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Volvo S80 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 S80 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 S80 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volvo S80 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 S80 cars and light trucks from 1990+
Orifice Tube/Expansion Valve Locations -> Imported Cars & Light Trucks & Vans -> 2003-04
Vehicle: 2004 Volvo S80 2.5T AWD 2.5 L5 GAS
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BRAKE SERVICE PROCEDURES FOR Volvo S80 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volvo S80 cars and light trucks from 1990+.
Anti-lock Brakes -> System Service -> Brake System Bleed -> Component Replacement -> Control Module -> Hydraulic Modulator -> Less Multi-Link Rear Suspension -> Multi-Link Suspension -> Rear Sensor
Vehicle: 1999 Volvo S80 2.8 L6 GAS
Brake System Bleed
Refer to "Brake System Bleed" section under "Hydraulic Brake Systems."
Component Replacement
Control Module
- Ensure ignition is off.
- Remove sound proofing under instrument panel.
- Loosen band holding control module and lift module out.
- Remove control module connector.
- Reverse procedure to install.
Hydraulic Modulator
- Remove cover over hydraulic modulator.
- Remove both relays and connector.
- Disconnect ground lead from modulator
- Remove hydraulic lines to modulator noting position for installation.
- Remove screw from support and push support to right. Remove hydraulic modulator
- Reverse ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Volvo S80 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volvo S80 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: 2004 Volvo S80 2.5T AWD 2.5 L5 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 S80 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volvo S80 cars and light trucks from 1990+.
Driveshaft, Replace
Vehicle: 2000 Volvo S80 2.8 L6 GAS
If same propeller shaft is to be reinstalled, mark propeller shaft CV joint in relation to bevel gear flange.
- Raise and support vehicle.
- Remove front member from body, exhaust pipe and Three-Way Catalytic Converter (TWC).
- Remove brake pipe from mountings in member.
- Remove screws from propeller shaft. Use a suitable counterhold tool.
- Support front section of exhaust pipe so as not to put strain on exhaust manifold.
- Remove rear exhaust system assembly. If same propeller shaft is to be reused, mark propeller shaft CV joint in relation to flange.
- Remove screws from joint. Use a suitabl...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Volvo S80 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 S80 cars and light trucks sold in the U.S. from mid 1990's+.
Component Replacement -> Installation -> Removal -> TPMS Pressure Warning Valve & Transmitter
Vehicle: 2007 Volvo S80 3.2 3.2 L6 GAS
TPMS Pressure Warning Valve & Transmitter
For series C70, S40, V50 and 2007 S80, refer to Fig. service TPMS sensor identification.
For series V70, XC70, 2005-06 S80, S60 up to chassis number 688292 and XC90 up to chassis number 456766, refer to Fig. TPMS sensor identification.
On S60 and XC90 vehicles, a newer version of the TPMS sensor, Fig. , with a rubber valve stem and a snap-in transmitter was introduced in production starting with following S60 chassis numbers 688293 and XC90 chassis number 456767. The appearance of a rubber valve stem does not indicate lack of TPMS sen...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volvo S80 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volvo S80 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2005 Volvo S80 2.5T 2.5 L5 GAS
- Disconnect battery ground cable.
- Remove intake manifold between front cover plate and air cleaner housing.
- On models equipped with turbo, loosen hose clamps between charge air cooler and electronic throttle module, disconnect electrical connector and remove charge air cooler hose.
- On all model...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Volvo S80 AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Volvo S80 cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2001 Volvo S80 2.8 L6 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.
- Remove the cabin air filter cover retaining screws, then the cover, Fig. .
- Press down on the cabin air filte...
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MAINTENANCE LAMP RESET PROCEDURES FOR Volvo S80 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volvo S80 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: 2002 Volvo S80 2.9 L6 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 S80 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volvo S80 cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 Volvo S80 2.9 L6 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 S80 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Volvo S80 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2005 Volvo S80 T6 2.9 L6 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR Volvo S80 AUTOMOBILES
Component location diagrams for most Volvo S80 cars and light trucks sold in the U.S. from 1990+.
 Electronic Power Steering Components Diagram for 1999 Volvo S80 2.8 L6 GASComponents on diagram: |
 HVAC Components Diagram for 2007 Volvo S80 V8 4.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Volvo S80 AUTOMOBILES
OEM drawn wiring diagrams for most Volvo S80 cars and light trucks sold in the U.S.
 2004 Volvo S80 2.5T 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2008 Volvo S80 T6 3.0 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volvo S80 AUTOMOBILES
OEM TSB listings for most Volvo S80 cars and light trucks sold in the U.S. from 1985+.
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Document: AUTO-UP WINDOW OPERATION Vehicle: 2008 Volvo S80 V8 4.4 V8 GAS Auto Systems: |
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Document: KNOCKING NOISE WHILE TURNING Vehicle: 2002 Volvo S80 2.9 L6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volvo S80 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volvo S80 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 S80 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 S80 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 S80 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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