1996-2004 Volvo S40 V40 - How to replace the front seatbelt tensioner and/or seatbelt

[gatos]

This is a guide of how to replace the drivers seat belt tensioner assembly. The second half of this guide, shows how to replace the belt part of the seatbelt only, without removing the tensioner.

For this job, you will need:

• A Philips screwdriver
• Ratchet with extension, 14mm and 16mm sockets
• T30 torx key

Before you get started, you need to:

• Make a note of the anti-theft radio code
• Switch off the ignition
• Disconnect the battery negative lead
• Wait at least five minutes before starting any work

This is only a guide and I would advice caution when attempting to follow my instructions, as there is a pyrotechnic device at the bottom part of the seatbelt mechanism which is meant to be activated in case of an accident.

First thing to do is to undo the two screws on the drivers kickplate and lift it up carefully. Some later 2003/2004 models have the “all plastic” kickplates, in which case, you just lift them up.


Also remove the rear passengers kickplate by lifting it up


You need to remove this plastic trim. Easy to take out. There is one clip on the top right hand side of it which releases very easily. See also next photo. Do not remove the screw holding the seatbelt yet. We will do so later on.




Remove the lower plastic trim first. release the lower part first and then wiggle it out.


Undo a bit of the inner door seals on both the drivers and rear passengers door frames (see photo). Be a bit careful with the top grey plastic trim. If you just pull it, you may break the plastic clip holding it. The way to remove it is to push gently the lower part towards the front of the car (see arrow) and it will come of the clip. Then move it slightly downwards and take it out. check the next two photos and you will see what I mean




Remove the metal clip from the car frame and put it back in its place on the upper grey trim. You will need to push the two ends of the clip so it is released from the frame


Carefully unplug the connector pointed by the red arrow. Remove the T30 screw pointed by the green arrow. Finally, remove the two 16mm bolts pointed by the yellow arrows (undo the bottom one first).


Undo the 14mm and job done. Well you need to put everything back together in the reverse order. If you have a torque wrench, tighten the two 16mm and the 14mm bolts to 48 Nm



REPLACING THE BELT PART ONLY
If you want to replace the belt part only, you can either remove the whole tensioner and take it indoors and replace the belt, or you can do it with the seatbelt tensioner on the car. I personally find it a lot easier and faster to do this with the tensioner on the car.

Pull out the seatbelt all the way out. When doing so, try to have the part highlighted in the green circle (oval) facing the way I have it on the photo. You will have to pul out the seatbelt from there. The spring mechanism needs to be secured to this position. To do so, I used some electrical tape. I used 3 bits and the mechanism was not moving any more. Use you common sense when doing so and be careful the tape comes undone. If this happens, you will have to rewind the whole rotating mechanism and you will not know how far to go. So whatever you do, make sure you secure it properly. See also next photo of how I secured it.




Once secured, pull out the seatbelt and slide off the pin which is securing it on the rotating spring mechanism. See also next photo



Before you pull out the seatbelt, feed the new seatbelt though the upper plastic trim and have it ready to be fitted to the rotating mechanism.


.......CONTINUES ON THE NEXT POST

[gatos]

Pull out the old seatbelt and immediately feed the new one through the gap and secure it with the pin. In order to feed the new seatbelt in, you will have to rotate the spring mechanism about 90 degrees. If you have taped the mechanism the same way I did, it should be able to move in one direction only.




Undo the bolt (size 14 socket), remove the old seatbelt and put the new one in.



Job done. Well you need to put everything back together in the reverse order. If you have a torque wrench, tighten the 14mm bolt to 48 Nm


Good luck and if you have any questions, suggestions or better ways to do things, please feel free to comment

[S40kieran]

Wicked Alex