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2004 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
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- Technical Service Bulletins
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- A/C & Heater 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 2004 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 2004 Volvo S40 AUTOMOBILES
Charging Valve Locations -> Imported Cars & Light Trucks & Vans -> 2003-04
Vehicle: 2004 Volvo S40 1.9 L4 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Volvo S40 AUTOMOBILES
Volvo -> Fuel Filter Scheduled Maintenance -> 2004 S40 w/1.9L Engine, V40 & C70 -> Normal Service -> Severe Service
Vehicle: 2004 Volvo S40 1.9 L4 GAS
Normal Service
Replace...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Volvo S40 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 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 2004 Volvo S40 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Volvo S40 1.9 L4 GAS
- Disconnect battery ground cable.
- Remove bolts 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 holding cable harness and move cable harness below air cleaner module.
- Remove bolt securing oil dipstick tube.
- Detach hose clamp for rubber hose on electronic throttle module then move hose to one side.
- Remove bolts for elec...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Volvo S40 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2004 Volvo S40 T5 2.5 L5 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 2004 Volvo S40 AUTOMOBILES
Volvo -> Air Bag Warning Lamp ->
Vehicle: 2004 Volvo S40 I 2.4 L5 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Volvo S40 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Volvo S40 T5 2.5 L5 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 2004 Volvo S40 AUTOMOBILES
Serpentine Drive Belt, Replace -> Inner Drive Belt -> Outer Drive Belt
Vehicle: 2004 Volvo S40 T5 2.5 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 2004 Volvo S40 AUTOMOBILES
Component location diagrams for most 2004 Volvo S40 cars and light trucks sold in the U.S. from 1990+.
 Climate Control Unit Diagram for 2004 Volvo S40 T5 2.5 L5 GASComponents on diagram: |
 Front Lights Diagram for 2004 Volvo S40 I 2.4 L5 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Volvo S40 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Volvo S40 cars and light trucks sold in the U.S.
 2004 Volvo S40 T5 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2004 Volvo S40 T5 2.5 L5 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Volvo S40 AUTOMOBILES
OEM TSB listings for most 2004 Volvo S40 cars and light trucks sold in the U.S. from 1985+.
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Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S40 1.9 L4 GAS Auto Systems: |
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Document: TRANSMISSION CONTROL MODULE (TCM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Volvo S40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 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 2004 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 2004 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 2004 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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