Auto Parts Search
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 Year
2010 | 2009 | 2008 | 2007 |
2006 | 2005 | 2004 | 2003 |
2002 | 2001 | 2000 |
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 -> Wiring Diagrams
Vehicle: 2004 Volvo S40 I 2.4 L5 GAS
CLICK HERE TO GET FULL ACCESS TO Volvo S40 A/C & HEATER SERVICE PROCEDURES
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 ...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 BRAKE SERVICE PROCEDURES
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 Scheduled Maintenance -> 2005-06 S40 & V50 -> Normal Service -> Severe Service
Vehicle: 2006 Volvo S40 2.4I 2.4 L5 GAS
Normal Service
Service as...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 FUEL FILTER REPLACEMENT PROCEDURES
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: 2008 Volvo S40 T5 2.5 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...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES
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+.
Relearn Procedures
Vehicle: 2008 Volvo S40 2.4I 2.4 L5 GAS
There are two ways to relearn a tire pressure sensor ID. Drive the vehicle faster than 25 mph for longer than 10 minutes. The warning for low tire pressure remains in the Driver information module (DIM) unt...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 TIRE PRESSURE MONITORING SYSTEM PROCEDURES
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: 2004 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 ...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 STARTER & ALTERNATOR REPLACEMENT PROCEDURES
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: 2006 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 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...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES
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 -> Air Bag Warning Lamp ->
Vehicle: 2002 Volvo S40 1.9 L4 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 MAINTENANCE LAMP RESET PROCEDURES
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: 2007 Volvo S40 2.4I 2.4 L5 GAS
- Drain coolant into suitable container.
- Remove electric cooling fan.
- Remove charge air cooler.
- Remove engine compartment panel.
- Remove radiator mounting on both sides.
- Slightly raise condenser and suspend from a suitable place, so ...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 RADIATOR & HOSE REPLACEMENT PROCEDURES
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: 2009 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...
CLICK HERE TO GET FULL ACCESS TO Volvo S40 SERPENTINE BELT SERVICE PROCEDURES
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+.
Heated Seat Components Diagram for 2000 Volvo S40 1.9 L4 GAS Components on diagram: |
GPS System Diagram for 2005 Volvo S40 T5 2.5 L5 GAS Components on diagram: |
CLICK HERE TO GET FULL ACCESS TO Volvo S40 PARTS/COMPONENTS LOCATION DIAGRAMS!
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 T5 2.5 L5 GAS Wiring Diagram Components on diagram: |
2005 Volvo S40 T5 2.5 L5 GAS Wiring Diagram Components on diagram: |
CLICK HERE TO GET FULL ACCESS TO Volvo S40 WIRING DIAGRAMS!
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: CENTRAL LOCKING MOTOR IN THE FRONT AND REAR DOORS, SECURING/CHANGING Vehicle: 2000 Volvo S40 1.9 L4 GAS Auto Systems: |
Document: RETAILER PROCEDURES FOR INCIDENT REPORTING Vehicle: 2003 Volvo S40 1.9 L4 GAS Auto Systems: |
CLICK HERE TO GET FULL ACCESS TO Volvo S40 TECHNICAL SERVICE BULLETINS!
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
CLICK HERE TO GET FULL ACCESS TO Volvo S40 SPECIFICATIONS DATA!
Shop online for auto body parts, engines, wheels, lights...
More parts |
Get the Complete Technical Service Bulletins! |
Access diagrams and repair information such as wiring diagrams, diagnosis and repair charts, manufacturer service bulletins, and OEM Part numbers of your Volvo S40 vehicle. |
Access the Complete guide! |