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2002 Volvo S40 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 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 2002 Volvo S40 AUTOMOBILES
Imported Cars & Light Trucks & Vans -> 2001-02 -> Precautions -> A/C Refrigerant Oil -> Battery Ground Cable -> Cleanliness -> Engine Coolant -> Exercise System -> General Service -> Product Compatibility -> R-134a -> Safety
Vehicle: 2002 Volvo S40 1.9 L4 GAS
Battery Ground Cable
Prior to service disconnect battery ground cable and isolate as required.
Product Compatibility
A/C Refrigerant Oil
Before replenishing refrigerant oil, ensure product compatibility with the system being serviced. Refer to "A/C Data" for specifications.
Engine Coolant
Before adding or replacing engine coolant, ensure product compatibility with the system being serviced. If using orange silicate-free coolant, do not mix with green silicated coolant. If mixed, premature engine, heater core or radiator corrosion may result.
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BRAKE SERVICE PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Hydraulic Brake Systems -> Component Replacement -> Master Cylinder -> Pressure Differential Warning Valve -> Regulating Valve
Vehicle: 2002 Volvo S40 1.9 L4 GAS
Master Cylinder
- Place a cover over the fender to protect paint from brake fluid.
- Disconnect brake lines and cap openings.
- Remove retaining nuts, then the master cylinder.
- Reverse procedure to install. Bleed master cylinder prior to installation.
Regulating Valve
The regulating valve must be replaced as an assembly.
- Disconnect brake pipe from valve, replace unions if required.
- ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Volvo -> Fuel Filter Replacement -> C70, S60, S80, V40, XC90 & S40 w/1.9L Engine
Vehicle: 2002 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 2002 Volvo S40 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2002 Volvo S40 1.9 L4 GAS
- Raise and support vehicle on lift.
- Remove lefthand hub cap.
- Remove lefthand driveshaft nut and washer.
- Remove left front wheel lug nuts.
- Remove lefthand splash guards under engine.
- Remove lefthand splash guard in wheel arch
- Remove drive shaft from transmission enough to free snap ring in differential drive using suitable tool.
- Disconnecting drive shaft from hub using suitable tool. If the drive shaft sticks in the hub, tap it with a copper or rubber mallet. If required, use a universal puller. The drive shaft can be pressed in approximately 15mm.
- Remove brake hose from the mounti...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Starter, Replace
Vehicle: 2002 Volvo S40 1.9 L4 GAS
- Remove hose and pipe for charge air cooler.
- Remove splash guard.
- Remove power cable and antenna from starter motor.
- ...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2002 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 2002 Volvo S40 AUTOMOBILES
Volvo -> Check Engine Lamp ->
Vehicle: 2002 Volvo S40 1.9 L4 GAS
This lamp should be illuminated when the ignition switch is placed in the On position. After the engine has been started, the lamp should go out. If it remains lit, a problem has b...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 Volvo S40 1.9 L4 GAS
Lower
- Drain coolant into a suitable container.
- Reposition clamp at radiator and remove hose.
- Reposition clamp at coolant pipe and remove hose.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Volvo S40 1.9 L4 GAS
- On Turbocharged equipped models, remove righthand engine cover and cover over right headlamp.
- On all ...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Volvo S40 AUTOMOBILES
Component location diagrams for most 2002 Volvo S40 cars and light trucks sold in the U.S. from 1990+.
 Central Electronic Module Diagram for 2002 Volvo S40 1.9 L4 GASComponents on diagram: |
 Climate Control Unit Diagram for 2002 Volvo S40 1.9 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Volvo S40 AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Volvo S40 cars and light trucks sold in the U.S.
 2002 Volvo S40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
 2002 Volvo S40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Volvo S40 AUTOMOBILES
OEM TSB listings for most 2002 Volvo S40 cars and light trucks sold in the U.S. from 1985+.
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Document: STUCK CDS IN AUDIO UNIT Vehicle: 2002 Volvo S40 1.9 L4 GAS Auto Systems: |
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Document: UPDATED PROCEDURE, PROPELLER SHAFT, REMOVAL/INSTALLATION Vehicle: 2002 Volvo S40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Volvo S40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 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 2002 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 2002 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 2002 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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