The Volvo S40, produced from 1995 to 2004 on the P1 platform, represents Volvo's commitment to safety, durability, and Scandinavian design in the compact executive sedan segment. This model, often seen as a successor to the 440/460 series, offers a blend of refined interiors, ergonomic focus, and robust engineering, making it a popular choice for professionals and families seeking comfort and security. It features a naturally aspirated 2.0-liter inline 4-cylinder engine (B4204S) producing 115 PS, with front-wheel drive and a choice of a 5-speed manual or a 4-speed automatic transmission. Volvo's inherent reputation for safety is evident in features like a reinforced safety cage, crumple zones, standard front airbags, and three-point seatbelts with pretensioners, alongside active safety systems such as front ventilated disc brakes with standard ABS on most models. This comprehensive workshop service repair manual is designed for both do-it-yourself enthusiasts and experienced mechanics, covering all essential aspects of the Volvo S40. It provides detailed information on powertrain systems including the engine, transmission, and drivetrain, as well as chassis components like suspension, steering, and brakes. The manual also delves into the complete electrical system, bodywork, and interior systems, offering extensive maintenance schedules, step-by-step repair procedures, and troubleshooting guides for common and uncommon issues. With hundreds of illustrations and factory-level detail, this manual equips users with the knowledge to effectively maintain and repair their vehicle, ensuring its longevity and optimal performance. 🏷️ Basic Information Identification Make: Volvo Model: S40 Year: 1996 Codes Chassis Code: P1 Platform: Hyundai Elantra (XD) 👋 Introduction Market Position Segment: Compact Executive Sedan Target Audience: Professionals, families seeking safety and comfort Competitive Analysis Key Competitors: Audi A3, BMW 3 Series Compact (E36/5), Mercedes-Benz C-Class (W202), Volkswagen Golf GTI Key Features Brand Identity: Volvo's reputation for safety, durability, and comfortable interiors Design Philosophy: Scandinavian design, focus on ergonomics and passenger safety 📋 Manual Details Coverage Areas Primary Markets: North America, Europe Region Specific Variants: Includes information pertinent to models sold globally Page Count Estimated Pages: Hundreds (exact count not specified, but described as comprehensive) Manual Type Type: Workshop Service Repair Manual Purpose: Do-it-yourselfer and experienced mechanic Language Language: English Format File Format: PDF Delivery Method: Digital Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drivetrain, exhaust system Chassis: Suspension, steering, brakes, wheels and tires Electrical: Complete electrical system, wiring diagrams, troubleshooting Body: Body panels, interior trim, climate control, safety systems (airbags, seatbelts) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements Repair: Step-by-step repair procedures for all major components Troubleshooting: Diagnosis and resolution of common and uncommon faults Diagnostics: Diagnostic procedures, fault codes, and electrical system diagnostics Technical Depth Depth: Comprehensive factory-level detail, including full disassembly and reassembly Illustrations: Hundreds of photos and illustrations, including enlarged insets Guidance: Detailed substeps, notes, cautions, and warnings 📊 Manual Specifications File Format File Type: PDF Searchability: Assumed searchable due to PDF format (though not explicitly stated) Print Quality Printability: Printable without restriction Print Options: Print entire manual or select pages Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: B4204S (2.0L) Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 1948 cc (2.0 Liters) Bore X Stroke: 82.7 mm x 93.2 mm Compression Ratio: 10.3:1 Performance Horsepower: 115 PS (113 hp; 85 kW) at 5500 rpm Torque: 170 Nm (125 lb-ft) at 4000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (95 RON recommended) Engine Variations Other Engines: 1.8L Turbo (B18FT, 115hp), 1.8L Turbo (B18FT, 160hp), 2.0L Turbo (B204FT, 163hp), 2.0L Turbo (B204FT, 200hp - T5) 🔧 Transmission Standard Type: 5-speed Manual Optional Type: 4-speed Automatic (AW50-42LE) Features Drivetrain: Front-Wheel Drive (FWD) Clutch: Hydraulically operated, single dry plate 📐 Dimensions Exterior Length: 4478 mm (176.3 in) Width: 1718 mm (67.6 in) Height: 1398 mm (55.0 in) Wheelbase: 2619 mm (103.1 in) Weights Curb Weight: Approx. 1300 kg (2866 lbs) for 2.0L model Gross Vehicle Weight Rating: Varies by model and equipment Cargo Trunk Volume: Approx. 450 liters (15.9 cu ft) 🛡️ Safety Features Ratings Historic Ratings: While NHTSA/IIHS ratings for the 1996 model specifically are scarce, Volvo vehicles of this era generally performed well in crash tests due to the brand's strong safety focus. Active Features Brakes: Front ventilated discs, rear solid discs; ABS standard on most models Traction Control: Optional on some models Passive Features Airbags: Driver and front passenger airbags standard Seat Belts: Three-point inertia-reel seatbelts with pretensioners Body Structure: Reinforced safety cage, crumple zones 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player with optional amplifier and speaker upgrades. Climate Control: Manual air conditioning, optional automatic climate control on higher trims. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Exterior Features: Body-colored door handles and mirrors, power-adjustable heated...