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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 -> Automatic Temperature Control System Diagnosis & Testing -> Technical Service Bulletins -> S60, V70 & V70 XC -> Whistling Noise At Climate Control Air Intake
Vehicle: 2003 Volvo S40 1.9 L4 GAS
Whistling Noise At Climate Control Air Intake
S60, V70 & V70 XC
On these models there may be whistling noises at the air intake caused by improper air flow between the recirculation and outer air shutters.
To correct this condition, proceed as follows:
- Remove windshield wiper arm assemblies.
- Remove plenum chamber and gutter.
- Remove water deflector shield by carefully prying up on hooks while lifting shield, Fig. .
- Turn ignition On, then turn REC button to MAN position.
- Turn blower switch until fi...
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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+.
Disc Brakes -> Caliper Service -> Rear -> Removal & Overhaul
Vehicle: 2003 Volvo S40 1.9 L4 GAS
Rear
Removal & Overhaul
- Raise and support rear of vehicle, then remove rear tires.
- Disconnect brake lines, then remove two caliper attaching bolts and caliper.
- Remove piston dust cover, then place a piece of wood or suitable material between both pistons. Force pistons out of bore using low pressure compressed air.
- Remove sealing rings, then bleeder screw. Do not separate brake caliper into two separate halves.
- Clean caliper assembly thoroughly using brake fluid or denatured alcohol.
- Remove any ...
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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 -> S40 w/2.4L & 2.5L Engines & V50 -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 2006 Volvo S40 2.4I 2.4 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.
Fuel Sy...
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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: 2010 Volvo S40 2.4I 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+.
Component Replacement -> Installation -> Removal -> TPMS Pressure Warning Valve & Transmitter
Vehicle: 2008 Volvo S40 T5 2.5 L5 GAS
TPMS Pressure Warning Valve & Transmitter
For series C30, C70, S40, S80, V50, V70 and XC70, refer to Fig. service TPMS sensor identification.
For series 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 sensors. The sen...
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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: 2009 Volvo S40 2.4I 2.4 L5 GAS
- Remove battery negative lead.
- Remove air cleaner housing.
- Remove pipes and pipe bracket.
- Remove battery positive cable to starter solenoid.
- Remove battery positive cable to starter motor lead.
- Remove starter mount...
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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 -> 2005-09 S40, V50 & 2006-09 C70
Vehicle: 2007 Volvo S40 2.4I 2.4 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 four hidden instrument panel center cover clips, then the cover, Fig. .
- Using a weather strip tool, or other suitable tool, remove the left instrument panel end cover. Use care not to damage the cover during removal.
- From the left end of the instrument panel, remove the sound proofing panel retaining clip, Fig. .
- Remove the three driver side sound proofing panel retaining screws, Fig. .
- Detach the in-car temperature sensor fro...
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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 -> Check Engine Lamp ->
Vehicle: 2007 Volvo S40 2.4I 2.4 L5 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 Volvo S40 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volvo S40 cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2010 Volvo S40 2.4I 2.4 L5 GAS
- Drain coolant into a suitable container.
- Remove electric cooling fan.
- Install four bracket screws for radiator lightly.
- Remove charge air cooler (CAC).
- Remove screws fastening engine compartment panel and panel.
- Remove upper radiator mounting screws on both side.
- Slightly raise condenser and su...
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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: 2008 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 Volvo S40 AUTOMOBILES
Component location diagrams for most Volvo S40 cars and light trucks sold in the U.S. from 1990+.
 Audio Components Diagram for 2004 Volvo S40 1.9 L4 GASComponents on diagram: |
 Back-Up Lamps Components Diagram for 2000 Volvo S40 1.9 L4 GASComponents 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.
 2008 Volvo S40 T5 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2007 Volvo S40 T5 2.5 L5 GAS Wiring DiagramComponents 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+.
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Document: REPLACING AND RELOCATING THE FUEL PUMP CONTROL MODULE Vehicle: 2006 Volvo S40 2.4I 2.4 L5 GAS Auto Systems: |
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Document: RECALL - SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER Vehicle: 2007 Volvo S40 2.4I 2.4 L5 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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