Welcome to the comprehensive guide for the Volvo S40, produced from 1995 to 2004, representing the first generation (Type MS) of this compact executive sedan. Built upon a platform shared with the Mitsubishi Carisma, the S40 embodies Volvo's core principles of safety, durability, and Scandinavian design. This model is equipped with a range of inline-4 engines, including 1.8L, 2.0L naturally aspirated, and a 1.9L turbocharged variant, paired with either a 5-speed manual or an optional 4-speed automatic transmission. Notable features include a robust chassis, advanced safety systems like SIPS and optional TRACS, and a comfortable interior, making it a reliable choice for daily commuting and longer journeys. This workshop manual provides exhaustive coverage for the Volvo S40, designed to assist both do-it-yourself mechanics and professional automotive technicians. It details all aspects of the vehicle, from routine scheduled maintenance, fluid changes, and tune-ups to in-depth repair procedures for the engine, transmission, drivetrain, suspension, steering, brakes, and electrical systems. Troubleshooting guides, diagnostic procedures, and detailed wiring diagrams are included to help identify and resolve issues efficiently. With hundreds of illustrations and step-by-step instructions, this manual is an indispensable resource for maintaining the performance, safety, and longevity of your Volvo S40. 🏷️ Basic Information Identification Make: Volvo Model: S40 Year: 1998 Generation Generation Designation: First Generation (MS) Codes Chassis Code: Type MS 👋 Introduction Market Position Segment: Compact Executive Sedan / Compact Car Competitive Analysis Key Competitors: Audi A3, BMW 3 Series Compact (E36/5), Mercedes-Benz A-Class (W168), Volkswagen Golf Mk4, Honda Civic Key Features Design Philosophy: Volvo's focus on safety, durability, and Scandinavian design principles Platform Sharing: Shared platform with Mitsubishi Carisma Target Audience Audience: Do-it-yourself mechanics and experienced automotive technicians 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service and Repair Page Count Estimated Pages: Hundreds (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, diagnosis, repair, timing belt, lubrication, cooling system Engine Management: Fuel injection system, ignition system, emission control systems, ECU diagnosis Transmission: Manual and Automatic transmission service, diagnosis, and repair Drivetrain: Front-wheel drive system, CV joints, drive shafts Suspension: Front and rear suspension components, alignment, diagnosis Steering: Steering rack, power steering system, diagnosis Brakes: Brake system components (discs, pads, calipers, ABS), diagnosis, repair Electrical System: Wiring diagrams, starter, alternator, battery, lighting, body electrical, comfort systems Body And Chassis: Body panels, doors, glass, interior trim, structural components Heating Ventilation Air Conditioning: HVAC system diagnosis and repair Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides Repair Procedures: Step-by-step instructions for disassembly, reassembly, and component replacement Diagnostics: Component testing, electrical circuit testing, fault code interpretation Electrical Troubleshooting: Detailed wiring diagrams, circuit tracing, diagnostic procedures for electrical faults Technical Depth Depth Level: Comprehensive Factory Level Detail Detail Scope: From basic maintenance to complete engine and transmission rebuilds Visual Aids: Hundreds of photos, illustrations, and detailed drawings 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without restriction (entire manual or individual pages) Binding Type Binding: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - Printable) Software Requirements Reader Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Variant 1: 2.0L 16V Inline-4 (B4204S) Engine Variant 2: 1.9L 16V Turbocharged Inline-4 (B4194T) Engine Variant 3: 1.8L 16V Inline-4 (B4184S) Performance Horsepower 2.0L: 120 PS (88 kW; 118 hp) Torque 2.0L: 174 Nm (128 lb-ft) Horsepower 1.9T: 160 PS (118 kW; 158 hp) Torque 1.9T: 205 Nm (151 lb-ft) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Construction Block Material: Aluminum Alloy Head Material: Aluminum Alloy Engine Codes Coverage Covered Engine Codes: B4184S, B4194T, B4204S (and potential minor variations) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Optional Optional Transmission Type: 4-Speed Automatic (AW50-42LE) Features Automatic Features: Electronically controlled, 'Geartronic' manual override (on some models) 📐 Dimensions Exterior Length: 4495 mm (177.0 in) Width: 1715 mm (67.5 in) Height: 1415 mm (55.7 in) Weights Curb Weight Approx: 1270-1350 kg (2800-2976 lb) 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (Euro NCAP 1999) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Optional (TRACS - Traction Control and Anti-Skid System) Passive Features Airbags: Front airbags (driver and passenger), optional side airbags Body Structure: Volvo's Side Impact Protection System (SIPS) 💡 Technology Features Infotainment Audio System: Factory AM/FM/Cassette/CD player options, various speaker configurations Driver Assistance Cruise Control: Standard on most trims Connectivity Auxiliary Input: Typically not standard; aftermarket solutions often available 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 miles or 12 months, whichever comes first (refer to specific owner's manual for precise intervals) Timing Belt Replacement: Recommended every 60,000-80,000 miles or 5 years (critical maintenance...