Volvo S40 Starter and Air Cleaner Assembly, Removal and Installation

In this video, I show how I disconnected the vacuum hoses and some electrical harness connectors before removing the air cleaner assembly components and housing.
After I unfastened the lower rubber mount holder to access the two bolts holding the starter in place.
I removed the starter, I fixed it with a new brush kit and I refitted it.
After, I show the key moments of the re-installation of all the parts.

[@perrydoran]

Great video, thanks for the tips on the airbox removal. I watched some of the Patriot videos when working on a friends vehicle. You can only imagine my excitement when I saw your channel pop up when I saw you working on the Volvo too!! You’re video are professional level, and so helpful!!!

[@mtlcarguy]

Thanks. Sometimes when the RHS engine mount is too old, the rubber is too compressed and the engine lowers a bit. This reduces the space required to remove the air box and the engine may need to be lifted a fraction to gain 2 or 3 mm to be able to remove the part.

[@perrydoran]

@@mtlcarguy in my case, the rubber isolator stuck to the mounting pin, giving me no clearance. I took the rubber isolator off and put it back in place, and was able to maneuver it back in like you did in the video.

[@villasandvistas]

Great video. Just completed the task. It’s very tight with the air box. Also, caution should be taken near the coolant hose plastic union when removing the bracket to access the starter bolts. This is a common failure point on these cars and too much movement on mine almost caused a crack. I added worm gear clamps for extra security.

[@mtlcarguy]

Good comment ! ....and happy new year. To reduce the risk of damaging the coolant overflow hose quick connect, the hose can be slackened and rerouted temporarily by disconnecting the hose from the coolant reservoir side.

[@perrydoran]

Mine cracked when doing this, I may 3d print a new clip.