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Volvo S40 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Volvo S40 car and truck repair procedures including Volvo engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Volvo S40 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volvo S40 AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Volvo S40 cars and light trucks from 1990+
Volvo -> Component Replacement & Adjustment -> Precautions -> Air Bag System Disarming & Arming -> Battery Ground Cable -> Product Compatibility
Vehicle: 2000 Volvo S40 1.9 L4 GAS
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming procedures.
Battery Ground Cable
Prior to service, disconnect battery ground cable ...
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BRAKE SERVICE PROCEDURES FOR Volvo S40 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volvo S40 cars and light trucks from 1990+.
Anti-lock Brakes -> Description
Vehicle: 2002 Volvo S40 1.9 L4 GAS
The Anti-Lock Brake System (ABS) uses a control unit, hydraulic modulator, transient surge protector, front speed sensors and a speedometer sensor to control wheel lock-up. The control unit receives vehicle speed, wheel speed and wheel acceleration information from the sensors, then sends the information to the hydraulic modulator. The hydraulic modulator uses this information to ensure correct hydraulic ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Volvo S40 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volvo S40 cars and light trucks sold in the U.S. for 1980+.
Volvo -> Fuel Filter Replacement -> C70, S60, S80, V40, XC90 & S40 w/1.9L Engine
Vehicle: 2000 Volvo S40 1.9 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Always disconnect the battery ground cable before replacing the fuel filter. Position a shop towel over fuel filter connections before disconnecting.
- Connect the adapter tool (Volvo tool No. 999 5484 or equivalent), to the fuel drainage unit (Volvo tool Nos. 981 2270, 2273 and 2282 or equivalents).
- Connect the adapter to fuel rail valve. Position the fuel drainag...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Volvo S40 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volvo S40 cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Left Side -> Right Side
Vehicle: 2004 Volvo S40 I 2.4 L5 GAS
Left Side
- Raise and support vehicle on lift.
- Remove hub cap.
- Remove front wheel lug nuts.
- Remove bolt for wheel hub driveshaft.
- Tap end of drive shaft approximately 15-20mm into wheel hub.
- Remove anti-roll bar strut from spring strut.
- Counterhold ball joint pinion so that ball joint boot cannot turn.
- Detach brake hose from its mounting lug in spring strut.
- Detach ABS line from its mounting lug in wheel arch.
- Slacken off nut for ball joint for control arm. Before removing the nuts from the ball joints, clean the exposed threads of rust. Lubricate using rust solvent before removing t...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Volvo S40 AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Volvo S40 cars and light trucks sold in the U.S. from mid 1990's+.
Description
Vehicle: 2005 Volvo S40 T5 2.5 L5 GAS
The TPMS (Tire Pressure Monitor System) has a CEM (Central Electronic Module), a remote RRX (Receiver Module), or a RKE (Remote keyless Entry), if keyless entry is installed. There are sensors mounted in the wheels and are activated when the vehicle exceeds 25 mph. The sensors transmit...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volvo S40 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volvo S40 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2005 Volvo S40 I 2.4 L5 GAS
- Disconnect battery ground cable.
- Remove bolt for intake manifold front cover plate air cleaner module.
- Remove vacuum hose to MAF sensor and disconnect electrical connector.
- Disconnect brake vacuum hose from intake manifold.
- Disconnect vacuum hose from vacuum pump then move hoses to one side.
- Remove tie straps for cable harness on air cleaner module.
- Remove screw ...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Volvo S40 AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Volvo S40 cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2003 Volvo S40 1.9 L4 GAS
The cabin air filter should be replaced every 15,000 miles. The filter should be replaced more often if air flow is less than normal.
- Remove the sound proofing panel from under the passenger side of the instrument panel, Fi...
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MAINTENANCE LAMP RESET PROCEDURES FOR Volvo S40 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volvo S40 cars and light trucks sold in the U.S. from 1990+.
Volvo -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 2007 Volvo S40 T5 2.5 L5 GAS
The warning lamp is used to warn of an system fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diagnostic sy...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Volvo S40 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volvo S40 cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 Volvo S40 1.9 L4 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition clamp on heat exchanger feed pipe and remove hose.
- Reposition clamp on cylinder head nipple and remove hose.
- Remove hose from vehicle.
- Reverse procedur...
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SERPENTINE BELT SERVICE PROCEDURES FOR Volvo S40 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Volvo S40 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace -> Inner Drive Belt -> Outer Drive Belt
Vehicle: 2005 Volvo S40 I 2.4 L5 GAS
Outer Drive Belt
- Raise and support vehicle.
- Remove right front wheel and tire.
- Remove right fender liner. Remove screws at front edge and fold back fender liner.
- Rotate belt tensioner clockwise as far as it will go, using a suitable tool to relieve tension from drive belt.
- Remove ou...
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COMPONENT LOCATION DIAGRAMS FOR Volvo S40 AUTOMOBILES
Component location diagrams for most Volvo S40 cars and light trucks sold in the U.S. from 1990+.
Body Components Diagram for 2008 Volvo S40 T5 2.5 L5 GAS Components on diagram: |
Heated Seat Components Diagram for 2000 Volvo S40 1.9 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR Volvo S40 AUTOMOBILES
OEM drawn wiring diagrams for most Volvo S40 cars and light trucks sold in the U.S.
2007 Volvo S40 2.4I 2.4 L5 GAS Wiring Diagram Components on diagram: |
2006 Volvo S40 2.4I 2.4 L5 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volvo S40 AUTOMOBILES
OEM TSB listings for most Volvo S40 cars and light trucks sold in the U.S. from 1985+.
Document: RETAILER PROCEDURES FOR INCIDENT REPORTING Vehicle: 2003 Volvo S40 1.9 L4 GAS Auto Systems: |
Document: ON CALL ROAD SIDE ASSISTANCE PROGRAM OVERVIEW Vehicle: 2001 Volvo S40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volvo S40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volvo S40 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Volvo S40 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Volvo S40 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Volvo S40 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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