Volvo Vehicle Models Volvo V40 1995-2004
Volvo Vehicle Models Volvo V40 1995-2004 Torque Specifications
Complete Volvo Vehicle Models Volvo V40 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
Safety First
- Always verify torque specifications with your vehicle's factory service manual
- Use properly calibrated torque wrenches
- Replace all torque-to-yield (TTY) bolts - they are single-use only
- When in doubt, consult a professional mechanic
Quick Reference Guide
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
Cross Pattern
Used for gaskets and cover plates
Sequential Pattern
Used for head bolts and other critical components
Common Mistakes to Avoid
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
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
Convert between different torque units
1.6l I4 Engine
Torque specifications for 1.6L-I4 Engine
1.6l I4 Engine
Torque specifications for 1.6L-I4 Engine
Cylinder Head
1 Cylinder Head Bolts
M10 x 1.25
1
Cylinder Head Bolts
M10 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Follow the manufacturer’s torque sequence to ensure even clamping force and proper sealing.
Crankshaft And Bearings
1 Main Bearing Bolts
M12 x 1.5
1
Main Bearing Bolts
M12 x 1.5
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure proper alignment of the crankshaft before tightening.
2 Connecting Rod Nuts
M8 x 1.0
2
Connecting Rod Nuts
M8 x 1.0
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Ensure proper bearing clearance before tightening.
Flywheel And Clutch
1 Flywheel Bolts
M12 x 1.25
1
Flywheel Bolts
M12 x 1.25
Torque Specification
58 ft-lbs (78 N·m)
Important Notes
Use thread locker on the bolts to prevent loosening.
Oil System
1 Oil Pan Bolts
M6 x 1.0
1
Oil Pan Bolts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Ensure the oil pan gasket is properly seated to prevent leaks.
2 Oil Pump Bolts
M8 x 1.25
2
Oil Pump Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper alignment of the oil pump before tightening.
Valvetrain
1 Rocker Arms/Shafts Bolts
M8 x 1.25
1
Rocker Arms/Shafts Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure proper valve clearance before tightening.
2 Camshaft Bearing Cap Bolts
M8 x 1.25
2
Camshaft Bearing Cap Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure proper alignment of the camshaft before tightening.
1.8l I4 Engine
Torque specifications for 1.8L-I4 Engine
1.8l I4 Engine
Torque specifications for 1.8L-I4 Engine
Cylinder Head
1 Cylinder Head Bolts
M10 x 1.5
1
Cylinder Head Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Follow the manufacturer's specified torque sequence to prevent warping.
2 Valve Cover Bolts
M6 x 1.0
2
Valve Cover Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure proper alignment of the valve cover gasket.
3 Spark Plugs
M14 x 1.25
3
Spark Plugs
M14 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Applying anti-seize compound is recommended for aluminum cylinder heads.
Crankshaft And Bearings
1 Main Bearing Bolts
M10 x 1.25
1
Main Bearing Bolts
M10 x 1.25
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure bearing caps are properly seated before tightening.
2 Flywheel Bolts
M12 x 1.5
2
Flywheel Bolts
M12 x 1.5
Torque Specification
58 ft-lbs (78 N·m)
Important Notes
Ensure the flywheel is properly aligned with the crankshaft.
Engine Block Accessories
1 Oil Pan Bolts
M6 x 1.0
1
Oil Pan Bolts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Ensure the oil pan gasket is properly aligned.
2 Starter Motor Mounting Bolts
M10 x 1.25
2
Starter Motor Mounting Bolts
M10 x 1.25
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensure the starter motor is properly aligned with the flywheel.
Timing And Fuel System
1 Camshaft Sprocket Bolt
M8 x 1.25
1
Camshaft Sprocket Bolt
M8 x 1.25
Torque Specification
36 ft-lbs (49 N·m)
Important Notes
Ensure the sprocket is properly aligned with the camshaft.
2 Fuel Rail Bolts
M6 x 1.0
2
Fuel Rail Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the fuel rail is properly seated on the injectors.
2.0l Engine
Torque specifications for 2.0L Engine
2.0l Engine
Torque specifications for 2.0L Engine
Cylinder Head and Engine Block
1 Cylinder Head Bolts
M12 x 1.5
1
Cylinder Head Bolts
M12 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
2 Main Bearing Bolts
M14 x 2.0
2
Main Bearing Bolts
M14 x 2.0
Torque Specification
44 ft-lbs (60 N·m)
Crankshaft and Connecting Rods
1 Connecting Rod Nuts
M10 x 1.5
1
Connecting Rod Nuts
M10 x 1.5
Torque Specification
30 ft-lbs (40 N·m)
2 Flywheel Bolts
M12 x 1.5
2
Flywheel Bolts
M12 x 1.5
Torque Specification
58 ft-lbs (78 N·m)
Valve Train and Timing System
1 Camshaft Sprocket Bolt
M14 x 2.0
1
Camshaft Sprocket Bolt
M14 x 2.0
Torque Specification
36 ft-lbs (49 N·m)
2 Timing Belt/Chain Tensioner Bolt
M10 x 1.5
2
Timing Belt/Chain Tensioner Bolt
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Intake and Exhaust System
1 Intake Manifold Bolts
M10 x 1.5
1
Intake Manifold Bolts
M10 x 1.5
Torque Specification
14 ft-lbs (20 N·m)
2 Exhaust Manifold/Headers Bolts
M12 x 1.5
2
Exhaust Manifold/Headers Bolts
M12 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Turbocharger and Intercooler System
1 Turbocharger Mounting Bolts
M14 x 2.0
1
Turbocharger Mounting Bolts
M14 x 2.0
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Estimated value based on industry standards.
2 Intercooler Mounting Bolts
M12 x 1.5
2
Intercooler Mounting Bolts
M12 x 1.5
Torque Specification
20 ft-lbs (28 N·m)
Important Notes
Estimated value based on industry standards.
Fuel System
1 Fuel Rail Bolts
M10 x 1.5
1
Fuel Rail Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
2 Fuel Injector Bolts
M8 x 1.25
2
Fuel Injector Bolts
M8 x 1.25
Torque Specification
7 ft-lbs (10 N·m)
Ignition System
1 Spark Plugs
M14 x 1.25
1
Spark Plugs
M14 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
2 Ignition Coil Bolt
M10 x 1.5
2
Ignition Coil Bolt
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
Cooling System
1 Water Pump Bolts
M10 x 1.5
1
Water Pump Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
2 Thermostat Housing Bolts
M10 x 1.5
2
Thermostat Housing Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
2.0l I4 Engine
Torque specifications for 2.0L-I4 Engine
2.0l I4 Engine
Torque specifications for 2.0L-I4 Engine
Cylinder Head
1 Cylinder Head Bolts
M10 x 1.5
1
Cylinder Head Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper tightening sequence to avoid warping the cylinder head.
2 Valve Cover Bolts
M6 x 1.0
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
M10 x 1.25
1
Main Bearing Bolts
M10 x 1.25
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure bearings are properly seated and lubricated before tightening.
2 Flywheel Bolts
M12 x 1.5
2
Flywheel Bolts
M12 x 1.5
Torque Specification
58 ft-lbs (78 N·m)
Important Notes
Ensure the flywheel is properly aligned before tightening.
Timing System
1 Timing Belt/Chain Tensioner Bolt
M8 x 1.25
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
2
Camshaft Sprocket Bolt
M10 x 1.25
Torque Specification
36 ft-lbs (49 N·m)
Important Notes
Ensure the camshaft is properly aligned before tightening.
Oil System
1 Oil Pan Bolts
M6 x 1.0
1
Oil Pan Bolts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Ensure the oil pan gasket is properly seated before tightening.
2 Oil Drain Plug Bolt
M14 x 1.5
2
Oil Drain Plug Bolt
M14 x 1.5
Torque Specification
25 ft-lbs (35 N·m)
Important Notes
Ensure the sealing washer is in place before tightening.
2.0l I4 Turbo Engine
Torque specifications for 2.0L-I4-TURBO Engine
2.0l I4 Turbo Engine
Torque specifications for 2.0L-I4-TURBO Engine
Cylinder Head and Engine Block
1 Cylinder Head Bolts
M12 x 1.5
1
Cylinder Head Bolts
M12 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
2 Main Bearing Bolts
M14 x 2.0
2
Main Bearing Bolts
M14 x 2.0
Torque Specification
44 ft-lbs (60 N·m)
Crankshaft and Connecting Rods
1 Connecting Rod Nuts
M10 x 1.5
1
Connecting Rod Nuts
M10 x 1.5
Torque Specification
30 ft-lbs (40 N·m)
2 Flywheel Bolts
M12 x 1.5
2
Flywheel Bolts
M12 x 1.5
Torque Specification
58 ft-lbs (78 N·m)
Valve Train and Timing System
1 Camshaft Sprocket Bolt
M14 x 2.0
1
Camshaft Sprocket Bolt
M14 x 2.0
Torque Specification
36 ft-lbs (49 N·m)
2 Timing Belt/Chain Tensioner Bolt
M10 x 1.5
2
Timing Belt/Chain Tensioner Bolt
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Intake and Exhaust System
1 Intake Manifold Bolts
M10 x 1.5
1
Intake Manifold Bolts
M10 x 1.5
Torque Specification
14 ft-lbs (20 N·m)
2 Exhaust Manifold/Headers Bolts
M12 x 1.5
2
Exhaust Manifold/Headers Bolts
M12 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Turbocharger and Intercooler System
1 Turbocharger Mounting Bolts
M14 x 2.0
1
Turbocharger Mounting Bolts
M14 x 2.0
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Estimated value based on industry standards.
2 Intercooler Mounting Bolts
M12 x 1.5
2
Intercooler Mounting Bolts
M12 x 1.5
Torque Specification
20 ft-lbs (28 N·m)
Important Notes
Estimated value based on industry standards.
Fuel System
1 Fuel Rail Bolts
M10 x 1.5
1
Fuel Rail Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
2 Fuel Injector Bolts
M8 x 1.25
2
Fuel Injector Bolts
M8 x 1.25
Torque Specification
7 ft-lbs (10 N·m)
Ignition System
1 Spark Plugs
M14 x 1.25
1
Spark Plugs
M14 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
2 Ignition Coil Bolt
M10 x 1.5
2
Ignition Coil Bolt
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
Cooling System
1 Water Pump Bolts
M10 x 1.5
1
Water Pump Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
2 Thermostat Housing Bolts
M10 x 1.5
2
Thermostat Housing Bolts
M10 x 1.5
Torque Specification
7 ft-lbs (10 N·m)
Aw55 Transmission
Torque specifications for Aw55 Transmission
Aw55 Transmission
Torque specifications for Aw55 Transmission
Transmission Mounting
1 Transmission Mounting Bolts
M10 x 1.5
1
Transmission Mounting Bolts
M10 x 1.5
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure bolts are tightened in a cross pattern to maintain even pressure.
Oil Pan
1 Transmission Oil Pan Bolts
M6 x 1.0
1
Transmission Oil Pan Bolts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Ensure the gasket is properly seated before tightening.
2 Transmission Drain Plug
M12 x 1.5
2
Transmission Drain Plug
M12 x 1.5
Torque Specification
25 ft-lbs (35 N·m)
Important Notes
Ensure the sealing washer is in good condition or replace it.
Torque Converter
1 Torque Converter Bolts
M8 x 1.25
1
Torque Converter Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure the torque converter is properly seated before tightening.
Valve Body
1 Valve Body Bolts
M6 x 1.0
1
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
Body
Torque specifications for Body
Fuel System
1 Fuel Tank Strap Bolts
M8 x 1.25
1
Fuel Tank Strap Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
These bolts secure the fuel tank straps, ensuring the fuel tank remains firmly in place. Proper torque prevents fuel tank movement, which could lead to leaks or damage to the fuel system.
2 Fuel Filler Neck Bolts
M6 x 1.0
2
Fuel Filler Neck Bolts
M6 x 1.0
Torque Specification
9 ft-lbs (12 N·m)
Important Notes
These bolts attach the fuel filler neck to the vehicle body. Correct torque ensures a secure connection, preventing fuel leaks at the filler neck.
Air Intake
1 Air Intake Hose Clamps
M6 x 1.0
1
Air Intake Hose Clamps
M6 x 1.0
Torque Specification
1.1 ft-lbs (1.5 N·m)
Important Notes
These clamps secure the air intake hose to the throttle body. Proper torque ensures a tight seal, preventing air leaks that could affect engine performance.
Exhaust System
1 Exhaust Manifold Bolts
M10 x 1.25
1
Exhaust Manifold Bolts
M10 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
These bolts secure the exhaust manifold to the engine. Proper torque ensures a tight seal, preventing exhaust leaks. Torque sequence is critical to avoid warping the manifold.
Brakes
Torque specifications for Brakes
Brakes
Torque specifications for Brakes
Brake Caliper
1 Brake Caliper Bolts
M12 x 1.5
1
Brake Caliper Bolts
M12 x 1.5
Torque Specification
70 ft-lbs (95 N·m)
Important Notes
Ensure proper torque to prevent caliper movement and uneven braking.
2 Brake Caliper Mounting Bracket Bolts
M14 x 1.5
2
Brake Caliper Mounting Bracket Bolts
M14 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Correct torque is crucial for bracket stability and braking performance.
Brake Disc Drum
1 Brake Disc/Drum Retaining Bolts
M8 x 1.25
1
Brake Disc/Drum Retaining Bolts
M8 x 1.25
Torque Specification
25 ft-lbs (35 N·m)
Important Notes
Ensures the disc or drum remains securely attached to the hub.
2 Brake Rotor Set Screw
M6 x 1.0
2
Brake Rotor Set Screw
M6 x 1.0
Torque Specification
8 ft-lbs (12 N·m)
Important Notes
Estimated value based on similar small set screws. Ensures rotor alignment during wheel installation.
Brake Hydraulics
1 Brake Hose Banjo Bolt
M10 x 1.0
1
Brake Hose Banjo Bolt
M10 x 1.0
Torque Specification
16 ft-lbs (22 N·m)
Important Notes
Estimated value based on typical banjo bolt specifications. Prevents brake fluid leaks.
2 Brake Master Cylinder Mounting Bolts
M8 x 1.25
2
Brake Master Cylinder Mounting Bolts
M8 x 1.25
Torque Specification
16 ft-lbs (22 N·m)
Important Notes
Ensures a proper seal and prevents fluid leaks.
Brake Pedal
1 Brake Pedal Pivot Bolt
M10 x 1.25
1
Brake Pedal Pivot Bolt
M10 x 1.25
Torque Specification
19 ft-lbs (26 N·m)
Important Notes
Estimated value based on similar pivot bolts. Ensures smooth pedal operation.
Wheel
1 Wheel Lug Nuts
M12 x 1.5
1
Wheel Lug Nuts
M12 x 1.5
Torque Specification
80 ft-lbs (110 N·m)
Important Notes
Proper torque ensures correct alignment of the brake rotor or drum.
Drivetrain
Torque specifications for Drivetrain
Drivetrain
Torque specifications for Drivetrain
Engine Crankshaft
1 Flywheel Bolts
M10 x 1.25
1
Flywheel Bolts
M10 x 1.25
Torque Specification
58 ft-lbs (78 N·m)
Important Notes
Ensure flywheel is clean and properly aligned before torquing.
2 Main Bearing Bolts
M10 x 1.25
2
Main Bearing Bolts
M10 x 1.25
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure crankshaft is properly seated before torquing.
Transmission Assembly
1 Transmission Mounting Bolts
M12 x 1.75
1
Transmission Mounting Bolts
M12 x 1.75
Torque Specification
44 ft-lbs (60 N·m)
Important Notes
Ensure transmission is properly aligned before torquing.
2 Torque Converter Bolts
M8 x 1.25
2
Torque Converter Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure torque converter is properly seated before torquing.
3 Transmission Oil Pan Bolts
M6 x 1.0
3
Transmission Oil Pan Bolts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Avoid over-tightening to prevent gasket damage.
4 Transmission Drain and Fill Plugs
M14 x 1.5
4
Transmission Drain and Fill Plugs
M14 x 1.5
Torque Specification
25 ft-lbs (35 N·m)
Important Notes
Ensure threads are clean and free of debris.
Drivetrain
1 Drive Axle/Half Shaft Bolts
M12 x 1.75
1
Drive Axle/Half Shaft Bolts
M12 x 1.75
Torque Specification
52 ft-lbs (70 N·m)
Important Notes
Ensure axles are properly seated before torquing.
2 CV Joint/Axle Nut
M20 x 1.5
2
CV Joint/Axle Nut
M20 x 1.5
Torque Specification
185 ft-lbs (250 N·m)
Important Notes
Ensure CV joint is fully seated before torquing.
3 Propeller/Drive Shaft Bolts
M12 x 1.75
3
Propeller/Drive Shaft Bolts
M12 x 1.75
Torque Specification
52 ft-lbs (70 N·m)
Important Notes
Ensure driveshaft is properly aligned before torquing.
Differential Assembly
1 Differential Mounting Bolts
M14 x 2.0
1
Differential Mounting Bolts
M14 x 2.0
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Ensure differential is properly aligned before torquing.
2 Front Differential Output Shaft Bolts
M12 x 1.75
2
Front Differential Output Shaft Bolts
M12 x 1.75
Torque Specification
52 ft-lbs (70 N·m)
Important Notes
Ensure output shafts are properly seated before torquing.
3 Differential Drain/Fill Plug
M16 x 1.5
3
Differential Drain/Fill Plug
M16 x 1.5
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensure threads are clean and free of debris.
Transfer Case
1 Transfer Case Drain/Fill Plug
M16 x 1.5
1
Transfer Case Drain/Fill Plug
M16 x 1.5
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensure threads are clean and free of debris.
Clutch Assembly
1 Clutch Pressure Plate Bolts
M8 x 1.25
1
Clutch Pressure Plate Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure clutch disc is properly aligned before torquing.
Electrical
Torque specifications for Electrical
Electrical
Torque specifications for Electrical
Ignition System
1 Ignition Coil Bolt
M6 x 1.0
1
Ignition Coil Bolt
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure the ignition coil is properly seated before torquing.
Starting System
1 Starter Motor Mounting Bolts
M10 x 1.5
1
Starter Motor Mounting Bolts
M10 x 1.5
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensure the starter motor is properly aligned with the flywheel before torquing.
Charging System
1 Alternator Mounting Bolts
M10 x 1.5
1
Alternator Mounting Bolts
M10 x 1.5
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensure the alternator is properly aligned and the belt is correctly tensioned before torquing.
Battery System
1 Battery Terminal Nuts
M6 x 1.0
1
Battery Terminal Nuts
M6 x 1.0
Torque Specification
6 ft-lbs (8 N·m)
Important Notes
Ensure the battery terminals are clean before tightening.
Grounding System
1 Ground Strap Bolts
M6 x 1.0
1
Ground Strap Bolts
M6 x 1.0
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Estimated value based on similar components and bolt sizes.
Junction Box
1 Electrical Junction Box Mounting Bolts
M6 x 1.0
1
Electrical Junction Box Mounting Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components and bolt sizes.
Sensor System
1 Crankshaft Position Sensor Mounting Bolts
M6 x 1.0
1
Crankshaft Position Sensor Mounting Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value based on similar components and bolt sizes.
Emissions Sensors
Torque specifications for Emissions_sensors
Emissions Sensors
Torque specifications for Emissions_sensors
Egr
1 EGR Valve Bolts
M8 x 1.25
1
EGR Valve Bolts
M8 x 1.25
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Ensure the mating surfaces are clean before installation.
Exhaust Manifold
1 Exhaust Manifold/Headers Bolts
M10 x 1.5
1
Exhaust Manifold/Headers Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Follow the recommended torque sequence for even clamping force.
2 Exhaust Manifold/Headers to Cylinder Head Bolts
M10 x 1.5
2
Exhaust Manifold/Headers to Cylinder Head Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the gasket is properly seated before tightening.
Exhaust Pipe
1 Exhaust Pipe to Exhaust Manifold/Headers Bolts
M10 x 1.5
1
Exhaust Pipe to Exhaust Manifold/Headers Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure the exhaust pipe is aligned properly before tightening.
2 Catalytic Converter to Exhaust Pipe Bolts
M10 x 1.5
2
Catalytic Converter to Exhaust Pipe Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Inspect the catalytic converter gasket for damage before installation.
Sensors
1 Oxygen Sensor (O2 Sensor) Mounting
M12 x 1.25
1
Oxygen Sensor (O2 Sensor) Mounting
M12 x 1.25
Torque Specification
30 ft-lbs (40 N·m)
Important Notes
Ensure the O2 sensor is properly seated before tightening.
2 Exhaust Gas Temperature Sensor Bolts
M8 x 1.25
2
Exhaust Gas Temperature Sensor Bolts
M8 x 1.25
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Ensure the sensor is properly aligned before tightening.
Air Injection
1 Secondary Air Injection System Bolts
M6 x 1.0
1
Secondary Air Injection System Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure all connections are properly aligned before tightening.
Evap
1 Evaporative Emissions (EVAP) System Bolts
M6 x 1.0
1
Evaporative Emissions (EVAP) System Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensure all hoses and connections are properly secured.
Exhaust
Torque specifications for Exhaust
Exhaust
Torque specifications for Exhaust
Exhaust Manifold
1 Exhaust Manifold/Headers Bolts
M8 x 1.25
1
Exhaust Manifold/Headers Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure bolts are tightened in a crisscross pattern to avoid warping the manifold.
2 Exhaust Manifold/Headers to Cylinder Head Bolts
M8 x 1.25
2
Exhaust Manifold/Headers to Cylinder Head Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Use a crisscross pattern to ensure even pressure across the manifold.
Exhaust Pipe
1 Exhaust Pipe to Exhaust Manifold/Headers Bolts
M8 x 1.25
1
Exhaust Pipe to Exhaust Manifold/Headers Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure proper alignment before tightening to prevent leaks.
2 Catalytic Converter to Exhaust Pipe Bolts
M8 x 1.25
2
Catalytic Converter to Exhaust Pipe Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensure a proper seal to prevent exhaust leaks and maintain catalytic converter efficiency.
3 Exhaust Flange Bolts
M8 x 1.25
3
Exhaust Flange Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Ensures a leak-free seal at flanged connections in the exhaust system.
Muffler And Hangers
1 Muffler to Exhaust Pipe Bolts
M8 x 1.25
1
Muffler to Exhaust Pipe Bolts
M8 x 1.25
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Proper torque ensures a secure connection and prevents rattling.
2 Exhaust Hanger Bolts
M6 x 1.0
2
Exhaust Hanger Bolts
M6 x 1.0
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Prevents excessive movement of the exhaust system, reducing stress on joints.
Sensors And Shields
1 Oxygen Sensor Port Bolts
M12 x 1.5
1
Oxygen Sensor Port Bolts
M12 x 1.5
Torque Specification
26 ft-lbs (35 N·m)
Important Notes
Ensures proper sealing and prevents exhaust leaks.
2 Heat Shield Bolts
M6 x 1.0
2
Heat Shield Bolts
M6 x 1.0
Torque Specification
8 ft-lbs (11 N·m)
Important Notes
Prevents rattling and ensures the heat shield remains in place.
Fuel
Torque specifications for Fuel
Fuel
Torque specifications for Fuel
Fuel Rail System
1 Fuel Rail Bolts
M6 x 1.0
1
Fuel Rail Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Ensures proper sealing of the fuel rail to the intake manifold or cylinder head. Prevents fuel leaks.
2 Fuel Injector Bolts
M6 x 1.0
2
Fuel Injector Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Secures the fuel injectors to the intake manifold or cylinder head. Ensures a proper seal.
3 Fuel Injector Rail Bolts
M6 x 1.0
3
Fuel Injector Rail Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Secures the fuel injector rail in place. Ensures proper alignment and sealing of the injectors.
4 Fuel Pressure Regulator Bolts
M6 x 1.0
4
Fuel Pressure Regulator Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value. Ensures the fuel pressure regulator is securely mounted. Prevents leaks.
Fuel Delivery System
1 Fuel Pump Mounting Bolts
M8 x 1.25
1
Fuel Pump Mounting Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Secures the fuel pump to the fuel tank or mounting bracket. Prevents fuel leaks.
2 Fuel Filter Bolt/Nut
M8 x 1.25
2
Fuel Filter Bolt/Nut
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensures the fuel filter is securely mounted. Prevents leaks and maintains proper fuel flow.
3 Fuel Line Fittings
M8 x 1.25
3
Fuel Line Fittings
M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Estimated value. Secures fuel line connections to prevent leaks.
Fuel Tank System
1 Fuel Tank Strap Bolts
M10 x 1.5
1
Fuel Tank Strap Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Secures the fuel tank to the vehicle chassis. Prevents movement or detachment.
2 Fuel Filler Neck Bolts
M8 x 1.25
2
Fuel Filler Neck Bolts
M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Secures the fuel filler neck to the vehicle body. Ensures a proper seal during refueling.
3 Fuel Tank Sender Unit Bolts
M6 x 1.0
3
Fuel Tank Sender Unit Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value. Ensures the fuel level sender unit is properly sealed. Prevents leaks.
Evaporative Emission System
1 Fuel Evaporation Canister Bolts
M6 x 1.0
1
Fuel Evaporation Canister Bolts
M6 x 1.0
Torque Specification
7 ft-lbs (10 N·m)
Important Notes
Estimated value. Secures the charcoal canister in place. Ensures proper operation of the evaporative emission control system.
Hvac
Torque specifications for Hvac
Hvac
Torque specifications for Hvac
Air Conditioning Compressor
1 A/C Compressor Mounting Bolts
M10 x 1.5
1
A/C Compressor Mounting Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Air Conditioning Lines
1 A/C Line Fittings
N/A
1
A/C Line Fittings
N/A
Torque Specification
N/A
Important Notes
Hand tightening is recommended to prevent over-tightening.
Air Conditioning Condenser
1 A/C Condenser Mounting Bolts
M10 x 1.5
1
A/C Condenser Mounting Bolts
M10 x 1.5
Torque Specification
18 ft-lbs (25 N·m)
Important Notes
Estimated value based on industry standards.
Air Conditioning Evaporator
1 A/C Evaporator Mounting Bolts
M8 x 1.25
1
A/C Evaporator Mounting Bolts
M8 x 1.25
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Estimated value based on industry standards.
Air Conditioning Refrigerant Lines
1 A/C Refrigerant Line Bracket Bolts
M6 x 1
1
A/C Refrigerant Line Bracket Bolts
M6 x 1
Torque Specification
10 ft-lbs (14 N·m)
Important Notes
Estimated value based on industry standards.
Suspension
Torque specifications for Suspension
Suspension
Torque specifications for Suspension
Struts Shocks
1 Strut/Shock Absorber Mounting Bolts
M12 x 1.5
1
Strut/Shock Absorber Mounting Bolts
M12 x 1.5
Torque Specification
59 ft-lbs (80 N·m)
Important Notes
Ensures stability and alignment of the suspension system, preventing noise and vibration.
Control Arm
1 Control Arm Bolts
M14 x 1.5
1
Control Arm Bolts
M14 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Maintains alignment and handling stability by ensuring the control arm remains securely attached.
2 Ball Joint Nut
M12 x 1.25
2
Ball Joint Nut
M12 x 1.25
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Prevents loosening, which could lead to loss of control or suspension failure.
Steering
1 Tie Rod End Nut
M10 x 1.25
1
Tie Rod End Nut
M10 x 1.25
Torque Specification
33 ft-lbs (45 N·m)
Important Notes
Ensures the steering system operates smoothly and prevents play in the steering.
2 Steering Knuckle Bolts
M14 x 1.5
2
Steering Knuckle Bolts
M14 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Maintains alignment and steering precision by ensuring the knuckle remains securely attached.
Sway Bar
1 Sway Bar Link Nut
M10 x 1.25
1
Sway Bar Link Nut
M10 x 1.25
Torque Specification
40 ft-lbs (55 N·m)
Important Notes
Ensures the sway bar functions correctly, improving vehicle stability.
2 Sway Bar Bracket Bolts
M8 x 1.25
2
Sway Bar Bracket Bolts
M8 x 1.25
Torque Specification
25 ft-lbs (35 N·m)
Important Notes
Ensures the sway bar remains stable and functions effectively in reducing body roll.
Wheels Hub
1 Wheel Lug Nuts
M12 x 1.25
1
Wheel Lug Nuts
M12 x 1.25
Torque Specification
80 ft-lbs (110 N·m)
Important Notes
Ensures the wheel remains attached and prevents loosening, which could lead to wheel detachment.
Subframe
1 Subframe Mounting Bolts
M14 x 1.5
1
Subframe Mounting Bolts
M14 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Maintains suspension alignment and structural integrity by ensuring the subframe remains securely attached.
Troubleshooting Guide
Common issues, diagnostic steps, and prevention guidelines
Common Issues
Bolt stretching, stripped threads, uneven torque patterns
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
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
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 torque spec for the front wheel lug nuts on a 1998 Volvo V40?
Q1
What IS the torque spec for the front wheel lug nuts on a 1998 Volvo V40?
100 ft-lbs (135 Nm)
Q2 What IS the recommended torque for tightening the oil drain plug on a 2002 Volvo V40?
Q2
What IS the recommended torque for tightening the oil drain plug on a 2002 Volvo V40?
25 ft-lbs (33 Nm)
Q3 What IS the correct torque for the spark plugs on a 1995 Volvo V40?
Q3
What IS the correct torque for the spark plugs on a 1995 Volvo V40?
18 ft-lbs (24 Nm)
Q4 Can I use a generic torque wrench for working on my Volvo V40?
Q4
Can I use a generic torque wrench for working on my Volvo V40?
It IS recommended to use a torque wrench specifically calibrated for automotive applications. A generic wrench may not provide accurate results.
Q5 How often should I check the torque on critical bolts on my Volvo V40?
Q5
How often should I check the torque on critical bolts on my Volvo V40?
It IS advisable to follow the manufacturer's recommended maintenance schedule for torque inspections. Generally, critical bolts should be checked after every major repair or component replacement.
Q6 What are the potential consequences of over-tightening or under-tightening bolts?
Q6
What are the potential consequences of over-tightening or under-tightening bolts?
Over-tightening can damage threads, bolt heads, or even the components they are securing. Under-tightening can result in loose or rattling components, potentially leading to safety hazards or premature failure.
Environmental Considerations
Temperature, humidity, and seasonal effects on torque specifications
Temperature Effects
Includes: High Heat, Cold Weather, Thermal Cycling
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
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
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
Digital Torque Wrench (10-100 Nm)
Essential for tightening fasteners to precise torque specifications, preventing damage and ensuring proper assembly. This range IS suitable for many applications on the v40.
- Digital display for accurate readings
- Audible alarm when target torque IS reached
- Multiple units (Nm, ft-lb, in-lb)
- Reversible ratcheting mechanism
Service Procedures
Front Suspension - Upper Strut Mount Bolts
Step-by-step guide to tightening the upper strut mount bolts on a Volvo v40
- Raise the vehicle and support it on jack stands.
- Locate the upper strut mount bolts. There are three bolts on each side.
- Use a digital torque wrench to tighten the bolts to 25 Nm (18 ft-lb).
- Lower the vehicle and road test.
Rear Suspension - Control Arm Bush Bolts
Step-by-step guide to tightening the control arm bush bolts on a Volvo v40
- Raise the vehicle and support it on jack stands.
- Locate the control arm bush bolts. There are two bolts on each side.
- Use a digital torque wrench to tighten the bolts to 65 Nm (48 ft-lb).
- Lower the vehicle and road test.
Technical Service Bulletins
TSB 1995-06-01: Incorrect Torque Specifications for Engine Mount Bolts
1995-06-01Bulletin issued by Volvo regarding incorrect torque specifications for the engine mount bolts on certain v40 models.
1995-1999 v40
Resolution: The correct torque specifications for the engine mount bolts are as follows: - M10 bolts: 50 Nm (37 ft-lb) - M12 bolts: 70 Nm (52 ft-lb)
TSB 2001-03-15: Suspension Noise from Front Upper Strut Mount
2001-03-15Bulletin issued by Volvo regarding a suspension noise from the front upper strut mount on certain v40 models.
2000-2004 v40
Resolution: The resolution IS to tighten the upper strut mount bolts to 25 Nm (18 ft-lb).
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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.
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