Volvo S40 and V40 Service and Repair manual Haynes 1996 - 2004 NEW
Volvo S40 and V40 Service and Repair Manual 1996- March 2004 Haynes
covering S40 Saloon & V40 Estate, inc. T4 & special/limited editions, 1996 thru 2004. Does NOT cover new S40/V50 range introduced Mar 2004, Diesel or bi-fuel models
Engines (4 cyl petrol):
1.6 L (1588 cc) "B4164S" DOHC and variable valve timing "B4164S2" DOHC
1.8 L (1731 cc) "B4184S" DOHC
1.8 L (1783 cc) "B4184S2/3" DOHC with variable valve timing
1.8 L (1834 cc) "B4184SM" & "B4184SJ" Mitsubishi-designed DOHC direct-injection (GDI)
1.9 L (1855 cc) "B4194T" DOHC turbo and "B4194T2" variable valve timing DOHC turbo
2.0 L (1948 cc) "B4204S" DOHC and variable valve timing "B4204S2"
2.0 L (1948 cc) "B4204T" DOHC turbo, "B4204T2/3" & "B4204T5" DOHC turbo with variable valve timing
M3P 5-speed man (1.6- and early 1.8-litre except GDI)
M5p 5-speed man (2.0-litre non-turbo and later 1.8-litre except GDI)
M5M42 or F5M45 5-speed man (1.8-litre GDI)
M56L2 5-speed man (1.9-litre turbo T4)
M56H 5-speed man (2.0-litre low-pressure turbo)
AW 50-42 4-speed auto
AW 55-50 5-speed auto
With a Haynes manual, you can do it yourself…from simple maintenance to basic repairs. Haynes writes every book based on a complete teardown of the vehicle. We learn the best ways to do a job and that makes it quicker, easier and cheaper for you. Our books have clear instructions and hundreds of photographs that show each step. Whether you’re a beginner or a pro, you can save big with Haynes!
--Complete troubleshooting section
--Valuable short cuts
--Color spark plug diagnosis
Inside this manual:
Basic maintenance: simple weekly checks
Service your car: complete step-by-step guide
Fault finding: pinpoint specific problems easily
Roadside emergencies: how to deal with them
Pass the MOT: step-by-step test checks
Reference section: includes a detailed glossary
Braking System: safelty checks & repairs
Fuel & ignition systems: explained
Electrical system: fault finding & repairs
Engine: tune-up, minor & major repairs
Wiring diagrams: easy-to-follow layout
Fully indexed: find information quickly
About the Volvo S40 and V40
The Volvo S40 is a small family car produced by Volvo. It introduced the first generation S40 (Saloon) and V40 (Versatility/estate) cars in 1995. The second generation arrived in 2004, and the wagon's name changed to V50. In the summer of 1995 Volvo released the S4/F4 series but had to change the model's name as it conflicted with Audi who had already reserved the "S4" name. The quickly renamed S40 saloon (sedan) and V40 (Ferrari objected to F40) estate (station wagon), manufactured at the NedCar factory in Holland (a pre-Ford joint venture between Volvo and Mitsubishi Motors) and based on a common platform with the Mitsubishi Carisma. The V40, with Drag coefficient of 0.32, was the first whole model to be introduced under the direction of the British designer Peter Horbury, Volvo’s Design Director, and was marketed in Australia, North and South America, and the Far East. The V40 was named the ‘Most Beautiful Estate Car in the World’ at an Italian award ceremony.
In 2001 Volvo updated the 40 Series ("Phase II"), implementing a number of technical improvements, e.g., improved engine management, direct (diesel) fuel injection, extra safety features, larger brake discs, new front suspension and steering, revised rear suspension, larger tires and a widening of the track width. A minor facelift gave larger headlights, more streamlining and larger rear light clusters as well as minor instruments and fascia re-design.
The 40 Series cars were equipped with four-cylinder engines, such as a 1.9 turbo diesel or 1.6 (1588 cc), 1.8 (1731 cc), 2.0T (1948 cc), 1.9 T4 (1855 cc) or 2.0 (1948 cc) fuel-injected gasoline engines all of which are derivatives of the modular whiteblock engine series that started life in the Volvo 960 and carried in both 5 and 6 cyl formats in Volvo's bigger FWD cars. There was also a 1.8 L (1834 cc) Gasoline direct injection engine provided by Mitsubishi as part of the platform sharing between the 40 series and the Carisma.
The low (2.0T) and high (1.9 T4) pressure turbo variants at the top of the motor range. The 2.0T was rounded down and badged as 1.9T and was the only engine available in North America. The 5 speed manual transmission, widely available in Europe was not certified in US-spec S40s, with the 5 Speed automatic as the only option. No electric CVT transmission was planned unlike the 440 HTA / High Tech Auto CVT that had been released before the 400 series was completely phased out.
A racing version (S40) was introduced in the British Touring Cars in 1997 and in 1998 the car, with Richard Rydell, took the championship. Due to the common platform, many components of the suspension and drive train are compatible with Carisma as well as the Mitsubishi Evolution III. and Proton Impian. The Volvo S40 was the first car to earn four stars in Euro-NCAP.
Volvo S40 and V40 Service and Repair Workshop Manual 1996- March 2004 Haynes 1997 1998 1999 2000 2001 2002 2003
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