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Notes Specified value Measured value

Tightening torques
Cylinder head instructions
Cylinder head
Renew bolts Yes
Stage 1 Tighten 20 Nm
Stage 2 Tighten 60 Nm
Stage 3 Tighten 130°
Other engine tightening torques
00000090 Main bearings Stage 1
Renew
Big end bearings Yes
bolts/nuts
Big end bearings Stage 1 1)15 Nm 2)25 Nm
Big end bearings Stage 2 3)100°
Oil pump to cylinder block 10 Nm
Sump bolts 17 Nm
Sump drain bolt 38 Nm
00000038 Flywheel/driveplate 45 Nm+65°
Clutch pressure plate 25 Nm
00000038 Crankshaft pulley/damper centre bolt 180 Nm
00000170 Camshaft sprocket/gear
Camshaft carrier/cap 16 Nm
Camshaft/rocker cover 14 Nm
Inlet manifold to cylinder head 19 Nm
00000038 Exhaust manifold to cylinder head 25 Nm
00000038 Exhaust downpipe to manifold 30 Nm
Water pump 17 Nm
Spark plugs 28 Nm
00000038 Fuel rail 10 Nm
Crankshaft position (CKP) sensor/engine speed (RPM)
10 Nm
sensor
Camshaft position (CMP) sensor 10 Nm
Engine coolant temperature (ECT) sensor 22 Nm
Lambda sensor (Oxygen) 45 Nm
Knock sensor (KS) 20 Nm
Engine oil pressure switch 27 Nm
Oil filter 35 Nm
Chassis tightening torques
00000038 Front hub 35 Nm+90°
Steering wheel 47 Nm
Steering rack/box mounting 80 Nm
Steering track rod end 40 Nm
Brake caliper to carrier Front 30 Nm
00000038 Brake caliper/carrier to hub Front 120 Nm
Brake caliper to carrier Rear 35 Nm
00000038 Brake caliper/carrier to hub Rear 70 Nm
Back plate to hub Rear 12 Nm

Manufacturer: Volvo Model: S40 (03-12) 2,4 (c) Autodata Limited 2013
Engine code: B5244S4 Output: 125 (170) 6000 . 16/05/2022
Tuned for: R-Cat Year: 2003-10 V9.200-
 ABS sensor Front 5 Nm
ABS sensor Rear 5 Nm
00000160 Road wheels

Autodata Note 38

Use new nuts/bolts.

Autodata Note 90

Main bearings

Use new M10 bolts.

Tighten bolts in the following order:
1) M10 = 20 Nm
2) M10 = 45 Nm
3) M8 = 24 Nm
4) M7 = 17 Nm
5) M10 = + 90°.

Autodata Note 160

Road wheels

Alloy wheels with rotating washer on nut and steel wheels:

1) 20 Nm
2) 110 Nm
Alloy wheels without rotating washer on nut:
1) 20 Nm
2) 130 Nm

Autodata Note 170

Camshaft sprocket/gear

M6 = 10 Nm
VVT centre bolt = 120 Nm
VVT centre plug = 35 Nm

Tightening sequence

Manufacturer: Volvo Model: S40 (03-12) 2,4 (c) Autodata Limited 2013
Engine code: B5244S4 Output: 125 (170) 6000 . 16/05/2022
Tuned for: R-Cat Year: 2003-10 V9.200-