1991 Volvo 940 Service and Repair Manual

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Covers all 1991 940 trims — T Wagon 4-Door, T Sedan 4-Door, SE Wagon 4-Door +3 more ·
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1991 Volvo 940 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • T Wagon 4-Door
  • T Sedan 4-Door
  • SE Wagon 4-Door
  • GLE Wagon 4-Door
  • GLE Sedan 4-Door
  • SE Sedan 4-Door

Engines covered

  • 2.3L 2316CC l4 GAS SOHC Turbocharged
  • 2.3L 2316CC l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #91V01000008/01/1991Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

IF CONDITIONS OF HIGH AMBIENT TEMPERATURE, OVERFILLING OF THE FUEL TANK, AND INSUFFICIENT TORQUE ON THE SENDING UNIT LOCK RING EXIST SIMULTANEOUSLY, FUEL SEEPAGE MAY OCCUR FROM THE TOP OF THE TANK.

Consequence

FUEL SEEPAGE COULD RESULT IN FIRE IN THE PRESENCE OF ANIGNITION SOURCE.

Remedy

RETORQUE SENDING UNIT LOCK RING; REPLACE LOCK RING GASKET IF FUEL SEEPAGE IS DETECTED. NOTE: THE O

NHTSA #91V07500006/05/1991Component: SEAT BELTS:FRONT:ANCHORAGE

SAFETY BELTS ARE DESIGNED TO BE ROUTED UNDER A DIAGONAL CROSS BRACE DURING FASTENING. THE INSTRUCTIONAL LABELS FOR THE BELT ROUTING ARE INADEQUATE, AND CAN RESULT IN INADVERTENT RELEASE OF THE BELT BU

Consequence

CONSEQUENCE OF DEFECT: SAFETY BELT MISUSE COULD CAUSE THE SEAT OCCUPANT TO FACE GREATER RISK OF INJ

Remedy

INSTALL LABELS TO INSTRUCT THE USER IN PROPER SAFETY BELT ROUTING; ALSO REPLACE SAFETY BELT BUCKLES.

TSB #10212891

VIDA QR Scanner Mobile App

TSB #10212892

Shipping and Handling of Volvo Lithium-ion 48V Mild Hybrid Battery to Global Battery Solutions (GBS)

TSB #10110161

*No Description

TSB #10110146

Seat Belt Extender

TSB #10110159

The Volvo Technical Helpdesk (THD) is a central contact point available to authorized Volvo dealer technicians to assist with difficult to repair situations. If for some reason our technical experts cannot solve an issue directly, it will b

TSB #51062

DIAGNOSTIC TROUBLE CODE (DTC) 1-4-4 IN IGNITION CONTROL MODULE (ICM), REX-I. *TW

TSB #46376

TECH DCS GRAM SUPERSEDES PREVIOUS ISSUE DATED 3/20/95. HALIFAX BUILT 940S (PLANT CODE 3), DID NOT HAVE THE NOISE/VIBRATION DAMPER INTRODUCED INTO PRODUCTION CAUSING FUEL SYSTEM NOISE/VIBRATION.

TSB #46381

NOISE CAN BE CAUSED BY THE LEGROOM ADJUSTMENT LATCH (TRIGGER ARM) PRESSING AGAINST METAL. NOISE CAN ALSO BE CAUSED BY RUDDING BETWEEN PLASTIC PROTECTORS AND THE HEIGHT ADJUSTMENT SPACER SCREW.

19960715Component: AIR BAGS:FRONTALCrash reported1 injured

AIR BAG DID NOT DEPLOY IN THE ACCIDENT. *AK CONSUMER WAS INJURED IN ACCIDENT. *SLC

19960904Component: SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLERFire reported

DRIVERS SEAT WARMING ELEMENT SHORTED, CAUSING FIRE.

19960206Component: SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLERFire reported

SEAT HEATER ELEMENT CAUGHT FIRE. *SD

19951201Component: SEATS:FRONT ASSEMBLY:POWER ADJUSTFire reported

ELECTRICAL BOX IN SEAT SHORTED, CAUSING FIRE. *DSH

20051116Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

DT: THE CONTACT STATES THERE IS NHTSA RECALL 91V010000 CONCERNING THE FUEL SYSTEM GASOLINE DELIVERY: FUEL PUMP. THIS VEHICLE IS EXPERIENCING THE SAME PROBLEMS AS INDICATED IN THE RECALL, BUT IS NOT

Showing the 5 most serious of 11 complaints filed with NHTSA.

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