proper sealing.
2

Valve Cover Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the valve cover gasket is properly seated before tightening.
3

Camshaft Sprocket Bolt

M8 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure proper alignment of the timing marks before tightening.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.5
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Follow the specified torque sequence to ensure proper alignment.
2

Connecting Rod Nuts

M8 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure proper alignment of the connecting rod caps.
3

Flywheel Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Use thread locker on flywheel bolts.

Oil System

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the oil pan gasket is properly seated before tightening.
2

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Replace the crush washer during installation.
3

Oil Filter Housing Bolt

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the oil filter housing gasket is properly seated.

Timing System

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper tension on the timing belt/chain before tightening.
2

Crankshaft Pulley/Harmonic Balancer Bolt

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Use a holding tool to prevent the crankshaft from rotating.

2.0l I4 Turbo Engine

Torque specifications for 2.0L-I4-TURBO Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.5
Torque Specification
1. 18 ft-lbs (25 N·m) 2. 90°
Important Notes
Follow the manufacturer's specified torque sequence for the cylinder head bolts.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.75
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Ensure the crankshaft is properly seated before tightening.
2

Connecting Rod Nuts

M8 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the connecting rods are properly aligned with the crankshaft.

Flywheel

1

Flywheel Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Use thread locker on the flywheel bolts.

Oil System

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Use a new gasket and ensure the sealing surface is clean.
2

Oil Filter Housing Bolt

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the O-ring is properly seated.
3

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Use a new crush washer.

Turbocharger

1

Turbocharger Mounting Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the turbocharger is properly aligned before tightening.
2

Turbocharger Oil Feed Line Bolts

M6 x 1.0
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the oil feed line is properly aligned.

Aw55 Transmission

Torque specifications for Aw55 Transmission

Transmission Mounting

1

Transmission Mounting Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure proper alignment of the transmission before tightening.
2

Transmission Bellhousing Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the bellhousing is properly aligned with the engine block.

Oil Pan

1

Transmission Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the oil pan gasket is properly seated before tightening.
2

Transmission Fluid Drain/Fill Plug

M12 x 1.5
Torque Specification
29 ft-lbs (39 N·m)
Important Notes
Ensure the plug threads are clean and undamaged before installation.

Drivetrain

1

Drive Axle/Half Shaft Bolts

M12 x 1.5
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the axle is properly seated in the transmission output shaft.
2

CV Joint/Axle Nut

M24 x 1.5
Torque Specification
184 ft-lbs (250 N·m)
Important Notes
Use a torque wrench capable of handling high torque values.
3

Propeller/Drive Shaft Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the drive shaft is properly aligned with the transmission.

Starter Motor

1

Starter Motor Mounting Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the starter motor is properly aligned with the transmission housing.

Torque Converter

1

Torque Converter Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the torque converter is properly seated in the flexplate.

Shift Linkage

1

Shift Linkage Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the shift linkage is properly aligned with the transmission.

Cooling System

1

Transmission Cooler Line Fittings

M12 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the cooler lines are properly aligned with the transmission fittings.

Valve Body

1

Transmission Valve Body Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the valve body is properly seated before tightening.

Body

Torque specifications for Body

Fuel System

1

Fuel Tank Strap Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure straps are evenly tensioned to avoid fuel tank damage.
2

Fuel Filler Neck Bolts

M6 x 1.0
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper alignment of the filler neck to prevent fuel leaks.

Electrical System

1

Battery Terminal Nuts

M6 x 1.0
Torque Specification
3 ft-lbs (4 N·m)
Important Notes
Avoid over-tightening to prevent damage to the battery terminals.

Seating System

1

Seat Mounting Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Critical for passenger safety. Ensure proper alignment and secure attachment.

Door System

1

Door Hinge Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper door alignment to prevent sagging or misalignment.

Hood System

1

Hood Hinge Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper hood alignment to prevent misalignment or rattling.

Trunk System

1

Trunk Lid Hinge Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper trunk alignment to prevent rattling or misalignment.

Exterior System

1

Bumper Mounting Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper bumper alignment for safety and aesthetics.
2

Roof Rack Mounting Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the roof rack is securely attached to handle intended loads.

Brakes

Torque specifications for Brakes

Brake Caliper

1

Brake Caliper Bolts

M10 x 1.25
Torque Specification
32 ft-lbs (43 N·m)
Important Notes
Ensure the caliper is properly aligned before torquing.
2

Brake Caliper Mounting Bracket Bolts

M12 x 1.5
Torque Specification
78 ft-lbs (106 N·m)
Important Notes
Ensure the bracket is securely seated against the steering knuckle or hub assembly.

Brake Disc Drum

1

Brake Disc/Drum Retaining Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the disc/drum is properly seated against the hub before torquing.

Brake Hydraulics

1

Brake Hose Banjo Bolt

M10 x 1.0
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the sealing washers are properly seated and not damaged.
2

Brake Master Cylinder Mounting Bolts

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the master cylinder is properly aligned with the brake booster.
3

Brake Booster Mounting Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the booster is properly seated against the firewall.

Brake Pedal

1

Brake Pedal Assembly Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the pedal assembly is properly aligned with the master cylinder pushrod.

Abs System

1

ABS Sensor Mounting Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the sensor is properly seated and aligned with the tone ring.

Wheel Assembly

1

Wheel Lug Nuts

M12 x 1.5
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Always use a torque wrench to ensure proper tightening. Over-tightening can damage the wheel or hub.

Drivetrain

Torque specifications for Drivetrain

Flywheel And Crankshaft

1

Flywheel Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure bolts are tightened in a star pattern to evenly distribute torque.
2

Crankshaft Pulley/Harmonic Balancer Bolt

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Use a holding tool to prevent the crankshaft from rotating during tightening.

Transmission

1

Transmission Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the transmission is properly aligned before tightening.
2

Transmission Oil Pan Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Over-tightening can damage the oil pan gasket.
3

Transmission Bellhousing Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the bellhousing is properly aligned with the engine block.

Driveshaft And Axles

1

Drive Axle/Half Shaft Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the axle is properly seated before tightening.
2

CV Joint/Axle Nut

M24 x 1.5
Torque Specification
184 ft-lbs (250 N·m)
Important Notes
Use a holding tool to prevent the axle from rotating during tightening.
3

Propeller/Drive Shaft Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the drive shaft is properly aligned before tightening.

Differential And Transfer Case

1

Differential Mounting Bolts

M12 x 1.5
Torque Specification
78 ft-lbs (106 N·m)
Important Notes
Ensure the differential is properly aligned before tightening.
2

Transfer Case Mounting Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the transfer case is properly aligned before tightening.
3

Differential Drain/Fill Plug

M12 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the plug is properly seated before tightening.
4

Transfer Case Drain/Fill Plug

M10 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the plug is properly seated before tightening.

Clutch

1

Clutch Pressure Plate Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the pressure plate is properly aligned before tightening.

Rear Axle

1

Rear Axle Hub Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the hub is properly seated before tightening.

Electrical

Torque specifications for Electrical

Ignition System

1

Ignition Coil Bolt

M6 x 1.0
Torque Specification
8 ft-lbs (11 N·m)
Important Notes
Ensure proper alignment of the ignition coil to prevent electrical arcing.

Starting System

1

Starter Motor Mounting Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the starter motor is properly aligned with the flywheel to prevent misalignment or vibration.

Charging System

1

Alternator Mounting Bolts

M10 x 1.5
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the alternator is properly aligned with the drive belt to prevent belt slippage.

Battery System

1

Battery Terminal Nuts

M6 x 1.0
Torque Specification
3 ft-lbs (4 N·m)
Important Notes
Ensure the battery terminals are clean and free of corrosion before tightening.

Fuel Delivery System

1

Fuel Pump Mounting Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the fuel pump is properly sealed to prevent fuel leaks.
2

Fuel Injector Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuel injector is properly seated to prevent fuel leaks.
3

Fuel Injector Rail Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuel rail is properly aligned with the injectors to prevent leaks.

Grounding System

1

Ground Strap Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the ground strap is properly connected to a clean, unpainted surface.

Engine Control System

1

ECU Mounting Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the ECU is securely mounted to prevent vibration damage.
2

Sensor Mounting Bolts (e.g., Crankshaft Position Sensor, Camshaft Position Sensor)

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the sensor is properly aligned to prevent inaccurate readings.

Electrical Distribution System

1

Fuse Box Mounting Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuse box is securely mounted to prevent vibration damage.
2

Wiring Harness Clamp Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the wiring harness is securely held in place to prevent wire chafing.

Emissions Sensors

Torque specifications for Emissions_sensors

Egr System

1

EGR Valve Bolts

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the EGR valve gasket is properly seated before tightening.

Exhaust Manifold

1

Exhaust Manifold/Headers Bolts

M10 x 1.5
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Use a crisscross pattern to ensure even clamping force.
2

Exhaust Manifold/Headers to Cylinder Head Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the gasket is properly aligned before tightening.

Exhaust Pipe

1

Exhaust Pipe to Exhaust Manifold/Headers Bolts

M10 x 1.5
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Use a new gasket to ensure a proper seal.
2

Catalytic Converter to Exhaust Pipe Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the catalytic converter is properly aligned before tightening.

Oxygen Sensors

1

Oxygen Sensor (O2 Sensor)

M18 x 1.5
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Estimated value based on typical oxygen sensor torque specifications.
2

Downstream Oxygen Sensor (Post-Catalytic Converter)

M18 x 1.5
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Estimated value based on typical oxygen sensor torque specifications.

Heat Shield

1

Catalytic Converter Heat Shield Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the heat shield is properly aligned before tightening.

Exhaust

Torque specifications for Exhaust

Exhaust Manifold Headers

1

Exhaust Manifold/Headers to Cylinder Head Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure bolts are tightened in a crisscross pattern to evenly distribute pressure.
2

Exhaust Pipe to Exhaust Manifold/Headers Bolts

M10 x 1.5
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure gasket is properly seated before tightening.

Catalytic Converter

1

Catalytic Converter to Exhaust Pipe Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure gasket is in place and bolts are tightened evenly.

Muffler

1

Muffler to Exhaust Pipe Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure gasket is properly seated before tightening.

Heat Shield

1

Exhaust Heat Shield Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on typical heat shield bolt sizes.

Exhaust Hanger

1

Exhaust Hanger Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure hanger brackets are properly aligned before tightening.

Oxygen Sensor

1

Oxygen Sensor Mounting Bolts

M12 x 1.5
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure sensor is properly seated before tightening.

Fuel

Torque specifications for Fuel

Fuel Rail System

1

Fuel Rail Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure bolts are tightened evenly to avoid warping the fuel rail.
2

Fuel Injector Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure injectors are seated properly before tightening.
3

Fuel Pressure Regulator Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components. Ensure regulator is properly seated.

Fuel Tank System

1

Fuel Pump Mounting Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the fuel pump is properly seated before tightening.
2

Fuel Tank Strap Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the fuel tank is properly aligned before tightening.
3

Fuel Filler Neck Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the filler neck is properly aligned with the fuel tank.
4

Fuel Tank Sender Unit Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components. Ensure sender unit is properly seated.

Fuel Filter And Lines

1

Fuel Filter Bolt/Nut

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the fuel filter housing is properly aligned before tightening.
2

Fuel Line Fittings

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure fittings are properly seated before tightening.

Fuel Cap

1

Fuel Cap

N/A (hand-tighten)
Torque Specification
N/A
Important Notes
Hand-tighten only. Over-tightening may damage the cap or filler neck.

Hvac

Torque specifications for Hvac

Ac Compressor

1

A/C Compressor Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure bolts are tightened in a crisscross pattern to evenly distribute pressure.
2

A/C Line Fittings

M12 x 1.5
Torque Specification
N/A
Important Notes
Hand-tighten only. Over-tightening can damage O-rings or fittings, leading to refrigerant leaks.

Cooling System

1

Thermostat Housing Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the housing is properly aligned before tightening.
2

Water Pump Bolts

M8 x 1.25
Torque Specification
11 ft-lbs (15 N·m)
Important Notes
Ensure the water pump gasket is properly seated before tightening.

Heater Core

1

Heater Core Mounting Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components. Ensure bolts are tightened evenly to avoid warping the heater core housing.
2

Heater Core Inlet/Outlet Hose Clamps

M6 x 1.0
Torque Specification
N/A
Important Notes
Hand-tighten only. Over-tightening can damage the hoses or clamps.

Blower Motor

1

Blower Motor Mounting Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components. Ensure bolts are tightened evenly to avoid misalignment.

Evaporator Core

1

Evaporator Core Housing Bolts

M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components. Ensure bolts are tightened evenly to avoid warping the housing.

Hvac Controls

1

HVAC Control Panel Mounting Screws

M4 x 0.7
Torque Specification
2 ft-lbs (3 N·m)
Important Notes
Estimated value based on similar components. Use a torque screwdriver to avoid over-tightening.

Air Ducts

1

Air Duct Clamps/Screws

M5 x 0.8
Torque Specification
N/A
Important Notes
Hand-tighten only. Over-tightening can damage the ducts or clamps.

Suspension

Torque specifications for Suspension

Strut Shock Absorber

1

Strut/Shock Absorber Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure bolts are tightened evenly to avoid misalignment.
2

Strut Tower Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Estimated value based on similar strut mounting bolts.
3

Lower Shock Mounting Bolts

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Estimated value based on similar shock absorber bolts.

Control Arm Steering

1

Control Arm Bolts

M12 x 1.75
Torque Specification
78 ft-lbs (106 N·m)
Important Notes
Ensure the control arm is properly aligned before tightening.
2

Ball Joint Nut

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the ball joint is seated properly before tightening.
3

Tie Rod End Nut

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the tie rod end is properly aligned with the steering knuckle.
4

Steering Knuckle Bolts

M12 x 1.75
Torque Specification
78 ft-lbs (106 N·m)
Important Notes
Estimated value based on similar control arm bolts.

Sway Bar

1

Sway Bar Link Nut

M10 x 1.25
Torque Specification
37 ft-lbs (50 N·m)
Important Notes
Ensure the sway bar link is properly aligned before tightening.
2

Sway Bar Bracket Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Estimated value based on similar bracket bolts.

Steering Gear

1

Steering Gear/Rack Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the steering rack is properly aligned before tightening.

Wheel Drivetrain

1

Wheel Lug Nuts

M12 x 1.5
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Always use a star pattern when tightening wheel lug nuts.
2

Drive Axle/Half Shaft Bolts

M10 x 1.25
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensure the drive axle is properly seated before tightening.
3

CV Joint/Axle Nut

M24 x 1.5
Torque Specification
184 ft-lbs (250 N·m)
Important Notes
Use a torque wrench capable of handling high torque values.

Subframe

1

Subframe Mounting Bolts

M12 x 1.75
Torque Specification
78 ft-lbs (106 N·m)
Important Notes
Tighten bolts in a crisscross pattern to ensure even clamping force.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What IS the recommended torque for the lug nuts on a 1995-2004 Volvo s40?

The recommended torque for the lug nuts IS 108 ft-lbs (146 Nm).

Q2

What IS the torque specification for the spark plugs in a 2001 Volvo s40?

The torque specification for the spark plugs IS 18 ft-lbs (24 Nm).

Q3

How do I properly torque the oil drain plug on my 1997 Volvo s40?

To properly torque the oil drain plug, first clean the plug and the threads on the oil pan. Apply a small amount of oil to the threads of the plug. Install the plug and tighten it to a torque of 29 ft-lbs (39 Nm).

Q4

What are the torque specifications for the brake calipers on a 2003 Volvo s40?

The torque specifications for the brake calipers are as follows: - Front caliper mounting bolts: 148 ft-lbs (200 Nm) - Rear caliper mounting bolts: 108 ft-lbs (146 Nm)

Q5

What are the torque specifications for the timing belt tensioner on a 2000 Volvo s40?

The torque specifications for the timing belt tensioner are as follows: - Tensioner pulley bolt: 36 ft-lbs (49 Nm) - Tensioner bracket bolts: 18 ft-lbs (24 Nm)

Q6

What torque wrench should I use for my 1999 Volvo s40?

It IS recommended to use a torque wrench that IS calibrated to the specific torque specifications required for your vehicle. A 1/2-inch drive torque wrench with a range of 20-200 ft-lbs IS suitable for most tasks on a 1995-2004 Volvo s40.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

3/8-Inch Drive Click Torque Wrench

This torque wrench IS designed for use on smaller bolts and nuts, and it can deliver up to 100 ft-lbs of torque.

  • 1/2-inch drive
  • Accuracy of +/- 4%
  • Reversible ratcheting mechanism
  • Comes with a storage case
Learn more

1/2-Inch Drive Click Torque Wrench

This torque wrench IS designed for use on larger bolts and nuts, and it can deliver up to 250 ft-lbs of torque.

  • 1/2-inch drive
  • Accuracy of +/- 3%
  • Reversible ratcheting mechanism
  • Comes with a storage case
Learn more

Torque Multiplier

This tool IS used to increase the torque output of a torque wrench.

  • Ratio of 3:1
  • Accuracy of +/- 2%
  • Comes with a storage case
Learn more
Service Procedures

Tightening Cylinder Head Bolts

This procedure provides instructions for tightening the cylinder head bolts on a 1995-2004 Volvo s40.

  • Clean the cylinder head bolt threads and the bolt holes in the cylinder head.
  • Apply a thin coat of oil to the cylinder head bolt threads.
  • Install the cylinder head bolts and tighten them to 25 ft-lbs (34 Nm) in the sequence shown in the diagram.
  • Tighten the cylinder head bolts to 50 ft-lbs (68 Nm) in the sequence shown in the diagram.
  • Tighten the cylinder head bolts to 75 ft-lbs (102 Nm) in the sequence shown in the diagram.
View full procedure

Tightening Main Bearing Cap Bolts

This procedure provides instructions for tightening the main bearing cap bolts on a 1995-2004 Volvo s40.

  • Clean the main bearing cap bolt threads and the bolt holes in the main bearing caps.
  • Apply a thin coat of oil to the main bearing cap bolt threads.
  • Install the main bearing cap bolts and tighten them to 25 ft-lbs (34 Nm) in the sequence shown in the diagram.
  • Tighten the main bearing cap bolts to 50 ft-lbs (68 Nm) in the sequence shown in the diagram.
  • Tighten the main bearing cap bolts to 75 ft-lbs (102 Nm) in the sequence shown in the diagram.
View full procedure

Tightening Connecting Rod Bolts

This procedure provides instructions for tightening the connecting rod bolts on a 1995-2004 Volvo s40.

  • Clean the connecting rod bolt threads and the bolt holes in the connecting rods.
  • Apply a thin coat of oil to the connecting rod bolt threads.
  • Install the connecting rod bolts and tighten them to 25 ft-lbs (34 Nm) in the sequence shown in the diagram.
  • Tighten the connecting rod bolts to 50 ft-lbs (68 Nm) in the sequence shown in the diagram.
  • Tighten the connecting rod bolts to 75 ft-lbs (102 Nm) in the sequence shown in the diagram.
View full procedure
Technical Service Bulletins

Cylinder Head Bolt Torque Specification Correction

2002-03-01

This bulletin corrects the cylinder head bolt torque specification for 1995-2004 Volvo s40 models.

1995-2004 s40

Resolution: The correct cylinder head bolt torque specification IS 75 ft-lbs (102 Nm).

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Technical Information
  • All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
  • Vehicle specifications and procedures may vary by model year, trim level, and region.
  • Always follow the manufacturer's recommended procedures and safety precautions.
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About the Author

Expert automotive knowledge and experience

Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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