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For the musty odor, while the filter is out, spray Lysol or a product from your local autoparts store designed for this problem, into the cavity with the fan on high and set for the AC. Then look around for the drain tube for the evaporator and make sure it is not clogged or restricted.
Not having an S40, I just googled 'volvo s40 air filter replacement'. One of the sites complained about the self locking nuts on the gas pedal being very hard to put back on.
Klaus
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Did you do your Random Act of Kindness today?
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