This is probably simple for a few, but hopefully will help those who want to save some money and replace their right hand engine mount which is a common failure item on the S40.
First of all get your car on a level surface and support your engine using a jack along with a piece of wood. I put the jack just behind the oil filter and literally just took the weight of the engine, nothing more.
Then, remove the four clips that hold on the plastic cover to the far right (looking from the back of the car). Just undo the centre screws and the cover should just pull off, if not then undo the screws a bit more.
You will need an 18mm socket, and a 15mm socket with a long extension bar for your ratchet.
There are only 4 bolts to remove, a centre bolt that goes through the mount on the bracket, and 3 more that bolt into the engine block. I removed the 3 bolts in the engine mount first although there is no reason why it shouldn’t be done the other way round. One bolt was very tight but came out eventually.
I then knocked the bolt going through the centre of the mount through towards the back of the engine bay. The A/C pipes are just out of the way but be careful not to pull on them.
I had to jack the engine up another 2-3 inches to give enough clearance to remove the mount, but some manouvreing did the trick.
Installing the new mount was in the style of Hayne’s, “the reverse of removal”. I did apply some grease on the side where it had been rubbing against the bracket.
I just manouvred the mounting into place, lined up the holes to get the bolt through the centre and then loosely screwed all the bolts in place.
I then released the weight from the jack and went round all four bolts tightening them up evenly. I did apply some copper grease to the bolt that was stiff, and getting that back in was a lot easier.
I then went for a drive to get it up to temperature, and came back to re-check the bolts. They were all nice and tight.
Inspecting the old mount showed up where it was failing.
The instructions in this tutorial will work in the following models / years:
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo S40
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo V40