Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2001 Volvo S40FACTORY OEM SERVICE PROCEDURE
Alarm, Doors And Lids - Removal, Replacement And Installation (644 Body)
- Alarm (2001-2004)
- Glass breakage sensor and cable harness
- Hood catch with and without switch
- Led (VGLA)
- Receiver
- Siren
- Tilt sensor
- Ultrasonic or glass breakage control module
- Ultrasonic sensor and cable harness
- VGLA-control module
- Fuel Tank Filler Cover (2003-2004)
- Fuel Tank Filler Cover (2001)
- Fuel Tank Filler Cover (Ch -850514; 2002)
- Fuel Tank Filler Cover (Ch 850515-999999; 2002)
- Locks And Handles (2001-2004)
- Central locking motor for the front side door
- Central locking motor for the rear side door
- Central locking motor for the trunk lid or tailgate
- Door module switch, front side door
- Door switches
- Lock and handle for the front side door
- The lock for the front side door
- The outer door handle for the front side door
- Removing the outer door handle for the front side door
- Removing the lock switch, driver's door
- Removing the lock cylinder, driver's door
- Removing the lock cylinder, passenger door
- Repair kit for the door lock cylinder
- Installing the lock cylinder, driver's door
- Installing the lock cylinder, passenger door
- Installing the lock switch, driver's door
- Installing the outer door handle for the front side door
- Replacing the door handle
- The lock unit and handle for the rear side door
- The switch for the child-proof lock
- Trunk/tailgate switch
- Power Window Mechanism (2001-2004)
- Replacement Of Components (2000)
- Checking/replacing operating switch
- Control unit, replacing/installing
- Door lock front door
- Door insulation, removal
- Removing the guide rails for the windows
- Inner lock unit front, removing
- Removing the door opener handle
- Lock switch in door lock, driver's door, removing
- Lock cylinder without lock switch, installing/removing
- Lock cylinder with lock switch, installing/removing
- Lock switch driver's door, installing
- Installing the door opening handle
- Inner lock unit front, installing
- Installing the guide rails for the windows
- Front door
- Front door lift mechanisms
- Rear door lock
- Removing rear door panel
- Remove insulation partly
- Removing window guide rail
- Removing handgrip (not for interior lock assembly)
- Removing interior lock assembly
- Installing interior lock assembly
- Installing guide plate
- Adjusting rods
- Installing handgrip
- Installing window guide rail
- Installing insulation
- Installing rear door panel
- Rear door window mechanism
- Removing/installing motor
- Removing/installing slide and tilt roof cassette assembly
- Preparation
- Removing cassette
- Installing cassette
- Install Drainage Hoses & Wiring
- Headlining, installing
- Install the headlining
- Installing loose components
- Installing the rear interior lighting, 5 door models
- Installing the cover for the high-mounted stop lamp, 4 door models
- Installing the C-post panel
- Installing the D-post panel, 5 door models
- Installing the rear reading lamps or lenses
- Installing the rear grab handle
- Installing the front grab handle
- Installing the B-post panel
- Installing the A-post panel
- Installing the sun visor and holder
- Installing the ultrasonic sensor (alarm)
- Installing the interior lighting
- Removing/installing sun shade
- Replacing boot lid components
- Sliding and tilting sun roof
- Possible causes of squeaking, knocking, rattling and rustling
- Seals
- Removing/installing sliding and tilting sun roof (glass panel)
- Removing/installing the glass panel
- Adjusting the glass panel in the roof opening
- Adjusting the glass panel vertically
- Checking the sun roof for wind noise
- Removing/installing the wind deflector
- Replacing the seal
- Removing/installing the weatherstrip for the sun roof
- Tailgate & Doors
- Replacing the tailgate
- Removing entire tailgate
- Installing the tailgate
- Adjusting the tailgate
- Adjusting doors
- Adjusting rear doors
- Adjusting the striker plate
- Installing and removing the door panel from rear doors
- Installing and removing rear door hinges
- Installing and removing rear door stops
- Installing and removing the door assembly
- Tailgate components, changing
- Trunk lid
- Replacement Of Components. Central Locking System (2000)
- Replacement Of Components. VGLA (2000)
- Replacing The Mechanical Emergency Opening Cable For The Tailgate (2002-2004)
- Side Door With Controls (2001-2004)
- Sun Roof (2001-2004)
- Tailgate (2001-2004)
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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