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2004 Volvo S80 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
- 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 2004 Volvo S80 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 S80 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Volvo -> Electric Cooling Fans -> Precautions -> Air Bag System Disarming & Arming -> Anti-Theft Audio Systems -> Battery Ground Cable -> Product Compatibility
Vehicle: 2004 Volvo S80 2.5T 2.5 L5 GAS
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming procedures.
Product Compatibility
Before replenishing refrigerant or refrigerant oil, ensure product is compatible with the system being serviced. Refer to for specifications.
Anti-Theft Audio Systems
Obtain radio anti-theft code from vehicle owner and record station presets, then turn radio off before disconnecting or connecting battery ground cable to prevent radio damage.
The coded anti-theft system will disable the radio when battery power is inte...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Volvo -> Component Locations -> 2003-06 Volvo XC90, 2001-06 S60, 2000-04 S40 & V40, 1999-06 S80, 1998-06 C70, S70, V70 & 1992-97 850
Vehicle: 2004 Volvo S80 2.5T 2.5 L5 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
CV AXLE SHAFT, Replace -> Left Side -> Right Side
Vehicle: 2004 Volvo S80 2.9 L6 GAS
Left Side
- Raise and support vehicle on lift.
- Remove front wheel lug nuts.
- Remove splash guard under engine.
- Remove bolt for wheel hub driveshaft.
- Counterhold ball joint using suitable tool so that ball joint boot does not rotate.
- Press down on control arm using suitable tool until it contacts subframe. Position tensioning straps as close to ball joints as possible.
- Unhook spring strut and ball joint from control arm.
- Pull out spring strut and remove drive shaft from hub.
- Hold spring strut to one side using a tensioning strap for more space when removing driveshaft. Later models ha...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Volvo S80 2.5T AWD 2.5 L5 GAS
- Disconnect battery ground cable.
- Detach pipe from control module box.
- Rotate or lift belt tensioner arm counterclockwise, using a suitable tool to relieve tension from drive belt.
- Remove drive belt.
- Loosen clamps and remove power steering pump hoses. Drain fluid in a clean suitable container. Avoid skin contact with power steering fluid.
- Remove cold air inlet hose to control module.
- Loosen bolt on power steering line lock bracket.
- Loosen pipe nipple on pump.
- Remove bolts from power steering pump pulley holes and lift pump up to remove.
- Loosen hose clamps, disconnect coolant hose fr...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2004 Volvo S80 2.5T AWD 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 sound proofing panel from under the passenger side of the instrument panel.
- Remove the cabin air filter cover retaining screws, then the cover, Fig. .
- Press down on the cabin air filte...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Volvo -> Check Engine Lamp ->
Vehicle: 2004 Volvo S80 2.5T 2.5 L5 GAS
This lamp should be illuminated when the ignition switch is placed in the On position. After the engine has been started, the lamp should go out. If it remains lit, a problem has b...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Volvo S80 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Volvo S80 2.5T AWD 2.5 L5 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 2004 Volvo S80 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Volvo S80 2.5T AWD 2.5 L5 GAS
- Disconnect negative battery cable.
- Remove cover over engine control module box and move it to one side.
- Remove engine control module by carefully pulling it up and out using a suitable tool. Do not touch terminal pins on engine contro...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Volvo S80 AUTOMOBILES
Component location diagrams for most 2004 Volvo S80 cars and light trucks sold in the U.S. from 1990+.
 Climate Control Unit Diagram for 2004 Volvo S80 2.9 L6 GASComponents on diagram: |
 Climate Control Unit Diagram for 2004 Volvo S80 2.9 L6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Volvo S80 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Volvo S80 cars and light trucks sold in the U.S.
 2004 Volvo S80 2.5T AWD 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2004 Volvo S80 2.9 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Volvo S80 AUTOMOBILES
OEM TSB listings for most 2004 Volvo S80 cars and light trucks sold in the U.S. from 1985+.
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Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S80 2.9 L6 GAS Auto Systems: |
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Document: TRANSMISSION CONTROL MODULE (TCM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S80 2.9 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Volvo S80 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Volvo S80 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 2004 Volvo S80 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 2004 Volvo S80 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 2004 Volvo S80 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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