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2003 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
- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 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 2003 Volvo S40 AUTOMOBILES
Volvo -> Manual A/C & Heater System Diagnosis & Testing -> System Diagnosis & Testing -> Accessing Diagnostic Trouble Codes (DTCs) -> Breakout Box Connection -> Clearing Diagnostic Trouble Codes -> Diagnostic Tests -> Diagnostic Trouble Code Interpretation -> Performance Test
Vehicle: 2003 Volvo S40 1.9 L4 GAS
Performance Test
Refer to as outlined under "Automatic Temperature Control System Diagnosis & Testing."
Accessing Diagnostic Trouble Codes (DTCs)
- Turn ignition On.
- Press REC button twice within three seconds to access DTCs.
- DTCs are displayed as REC indicator LED flashes.
Diagnostic Trouble Code Interpretation
- REC indicator LED flashes for one second and is off for .5 second.
- Timing between DTCs numbers sequence is two seconds.
- Timing between DTCs is five seconds.
- Refer to Fig. , for DTC interpretat...
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BRAKE SERVICE PROCEDURES FOR 2003 Volvo S40 AUTOMOBILES
Disc Brakes -> Rotor, Replace -> Front -> Rear
Vehicle: 2003 Volvo S40 1.9 L4 GAS
Front
- Remove retaining spring from caliper.
- Remove mounting bolts, then the caliper. Hang caliper from a steel wire as not to damage brake hose.
- Remove caliper mounting bracket.
- Remove rotor locating pins, then the rotor.
- Reverse procedure to install. Tighten locating pin and caliper mounting bracket bolts to specifications.
Rear
- Press out split pins with a .12 (3mm) mandrel, the remove retaining spring...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Volvo S40 AUTOMOBILES
Volvo -> Fuel Filter Replacement -> C70, S60, S80, V40, XC90 & S40 w/1.9L Engine
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
Alternator, Replace
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
Volvo -> Service Indicator Lamp -> 2000-04 S40
Vehicle: 2003 Volvo S40 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 2003 Volvo S40 AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 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 2003 Volvo S40 AUTOMOBILES
Component location diagrams for most 2003 Volvo S40 cars and light trucks sold in the U.S. from 1990+.
 Fuel System Components Diagram for 2003 Volvo S40 1.9 L4 GASComponents on diagram: |
 ABS Components Diagram for 2003 Volvo S40 1.9 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Volvo S40 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Volvo S40 cars and light trucks sold in the U.S.
 2003 Volvo S40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
 2003 Volvo S40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Volvo S40 AUTOMOBILES
OEM TSB listings for most 2003 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: 2003 Volvo S40 1.9 L4 GAS Auto Systems: |
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Document: STUCK CDS IN AUDIO UNIT Vehicle: 2003 Volvo S40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Volvo S40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 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 2003 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 2003 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 2003 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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