Volvo S40 V40 1996 – 2004 Haynes Service and Repair Manual

The purpose of this repair manual is to help the owner to use the full potential of the car. First of all, you will be able to understand which of the units of the car requires maintenance or repair, as well as evaluate the possibility of doing this on your own. This manual also provides a complete list of procedures for periodic ongoing maintenance. The most common faults and ways to detect and eliminate them are also given. We hope that you will be able to solve many of the problems that arise. Performing some procedures takes so little time that it is easier to do it yourself than to sign up for a service station, drive a car back and then pick it up. This way you can save not only your time, but also money.

This service repair manual provides detailed illustrated descriptions of the various components and mechanisms of the car. All maintenance and repair procedures are described step by step and illustrated.

The second-generation Volvo S40 sedan stood on the factory conveyor in the Belgian Ghent in 2004. The version with the station wagon received an index V50. The car was created on a common platform with second generation Ford Focus and first generation Mazda 3 models.


  • Safety first!
  • Introduction
  • Roadside repairs Introduction
  • If your car won’t start
  • Jump starting
  • Identifying leaks
  • Towing
  • Wheel changing
  • Weekly checks Introduction
  • Underbonnet check points
  • Engine oil level
  • Coolant level
  • Brake and clutch fluid level
  • Power steering fluid level
  • Battery
  • Electrical systems
  • Tyre condition and pressure
  • Screen washer fluid level
  • Wiper blades
  • Lubricants and fluids
  • Tyre pressures
  • Routine maintenance and servicing
  • Servicing specifications
  • Maintenance schedule
  • Maintenance procedures
  • Engine and associated systems Engine in-car repair procedures (except GDI)
  • Engine in-car repair procedures (GDI)
  • Engine removal and overhaul procedures
  • Cooling, heating and ventilation systems
  • Fuel system – except GDI engine
  • Fuel system – GDI engine
  • Exhaust and emission control systems
  • Starting and charging systems
  • Ignition system
  • Transmission Clutch
  • Manual transmission
  • Automatic transmission
  • Driveshafts
  • Brakes and suspension Braking system
  • Suspension and steering
  • Body equipment Bodywork and fittings
  • Body electrical systems
  • Wiring diagrams
  • Dimensions and weights
  • Conversion factors
  • Buying spare parts
  • Vehicle identification
  • General repair procedures
  • Jacking and vehicle support
  • Audio unit anti-theft system – precaution
  • Tools and working facilities
  • MOT test checks
  • Fault finding
  • Glossary of technical terms

Language: English
Format: PDF
Pages: 308

Volvo S40 V40 1996 – 2004 Haynes Service and Repair Manual