Clutch replacement: Volvo S40, V50, S40 vin 18292, V50 vin 2.0 TD (D4204T, D4204T2)

🧭 Before you start

Fits: platform code 2.0D

• Renewed: seal

Don't miss

• Always renew the drive shaft seals

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. Always renew the drive shaft seals
2. Check the clutch release bearing guide tube and fork; renew if necessary
3. Remove the clutch cover
4. Remove the clutch plate

Installation and checks

5. Remove the cone from the special tool

6. Fit the clutch plate
7. Note: Finger-tight only
8. Fit the special tool
9. Clutch alignment tool:
10. Vehicles without self-adjusting clutch
11. Note the position of the handle
12. Note the position of the handle
13. Apply tension to the clutch cover
14. Turn the handle
15. Vehicles with self-adjusting clutch
16. Tighten the screw until there is light contact with the diaphragm spring
17. Vehicles with self-adjusting clutch
18. The original position is shown by two stamped arrows
19. Continue to tighten the screw until the pressure plate moves to a free position
20. A snap is heard when the 'FREE' position is achieved
21. Or until a snap is heard
22. Check that the automatic adjuster is secured with the special tool
23. Fit the clutch cover
24. Note: Leave the tool in position
25. Remove the special tools
26. Fit the concentric slave cylinder
27. Reconnect the hydraulic line quick-release coupling
28. Renew the seal

Other VOLVO procedures

• Volvo 2.0 TD timing chain replacement
• Volvo V70, S80: renewal 2.0 TD D4204T DPF removal
• Volvo S40, V50, C30, C70, T2 2.0 TD starter motor removal
• Volvo C30 2.0 TD D4204T/D4204T12 clutch replacement
• Volvo V70, S80 2.0 TD D4204T timing belt replacement
• Volvo S80, V70 2.0 B4204S3/B4204S4 timing chain replacement
• Volvo B5244S gearbox removal & installation
• S40/V40 B4184S2 M5P/M56 clutch removal
• Volvo 1.6 TD D4164T timing chain replacement
• Volvo S40 >04, S9, S10, T5 timing belt replacement