Volvo S40 & V40 2004 Full Service Repair Manual

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Basic Information Identification Make: Volvo Model: V40 Year: 2004 Generation S40 V40 Generation: First Generation (1995–2004), Phase II facelift (2000–2004) Codes Chassis Codes: Volvo S40: MS, Volvo V40: MW Introduction Market Position Market Position: The Volvo S40 and V40 of this era occupied a niche in the premium compact sedan and wagon market, competing against established German marques like BMW (3 Series Compact) and Audi (A3), as well as premium Japanese offerings. Volvo differentiated itself with a strong emphasis on safety, Scandinavian design, and a comfortable, albeit somewhat understated, driving experience. Target Audience: Primarily aimed at professional automotive technicians and experienced DIY enthusiasts seeking in-depth information for maintenance, repair, and restoration of their Volvo S40 or V40. Competitive Analysis Competitive Analysis: Competed against models like the BMW 3 Series Compact (E46/5), Audi A3 (8L), Mercedes-Benz C-Class (W203), Volkswagen Golf/Bora, and various Japanese premium compacts. Volvo's key selling points were its renowned safety reputation, distinctive styling, and often a more accessible price point than its German rivals. Key Features Key Features: Renowned Volvo safety features (SIPS, WHIPS), distinctive Scandinavian design, turbocharged engine options for performance, comfortable and well-appointed interior, available all-wheel drive on certain models, practicality of the V40 wagon variant. Safety Focus: The manual reflects Volvo's unwavering commitment to safety, providing detailed information on SRS systems, seatbelt mechanisms, and structural integrity, essential for safe repairs. Manual Details Coverage Areas Coverage Areas: Global (English language edition) Page Count Estimated Page Count: Extensive (specific number not provided, but described as 'very detailed' and covering all diagnostic and repair procedures) Manual Type Manual Type: Full Service Repair Manual Language Language: English Format Format: PDF Download Digital Storage And Portability: The PDF can be saved to a hard drive for persistent access and can also be burned to a CD-ROM for offline use or backup. Delivery Delivery Method: Instant Download, eliminating shipping costs and wait times. Manual Coverage Systems Covered Systems Covered: Engine mechanicals (including disassembly, assembly, and rebuilding), Engine management system (ECM), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Starting and charging system, Clutch, Manual transmission, Automatic transmission, Driveshafts and axles, Suspension (front and rear), Steering system, Brakes (ABS, EBD), Body structure, Exterior and interior trim, HVAC system, Electrical system, Wiring diagrams, Diagnostics, Body control modules (BCM), SRS (airbag) system. Wiring Diagrams: Comprehensive electrical system coverage, including detailed wiring diagrams for all major vehicle systems. This is crucial for diagnosing electrical faults and component issues. Body And Chassis: Includes detailed procedures for body panel alignment, door mechanisms, window regulators, interior trim removal and installation, and basic chassis component inspection and replacement. Fuel Injection Systems: Detailed coverage of fuel delivery, injectors, fuel pressure regulators, and electronic control unit (ECU) functions for both naturally aspirated and turbocharged engines. Procedures Included Procedures Included: Routine maintenance, Scheduled maintenance, Troubleshooting, Diagnostic procedures, Repair procedures, Rebuilding procedures, Refurbishing, Restoration, Component testing, Fluid changes, Filter replacement, Belt replacement, Spark plug replacement, Brake pad and rotor replacement, Suspension component replacement, Steering component replacement, Electrical component diagnosis and repair, Wiring harness repair, HVAC system servicing, SRS system diagnostics, Emissions control system servicing. Diagnostic Procedures: The manual includes detailed diagnostic procedures for identifying common and uncommon faults across all vehicle systems. This likely covers onboard diagnostics (OBD-II) fault codes, component testing procedures, and systematic troubleshooting trees. Engine Rebuilding: The manual covers detailed engine rebuilding procedures, including cylinder head removal and reassembly, piston and connecting rod installation, crankshaft and bearing replacement, and timing component installation. Technical Depth Technical Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers all diagnostic and repair procedures in great detail, including sub-steps, notes, cautions, and warnings. Includes detailed illustrations, drawings, photos, and enlarged insets for critical components. Combines troubleshooting and electrical service procedures with detailed wiring diagrams. Repair Scope: Covers everything from basic maintenance and tune-ups to complete engine rebuilding, transmission overhauls, suspension and steering system repairs, and detailed electrical diagnostics. Manual Specifications File Format File Format Details: PDF (.pdf). Requires Adobe PDF Reader. Compatibility: Compatible with all versions of Windows and Mac operating systems. The PDF format ensures broad accessibility. Print Quality Print Quality: Full Printable. All pages can be printed from the downloaded PDF. Page Layout And Readability: The PDF is designed for clear readability, with numbered instructions, bold figure numbers for easy cross-referencing with illustrations, and well-organized tables of contents. Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: Not Applicable (digital format) Engine Specifications Primary Engine Engine Options: The 2004 Volvo S40 and V40 were typically equipped with Volvo's inline-five cylinder engines. Common variants include: - 1.9L (1855cc) turbocharged B4204T2 (2.0T) - 1.9L (1855cc) turbocharged B4204T3 (T4) - 1.9L (1855cc) turbocharged B4204T4 (2.0T) - likely a variant for specific markets - 1.9L (1855cc) naturally aspirated B4204S2 (2.0) - less common in export markets - 2.0L (1948cc)...

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Description

Basic Information
Identification
Make:	Volvo
Model:	V40
Year:	2004
Generation
S40 V40 Generation:	First Generation (1995–2004), Phase II facelift (2000–2004)
Codes
Chassis Codes:	Volvo S40: MS, Volvo V40: MW

Introduction
Market Position
Market Position:	The Volvo S40 and V40 of this era occupied a niche in the premium compact sedan and wagon market, competing against established German marques like BMW (3 Series Compact) and Audi (A3), as well as premium Japanese offerings. Volvo differentiated itself with a strong emphasis on safety, Scandinavian design, and a comfortable, albeit somewhat understated, driving experience.
Target Audience:	Primarily aimed at professional automotive technicians and experienced DIY enthusiasts seeking in-depth information for maintenance, repair, and restoration of their Volvo S40 or V40.
Competitive Analysis
Competitive Analysis:	Competed against models like the BMW 3 Series Compact (E46/5), Audi A3 (8L), Mercedes-Benz C-Class (W203), Volkswagen Golf/Bora, and various Japanese premium compacts. Volvo's key selling points were its renowned safety reputation, distinctive styling, and often a more accessible price point than its German rivals.
Key Features
Key Features:	Renowned Volvo safety features (SIPS, WHIPS), distinctive Scandinavian design, turbocharged engine options for performance, comfortable and well-appointed interior, available all-wheel drive on certain models, practicality of the V40 wagon variant.
Safety Focus:	The manual reflects Volvo's unwavering commitment to safety, providing detailed information on SRS systems, seatbelt mechanisms, and structural integrity, essential for safe repairs.

Manual Details
Coverage Areas
Coverage Areas:	Global (English language edition)
Page Count
Estimated Page Count:	Extensive (specific number not provided, but described as 'very detailed' and covering all diagnostic and repair procedures)
Manual Type
Manual Type:	Full Service Repair Manual
Language
Language:	English
Format
Format:	PDF Download
Digital Storage And Portability:	The PDF can be saved to a hard drive for persistent access and can also be burned to a CD-ROM for offline use or backup.
Delivery
Delivery Method:	Instant Download, eliminating shipping costs and wait times.

Manual Coverage
Systems Covered
Systems Covered:	Engine mechanicals (including disassembly, assembly, and rebuilding), Engine management system (ECM), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Starting and charging system, Clutch, Manual transmission, Automatic transmission, Driveshafts and axles, Suspension (front and rear), Steering system, Brakes (ABS, EBD), Body structure, Exterior and interior trim, HVAC system, Electrical system, Wiring diagrams, Diagnostics, Body control modules (BCM), SRS (airbag) system.
Wiring Diagrams:	Comprehensive electrical system coverage, including detailed wiring diagrams for all major vehicle systems. This is crucial for diagnosing electrical faults and component issues.
Body And Chassis:	Includes detailed procedures for body panel alignment, door mechanisms, window regulators, interior trim removal and installation, and basic chassis component inspection and replacement.
Fuel Injection Systems:	Detailed coverage of fuel delivery, injectors, fuel pressure regulators, and electronic control unit (ECU) functions for both naturally aspirated and turbocharged engines.
Procedures Included
Procedures Included:	Routine maintenance, Scheduled maintenance, Troubleshooting, Diagnostic procedures, Repair procedures, Rebuilding procedures, Refurbishing, Restoration, Component testing, Fluid changes, Filter replacement, Belt replacement, Spark plug replacement, Brake pad and rotor replacement, Suspension component replacement, Steering component replacement, Electrical component diagnosis and repair, Wiring harness repair, HVAC system servicing, SRS system diagnostics, Emissions control system servicing.
Diagnostic Procedures:	The manual includes detailed diagnostic procedures for identifying common and uncommon faults across all vehicle systems. This likely covers onboard diagnostics (OBD-II) fault codes, component testing procedures, and systematic troubleshooting trees.
Engine Rebuilding:	The manual covers detailed engine rebuilding procedures, including cylinder head removal and reassembly, piston and connecting rod installation, crankshaft and bearing replacement, and timing component installation.
Technical Depth
Technical Depth:	Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers all diagnostic and repair procedures in great detail, including sub-steps, notes, cautions, and warnings. Includes detailed illustrations, drawings, photos, and enlarged insets for critical components. Combines troubleshooting and electrical service procedures with detailed wiring diagrams.
Repair Scope:	Covers everything from basic maintenance and tune-ups to complete engine rebuilding, transmission overhauls, suspension and steering system repairs, and detailed electrical diagnostics.

Manual Specifications
File Format
File Format Details:	PDF (.pdf). Requires Adobe PDF Reader.
Compatibility:	Compatible with all versions of Windows and Mac operating systems. The PDF format ensures broad accessibility.
Print Quality
Print Quality:	Full Printable. All pages can be printed from the downloaded PDF.
Page Layout And Readability:	The PDF is designed for clear readability, with numbered instructions, bold figure numbers for easy cross-referencing with illustrations, and well-organized tables of contents.
Binding Type
Binding Type:	Digital Download (no physical binding)
Paper Type
Paper Type:	Not Applicable (digital format)

Engine Specifications
Primary Engine
Engine Options:	The 2004 Volvo S40 and V40 were typically equipped with Volvo's inline-five cylinder engines. Common variants include: - 1.9L (1855cc) turbocharged B4204T2 (2.0T) - 1.9L (1855cc) turbocharged B4204T3 (T4) - 1.9L (1855cc) turbocharged B4204T4 (2.0T) - likely a variant for specific markets - 1.9L (1855cc) naturally aspirated B4204S2 (2.0) - less common in export markets - 2.0L (1948cc) turbocharged B4204T ('2.0 Turbo' in some markets) - 1.8L (1783cc) naturally aspirated B4184S2 ('1.8') - 1.8L (1783cc) turbocharged B4184S ('1.8 Turbo') - less common - 1.6L (1587cc) naturally aspirated B4164S2 ('1.6') - common in European markets - 2.0L (1948cc) naturally aspirated B4204S3 ('2.0')
Inline Five Cylinder Advantage:	The adoption of inline-five cylinder engines by Volvo offered a smoother power delivery and a unique character compared to the inline-four cylinder engines found in many competitors, contributing to Volvo's premium positioning.
Performance
Horsepower Torque:	Horsepower and torque varied significantly by engine. For example: - 2.0T (B4204T3): Approx. 163 hp (122 kW) and 240 Nm (177 lb-ft) torque. - T4 (B4204T4): Approx. 200 hp (147 kW) and 300 Nm (221 lb-ft) torque. Specific figures should be verified based on the exact engine code and market.
Turbocharger Systems:	Detailed coverage of the turbocharger system for models like the 2.0T and T4, including turbocharger removal, installation, wastegate operation, and intercooler system maintenance.
Fuel System
Fuel System Type:	Multi-point Fuel Injection (MPI) with electronic control.

Transmission
Standard
Standard Transmission:	5-speed Manual Transmission
Optional
Optional Transmission:	4-speed Automatic Transmission (AW50-42LE or similar)
Features
Transmission Features:	Front-wheel drive (FWD) is standard. Some models may have offered optional All-Wheel Drive (AWD) systems, typically from Haldex.

Dimensions
Exterior
Length:	S40: Approx. 4468 mm (175.9 in); V40: Approx. 4516 mm (177.8 in)
Width:	Approx. 1710 mm (67.3 in)
Height:	Approx. 1430 mm (56.3 in)
Interior
Seating Capacity:	5 Passengers
Cargo
Cargo Volume S40:	Approx. 0.40 m³ (14.1 cu ft)
Cargo Volume V40:	Approx. 0.47 m³ (16.6 cu ft) with rear seats up, expandable when seats are folded.
Weights
Curb Weight:	Ranging from approximately 1300 kg to 1500 kg (2866 to 3307 lbs) depending on engine and trim.
Gvw Gcr:	Gross Vehicle Weight (GVW) and Gross Combination Weight (GCW) ratings will be specified in the manual, crucial for understanding payload capacities and towing limitations (though towing is not a primary forte of these models).

Safety Features
Ratings
Eucap Ratings:	Euro NCAP ratings for the phase II facelift were generally good for its time. Specific scores may vary by test year, but the car was known for its robust safety structure.
Active Features
Active Safety Features:	Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS) on some models, optional Cruise Control.
Passive Features
Passive Safety Features:	Volvo's Safety System (SIPS) with side-impact airbags, Whiplash Protection System (WHIPS) in front seats, dual-stage front airbags, front seatbelt pretensioners, reinforced passenger cage, Isofix child seat anchorages.

Technology Features
Infotainment
Infotainment System:	Basic infotainment systems typical for the era, often featuring a premium audio system with CD player, radio, and potentially an optional 6-disc CD changer. Steering wheel audio controls were often available.
Climate Control System:	Comprehensive diagnostic and repair procedures for both manual and automatic climate control systems, including refrigerant handling (if applicable) and component testing.
Driver Assistance
Driver Assistance Features:	Limited driver assistance features by modern standards. Primarily focused on passive and active safety systems like ABS, EBD, TCS, and airbag systems. Cruise control was an option.
Connectivity
Connectivity Options:	Very basic connectivity. May have had provisions for an external CD changer or an aftermarket auxiliary input for audio devices. No integrated Bluetooth or USB connectivity as standard.

Maintenance
Service Intervals
Recommended Service Intervals:	Typical intervals for 2004 Volvo S40/V40: - Oil and Filter Change: Every 10,000 miles (16,000 km) or 12 months, whichever comes first. - Air Filter: Inspect every 20,000 miles (32,000 km), replace every 40,000 miles (64,000 km). - Cabin Air Filter: Inspect annually, replace every 2 years or 20,000 miles (32,000 km). - Fuel Filter: Replace every 40,000 miles (64,000 km) or as per manual. - Spark Plugs: Replace every 60,000 miles (96,000 km) for standard plugs, longer for platinum/iridium. - Timing Belt (if applicable, check engine type): Replace at specific mileage (e.g., 70,000-100,000 miles or 10-12 years, depending on engine). The inline-5 engines often used timing chains, but some earlier 4-cylinder models used belts. The manual will clarify this. - Brake Fluid: Flush and replace every 2 years. - Coolant: Flush and replace every 2-3 years or as specified.
Fluid Specifications
Engine Oil Specification:	API SL or ACEA A3/B3/B4 compliant synthetic or semi-synthetic engine oil. Viscosity grade typically 5W-30 or 5W-40, depending on climate and specific engine. Check owner's manual or manual for exact OEM recommendations (e.g., Volvo VDS-3).
Transmission Fluid Manual:	SAE 75W-90 GL-4 or GL-5 gear oil (verify specific requirement).
Transmission Fluid Automatic:	Volvo specifies specific automatic transmission fluid (ATF). Typically, JWS 3309 (ATF 3309) or equivalent. Not a universal ATF.
Coolant Specification:	Volvo coolant, typically orange or pink colored (long-life coolant), based on ethylene glycol. Do not mix colors. Volvo Part Number 31439822 or equivalent.
Brake Fluid Specification:	DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:	Volvo's specified power steering fluid. Using the wrong fluid can damage the system. The manual will provide the specific Volvo part number or type.
Manual Transmission Fluid Type:	SAE 75W-80 or 75W-90 GL-4 manual transmission fluid is typically recommended. It's crucial to use a GL-4 specification fluid as GL-5 can be too aggressive for the brass synchro rings in some older transmissions.
Known Issues
Common Issues:	Common issues for this generation can include: - Electronic Module Failures (CEM, BCM) - Power steering leaks or pump failure - HVAC blower motor resistor failure - Ignition coil failures (especially on turbocharged models) - Suspension wear (bushings, ball joints) - Clutch master cylinder leaks - Turbocharger issues (lag, oil leaks) on turbocharged variants - Fuel pump failures - ABS sensor faults - Rear washer system leaks.
Turbo Hose Degradation:	Degradation of turbocharger hoses and boost pipes, leading to boost leaks and performance loss, is a common issue addressed by detailed replacement procedures in the manual.

Vehicle History
Brand Heritage
Brand Heritage:	Volvo, a Swedish manufacturer founded in 1927, has a long-standing reputation for safety, durability, and quality. The brand is synonymous with innovative safety technologies and a distinctive, functional design ethos.
Model Evolution
Model Evolution:	The Volvo S40 (sedan) and V40 (wagon) were introduced in 1995 as successors to the Volvo 440/460 and 480. They were based on the same platform as the Mitsubishi Carisma. The first generation underwent a significant facelift in 2000, bringing updated styling, improved interiors, and revised powertrains, including the introduction of the inline-five cylinder engines. The 2004 model year represents the final year of this generation before the introduction of the all-new second-generation S40 and V50 (based on the Ford Focus platform) for the 2005 model year.
Platform Sharing:	The first-generation S40/V40 shared its platform with the Mitsubishi Carisma, a collaboration that influenced certain aspects of its design and engineering, details of which might be implicitly or explicitly covered in specialized sections.
Production
Production Period:	First Generation: 1995-2004. Specific to 2004 model year.
Manufacturing Location:	Primarily manufactured in Ghent, Belgium, and Kalmar, Sweden.

Awards & Recognition
Recognitions
Safety Awards:	While specific awards for the 2004 model are hard to pinpoint, Volvo consistently received high safety ratings from organizations like Euro NCAP and IIHS throughout this period, reinforcing its brand image.