Recommended replacement interval for the part category Brake pad set : 30000 km

Important!

This replacement procedure can be used for:
VOLVO S40 II (544) D3, VOLVO S40 II (544) D4, VOLVO S40 II (544) D2, VOLVO S40 II (544) 2.0 F, VOLVO S40 II (544) 2.4, VOLVO S40 II (544) 2.4, VOLVO S40 II (544) T5, VOLVO S40 II (544) 2.0 D, VOLVO S40 II (544) T5 AWD, VOLVO S40 II (544) 1.8, VOLVO S40 II (544) 1.6, VOLVO S40 II (544) 1.6 D, VOLVO S40 II (544) 2.0, VOLVO S40 II (544) D5, VOLVO S40 II (544) T5, VOLVO S40 II (544) T5 AWD, VOLVO S40 II (544) 1.8 FlexFuel, VOLVO S40 II (544) D4, VOLVO S40 II (544) 2.0 CDI, VOLVO S40 II (544) 2.4 CDI … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Pads for S40 II (544) and other VOLVO models

Brake pad set

        Brake pad set for S40 II (MS, 544) Diesel (150 hp)
      
        Brake pad set for S40 II (MS, 544) Diesel (177 hp)
      
        Brake pad set for S40 II (MS, 544) Diesel (115 hp)
      
        Brake pad set for S40 II (MS, 544) Petrol/Ethanol (146 hp)
      
        Brake pad set for S40 II (MS, 544) Petrol (140 hp)
      
        Brake pad set for S40 II (MS, 544) Petrol (170 hp)
      
        Brake pad set for S40 II (MS, 544) Petrol (220 hp)
      
        Brake pad set for S40 II (MS, 544) Diesel (136 hp)
      
        Brake pad set for S40 II (MS, 544) Petrol (220 hp)

Replacement: brake pads – VOLVO S40 II (MS). Tools you might need:

                        Brake cleaner 
                      
                        Anti-squeal paste
                      
                        Copper grease 
                      
                        HEX bit no.H7.
                      
                        Wheel impact socket #19
                      
                        Brake caliper wind back tool
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Crow bar
                      
                        Wheel chock

Buy tools

Replacement: brake pads – VOLVO S40 II (MS). AUTODOC recommends:

Perform the replacement of brake pads in complete set for each axis. This provides effective braking.
The replacement procedure is identical for all brake pads on the same axle.
All work should be done with the engine stopped.

Replacement: brake pads – VOLVO S40 II (MS). Take the following steps:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #19.
Step 4

Raise the front of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. VOLVO S40 II (MS)
Step 6

Remove the wheel.
Step 7

Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 8

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 9

Spread the brake pads. Use a crowbar.
Step 10

Detach the brake caliper retaining spring. Use a crowbar.
Step 11

Remove the brake caliper.

Replacement: brake pads – VOLVO S40 II (MS). AUTODOC experts recommend:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 12

Remove the brake pads. Use a crowbar.

Replacement: brake pads – VOLVO S40 II (MS). Tip:
Measure the brake disc thickness. Upon reaching the wear limit the part must be replaced.
Step 13

Treat the brake pads in the area where their surface comes into contact with the brake caliper bracket. Use anti-squeal paste.
Step 14

Treat the brake caliper piston. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake pads – VOLVO S40 II (MS). After applying the spray, wait a few minutes.
Step 15

Press in the brake caliper piston. Use brake caliper wind back tool.

Replacement: brake pads – VOLVO S40 II (MS). Professionals recommend:
Make sure the disc surface is clean before installing the pads.
Step 16

Install new brake pads.

Replacement: brake pads – VOLVO S40 II (MS). Tip from AUTODOC experts:
Make sure the pads are installed with linings facing the disc.
Step 17

Install the brake caliper and fix it. Use HEX No.H7. Use a ratchet wrench.
Step 18

Install the brake caliper retaining spring.
Step 19

Tighten the brake caliper fasteners. Use HEX No.H7. Use a torque wrench. Tighten it to 28 Nm torque.
Step 20

Install the dust boot caps of the brake caliper guide pins.
Step 21

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 22

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake pads – VOLVO S40 II (MS). After applying the spray, wait a few minutes.
Step 23

Install the wheel.

Replacement: brake pads – VOLVO S40 II (MS). Tip from AUTODOC experts:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 24

Screw in the wheel bolts. Use wheel impact socket #19.
Step 25

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 110 Nm torque.
Step 26

Remove the jacks and chocks.

Replacement: brake pads – VOLVO S40 II (MS). Tip from AUTODOC:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 27

Tighten the brake fluid reservoir cap.

AUTODOC recommends:
VOLVO S40 II (MS) – Press the brake pedal several times with the engine shut down until you feel the resistance built up.
Step 28

Close the hood.

Replacement: brake pads – VOLVO S40 II (MS). Professionals recommend:
Slow down smoothly for first 150-200 km after the brake pads replacement. Avoid unneccessary and sharp braking to a stop.

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