Timing belt replacement: Volvo S40 >04 1.9 TD (D4192T, D4192T2)

🧭 Before you start

Fits: platform codes 1.9, TD

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

Don't miss

• Always check the timing marks before timing belt removal
• The arrows on the belt show the direction of rotation
• Never turn the engine in the direction opposite to that of normal operation
• Ensure the belt tensioner is loose to avoid damaging the belt during fitting
• The engine must be cold before timing belt adjustment

🔧 Engine codes this applies to

📐 12 workshop diagrams for D4192T

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

Preparation and removal

1. Always check the timing marks before timing belt removal
2. Never turn the engine in the direction opposite to that of normal operation
3. Remove the cover
4. Insert the gauge tool into the opening of the tensioning tool
5. Remove the studs

6. Remove the timing belt upper cover
7. Remove the wheel arch liner
8. Turn the crankshaft to TDC for cylinder 1
9. Check the timing marks
10. Remove the special tool
11. Remove the M6 bolt
12. Ensure the pin locks the crankshaft
13. Clean the crankshaft pulley bolt
14. Mark the position of the injection pump pulley
15. Remove the timing belt lower cover
16. Loosen the tensioner
17. Remove the timing belt
18. Fit the crankshaft locking pin

Installation and checks

19. Note the following when fitting the belt:
20. Note: The arrows on the belt show the direction of rotation
21. Ensure the belt tensioner is loose to avoid damaging the belt during fitting
22. Note: The engine must be cold before timing belt adjustment
23. Use an M6 bolt to adjust the timing belt tension
24. Adjust the timing belt tension
25. Fit the timing belt lower cover
26. Tighten the crankshaft pulley centre nut
27. Check the timing marks and timing belt tension again
28. Adjust if necessary
29. Remove the crankshaft locking pin
30. Refit the access plug
31. Refit the wheel arch liner
32. Refit the timing belt upper cover
33. Refit the studs
34. Refit the bolts
35. Refit the cover
36. Refit the bolts
37. Refit the engine mount
38. Tighten the bolts
39. Tighten the bolt by hand
40. Remove the engine support
41. Tighten the bolt
42. Vehicles with air conditioning:
43. Refit the bracket
44. All vehicles:
45. Fit the ancillary drive belt
46. Refit the oil filler cap
47. Refit the engine cover

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