2003 Volvo V40FACTORY OEM SERVICE PROCEDURE

Location of components

Fig 1: Identifying Fuel Pump In Fuel Tank
GLL114192Courtesy of VOLVO CARS OF NORTH AMERICA.

Fuel pump:Β 

in the fuel tank.

Fig 2: Identifying Fuel Filter By Left Rear Wheel
GLL114191Courtesy of VOLVO CARS OF NORTH AMERICA.

Fuel filter:Β 

by the left rear wheel.

Fig 3: Identifying Integrated Relay/Fusebox In Engine Compartment
GLL114330Courtesy of VOLVO CARS OF NORTH AMERICA.

Relays and fuses:Β 

In the integrated relay / fusebox in the engine compartment.

2/10 Air conditioning (A/C) relay
2/11 Engine cooling fan (FC) relay, low-speed
2/14 System relay
2/15 Engine cooling fan (FC), high-speed (only applies to cars with air conditioning (A/C))
Fig 4: Identifying Integrated Relay/Fusebox In Passenger Compartment
GLL112339Courtesy of VOLVO CARS OF NORTH AMERICA.

In the integrated relay / fusebox in the passenger compartment.

Fig 5: Identifying Engine Control Module (ECM) On Center Console Under Dashboard
GLL111975Courtesy of VOLVO CARS OF NORTH AMERICA.

Engine control module (ECM):Β 

On the center console under the dashboard.

Fig 6: Identifying Data Link Connector (DLC)
GLL112336Courtesy of VOLVO CARS OF NORTH AMERICA.

Data Link Connector (DLC):Β 

on the left-hand side of the center console (left-hand drive cars); on the right-hand side of the center console (right-hand drive cars).

Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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