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2002 Volvo S40 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
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- 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
A/C & HEATER SERVICE PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Volvo -> Automatic Temperature Control System Diagnosis & Testing -> Troubleshooting -> C70, S70 & V70
Vehicle: 2002 Volvo S40 1.9 L4 GAS
C70, S70 & V70
...
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BRAKE SERVICE PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Power Brake Units -> Power Brake Unit Service -> Check Valve, Replace -> Power Brake Booster, Replace
Vehicle: 2002 Volvo S40 1.9 L4 GAS
Power Brake Booster, Replace
- Remove master cylinder, then disconnect vacuum hose from power brake unit.
- Disconnect link arm from brake pedal, then remove bracket with clutch pedal stop.
- Remove nuts attaching power brake unit to dash panel.
- Pull power brake unit forward, then disconnect fork from link arm and remove brake unit.
Check Valv...
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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
Alternator, Replace
Vehicle: 2002 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 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 -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 2002 Volvo S40 1.9 L4 GAS
The warning lamp is used to warn of an system fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diagnostic sy...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Volvo S40 AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 Volvo S40 1.9 L4 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition clamp on heat exchanger feed pipe and remove hose.
- Reposition clamp on cylinder head nipple and remove hose.
- Remove hose from vehicle.
- Reverse procedur...
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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+.
Fuel System Components Diagram for 2002 Volvo S40 1.9 L4 GAS Components on diagram: |
Connectors Diagram for 2002 Volvo S40 1.9 L4 GAS Components 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 Diagram Components on diagram: |
2002 Volvo S40 1.9 L4 GAS Wiring Diagram Components 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+.
Document: STUCK CDS IN AUDIO UNIT Vehicle: 2002 Volvo S40 1.9 L4 GAS Auto Systems: |
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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