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2003 Volvo V40 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 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 2003 Volvo V40 AUTOMOBILES
Import Compressor Service -> Zexel Compressor -> Compressor Clutch Service -> DKS-13CH, DKS-15CH & DKS-17CH Compressors -> DKS-16H Compressor -> DKV-14C & DKV-14D Compressor -> Replacement -> V-6 Compressor
Vehicle: 2003 Volvo V40 1.9 L4 GAS
Replacement
DKV-14C & DKV-14D Compressor
- Install tool No. J-33939, or equivalent, hold clutch plate, then remove clutch assembly to shaft center bolt, Fig. .
- Install puller tool No. J-33944-A and forcing screw tool No. J-33944-4, or equivalents, remove driveplate, Fig. .
- Remove adjusting shims, Figs. and .
- Install snap ring pliers, remove snap ring.
- Remove pulley using a suitable puller, Fig. .
- Disconnect field coil lead wire, then remove field coil.
- Reverse procedure to install, noting the following:
-
...
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BRAKE SERVICE PROCEDURES FOR 2003 Volvo V40 AUTOMOBILES
Anti-lock Brakes -> Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Tests -> Diagnostic Trouble Code Interpretation -> Diagnostic Trouble Code Table -> F. Intermittent Faults -> G. Diagnostic Trouble Code (DTC) Table -> H. Test Drive -> Intermittent Faults -> J. Diagnostic Trouble Code (DTC)/Diagnosis Table -> K. Symptoms/Diagnosis Table -> L. Mechanical Components, Fault Tracing -> Less Volvo Diagnostic Key -> MA. Diagnostic Trouble Codes (DTC), Wheel Sensors -> MB-Diagnostic Trouble Code (DTC) 1-4-1 -> MC-Diagnostic Trouble Code (DTC) 1-4-2 -> MD-Diagnostic Trouble Code (DTC) 1-4-4 -> ME-Diagnostic Trouble Codes (DTC), Valves -> MF-Diagnostic Trouble Code (DTC) 4-2-4 -> MG-Diagnostic Trouble Code (DTC) 4-4-1 -> MH-Diagnostic Trouble Code (DTC) 4-4-3 -> MJ-Diagnostic Trouble Code (DTC) 4-4-4 -> NA-ABS-Warning Indicator Does Not Light -> NB-ABS-Warning Indicator Lit, No Diagnostic Trouble Codes (DTC) Displayed -> NC-TRACS Warning Indicator Does Not Light -> ND-TRACS Warning Indicator Lit, No Diagnostic Trouble Codes (DTC) Displayed -> NE-Brake Warning Indicator Does Not Light -> NF-Brake Warning Indicator Does Not Go Out -> NG-Diagnostic Trouble Codes (DTC) Cannot Be Read -> NH-Poor Braking -> NJ-Both Front Wheels Are Wholly Or Partially Locked -> NK-No TRACS Function -> P-Signal Description, Control Module -> Reading Diagnostic Trouble Codes -> Wiring Diagrams -> With Volvo Diagnostic Key
Vehicle: 2003 Volvo V40 1.9 L4 GAS
The control unit contains a monitoring circuit to detect any internal faults in the control unit and any electrical faults in the sensors, hydraulic modulator or signaling system.
If a fault occurs, the control unit disengages the ABS and illuminates a warning light. When the warning light comes on, a complete fault tracing procedure should be followed. The fault tracing procedure assumes that the standard braking system is fully operational.
Accessing Diagnostic Trouble Codes
Less Volvo Diagnostic Key
- Connect diagnostic lead to position 3 on diagnostic output A, then turn ignit...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Volvo V40 AUTOMOBILES
Volvo -> Fuel Filter Scheduled Maintenance -> 2003 C70, S40, S60, S80 & V40 -> Normal Service -> Severe Service
Vehicle: 2003 Volvo V40 1.9 L4 GAS
Normal Service
Replace a...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Volvo V40 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 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 2003 Volvo V40 AUTOMOBILES
Alternator, Replace
Vehicle: 2003 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 2003 Volvo V40 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 2000-04 S40 & V40
Vehicle: 2003 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 2003 Volvo V40 AUTOMOBILES
Volvo -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 2003 Volvo V40 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 2003 Volvo V40 AUTOMOBILES
Radiator, Replace
Vehicle: 2003 Volvo V40 1.9 L4 GAS
- Remove expansion tank cap, then remove guard from under radiator.
- Drain coolant into suitable container.
- Remove front engine cover retaining bolts, then front cover.
- Remove electric cooling fan.
- Disconnect upper and lower radiator h...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Volvo V40 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 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 2003 Volvo V40 AUTOMOBILES
Component location diagrams for most 2003 Volvo V40 cars and light trucks sold in the U.S. from 1990+.
 Heater Components Diagram for 2003 Volvo V40 1.9 L4 GASComponents on diagram: |
 Control Module Diagram for 2003 Volvo V40 1.9 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Volvo V40 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Volvo V40 cars and light trucks sold in the U.S.
 2003 Volvo V40 1.9 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Volvo V40 AUTOMOBILES
OEM TSB listings for most 2003 Volvo V40 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 V40 1.9 L4 GAS Auto Systems: |
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Document: STUCK CDS IN AUDIO UNIT Vehicle: 2003 Volvo V40 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Volvo V40 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 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 2003 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 2003 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 2003 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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