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Volvo V40 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 V40 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 V40 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volvo V40 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 V40 cars and light trucks from 1990+
Volvo -> Component Replacement & Adjustment -> Cooling System Bleed
Vehicle: 2003 Volvo V40 1.9 L4 GAS
- Close all drain petcocks.
- Fill system with coolant.
- Start engine and bring to operating tempera...
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BRAKE SERVICE PROCEDURES FOR Volvo V40 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volvo V40 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: 2002 Volvo V40 1.9 L4 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 V40 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volvo V40 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: 2000 Volvo V40 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 Volvo V40 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volvo V40 cars and light trucks from 1990+.
CV AXLE SHAFT, Replace
Vehicle: 2001 Volvo V40 1.9 L4 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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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volvo V40 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volvo V40 cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 2001 Volvo V40 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 Volvo V40 AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Volvo V40 cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2002 Volvo V40 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 Volvo V40 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volvo V40 cars and light trucks sold in the U.S. from 1990+.
Volvo -> Service Indicator Lamp -> 2000-04 V40
Vehicle: 2000 Volvo V40 1.9 L4 GAS
- Turn ignition Off.
- Depress trip odometer Reset button.
- Turn ignition On.
- SRI should start flashing when Reset button has been pressed for 10 seconds
- Release Reset ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Volvo V40 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volvo V40 cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2000 Volvo V40 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 Volvo V40 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Volvo V40 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2000 Volvo V40 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 Volvo V40 AUTOMOBILES
Component location diagrams for most Volvo V40 cars and light trucks sold in the U.S. from 1990+.
 Stop Lamp Component Diagram for 2000 Volvo V40 1.9 L4 GASComponents on diagram: |
 Heater Components Diagram for 2004 Volvo V40 1.9 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Volvo V40 AUTOMOBILES
OEM drawn wiring diagrams for most Volvo V40 cars and light trucks sold in the U.S.
 2003 Volvo V40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
 2002 Volvo V40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volvo V40 AUTOMOBILES
OEM TSB listings for most Volvo V40 cars and light trucks sold in the U.S. from 1985+.
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Document: VADIS - PIE 2 - ORDERING FUNCTIONALITY Vehicle: 2004 Volvo V40 1.9 L4 GAS Auto Systems: |
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Document: DOOR PANEL REPAIR Vehicle: 2001 Volvo V40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volvo V40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volvo V40 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 V40 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 V40 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 V40 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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