2001 Volvo S40FACTORY OEM SERVICE PROCEDURE

Connecting Breakout Box & Preliminary Check

  1. Turn ignition off. Wait 2 minutes. No voltage should be present at system relay before removing ECM. If cooling fan runs on after ignition is turned off, wait until 2 minutes after fan stops.
    CAUTION: DO NOT touch ECM pins. Static electricity can damage ECM components.
  2. Remove ECM. See ENGINE CONTROL MODULE in REMOVAL, OVERHAUL & INSTALLATION - S40 & V40 article.
  3. Pull wire harness with the control module connector over to the right of the center console to avoid interfering with pedals. Connector must be placed on the floor. Ensure that male and female terminals in ECM and connector are intact and secure.
  4. Connect Adapter (951-1314) to ECM connector. Connect Breakout Box (951-1428) to adapter.
  5. Ensure terminals in ECM and connector are secure and wiring to female terminals is secured to pins. To check power and ground circuits, see PIN VOLTAGE CHARTS article.
Factory Service Tools

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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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