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Volvo S40 2004 Workshop Service Repair Manual

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The 2004 Volvo S40 is a compact executive sedan, built on the P1 platform shared with other manufacturers, and represents Volvo's commitment to safety and Scandinavian design. This model offers...
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Stichworte: 2004 Car Cars S40 Volvo
Volvo S40 2004 Workshop Service Repair ManualVolvo S40 2004 Workshop Service Repair ManualVolvo S40 2004 Workshop Service Repair Manual
The 2004 Volvo S40 is a compact executive sedan, built on the P1 platform shared with other manufacturers, and represents Volvo's commitment to safety and Scandinavian design. This model offers a blend of refined engineering and practical utility, making it a competitive choice in its segment. Available with a 2.0-liter inline 4-cylinder engine producing approximately 136 horsepower and 187 Nm of torque, and also offered with 2.4-liter naturally aspirated or 2.5-liter turbocharged engines, the S40 provides a balanced driving experience. Its dimensions, including a length of 4476 mm and a wheelbase of 2635 mm, contribute to a comfortable interior and stable handling. The vehicle also features robust safety systems, including standard Anti-lock Braking System (ABS) and optional traction control, along with comprehensive airbag coverage. This workshop service repair manual provides complete factory-level detail for the 2004 Volvo S40, covering all trim levels. It encompasses a wide array of systems, including engine mechanicals, fuel and exhaust systems, cooling, lubrication, ignition, and engine management. The manual details both manual and automatic transmissions, as well as chassis components such as suspension, steering, and braking systems. Extensive coverage is also given to electrical systems, bodywork, and interior components. Included are essential maintenance procedures, detailed repair instructions for disassembly and reassembly, troubleshooting guides, and diagnostic flowcharts. This comprehensive resource is designed to assist both do-it-yourself enthusiasts and professional mechanics in maintaining and repairing the vehicle effectively.
🏷️ Basic Information
Identification
Make:
Volvo
Model:
S40
Year:
2004
Chassis Code:
P1
Codes
Platform:
P1 Platform (shared with Mazda 3, Ford Focus Mk2, etc.)
👋 Introduction
Market Position
Segment:
Compact Executive/Premium Compact Sedan
Target Audience:
Do-it-yourself enthusiasts and professional mechanics
Competitive Analysis
Key Competitors:
BMW 3 Series (E46), Audi A4 (B6), Mercedes-Benz C-Class (W203), Acura TSX, Lexus IS (XE10)
Key Features
Manual Advantage:
Comprehensive, factory-level detail, detailed illustrations, troubleshooting guidance, cost-effective repair solution
Vehicle Focus:
Designed to empower owners and technicians with the knowledge to maintain and repair the Volvo S40
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (primarily North American and European specifications)
Trim Level Coverage:
All trim levels
Page Count
Estimated Page Count:
Hundreds of pages (exact count not specified, but described as 'complete official full factory service repair manual')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine management, fuel system, exhaust system, cooling system, lubrication system, ignition system
Transmission:
Manual transmission, automatic transmission (including clutch, gear shifting mechanisms, hydraulics)
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), wheels and tires
Electrical:
Body electrical systems, lighting, instrumentation, infotainment, control modules, wiring diagrams, diagnostics
Body:
Body structure, exterior panels, interior trim, doors, windows, seats, HVAC system
Engine Management:
Engine control module (ECM) diagnostics, sensor testing, actuator testing, emissions control system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component repair
Diagnostics:
Troubleshooting guides, diagnostic procedures for engine, transmission, ABS, SRS, and other control modules
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Suspension Repair:
Strut replacement, shock absorber replacement, bushing replacement, ball joint service, control arm service
Technical Depth
Depth:
Complete disassembly and reassembly instructions, detailed component identification, wiring diagrams, diagnostic flowcharts
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems, including fuse box layouts and component locations.
Manual Completeness
Coverage:
Full factory service and repair coverage, not a condensed version.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All PC based Windows operating systems and Mac
Print Quality
Printability:
Printable without any restriction (individual pages or entire manual)
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Paper Type:
N/A (Digital)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirement:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Code:
B4204S3 (2.0L Naturally Aspirated)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1948 cc
Bore X Stroke:
81.0 mm x 95.2 mm
Performance
Horsepower:
136 hp @ 6000 rpm (approximate for B4204S3)
Torque:
187 Nm @ 4500 rpm (approximate for B4204S3)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Other Engines
Available Engines:
2.4L Naturally Aspirated (B5244S2), 2.5L Turbocharged (B5254T2 - T5 models)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual (M56H)
Optional
Optional Transmission:
5-speed Geartronic Automatic (AW55-50SN)
Features
Manual Clutch Type:
Hydraulically actuated, single dry plate
Automatic Features:
Sequential manual shifting (Geartronic)
📐 Dimensions
Exterior
Length:
4476 mm
Width:
1775 mm
Height:
1456 mm
Wheelbase:
2635 mm
Weights
Curb Weight:
1365 kg (approximate for 2.0L)
Gross Vehicle Weight Rating:
1900 kg (approximate)
Cargo
Trunk Volume:
405 liters
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2005 model, indicative of 2004 platform)
NHTSA Front Impact Passenger:
Good (for 2005 model, indicative of 2004 platform)
IIHS Front Offset Crashworthiness:
Good (for 2005 model, indicative of 2004 platform)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Optional/Standard on some trims (TRACS/DSTC)
Passive Features
Airbags:
Front airbags, side airbags, optional inflatable curtain airbags (IC)
Seatbelts:
Pretensioning seatbelts with load limiters
Child Safety:
ISOFIX child seat anchorage points
💡 Technology Features
Infotainment
Audio System:
Volvo Premium Sound System, CD player, optional CD changer
Display:
Central information display (CID) with trip computer
Driver Assistance
Cruise Control:
Standard
Connectivity
Optional Features:
Bluetooth connectivity (later models/optional), integrated phone
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 12,000 km, or annually, whichever comes first (typical Volvo recommendation)
Timing Belt Replacement:
Refer to manual for specific engine, typically around 105,000 miles (for timing belt driven engines).
Fluid Specifications
Engine Oil Type:
Synthetic 5W-30 API SM or higher (consult manual for exact spec)
Coolant Type:
Volvo Coolant VCS or equivalent (ethylene glycol-based, long-life)
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
SAE 75W-80 GL-4 or GL-5 (consult manual for exact spec)
Transmission Fluid Automatic:
AW-1 (for AW55-50SN)
Known Issues
Common Issues:
Ignition coil failure, ABS sensor issues, minor electrical gremlins, turbo hose leaks (on T5 models), fuel pump module issues.
📚 Vehicle History
Brand Heritage
Volvo Philosophy:
Emphasis on safety, durability, and Scandinavian design
Model Evolution
S40 Gen1 Vs Gen2:
The 2004 model represents the first generation of the S40, designed in collaboration with Mitsubishi (platform sharing).
P1 Platform Significance:
Marked a significant shift towards modern platform design and shared components with other manufacturers.
Production
Production Years:
2004-2004 (This generation ended with 2004, the second generation launched for 2005)
Manufacturing Location:
Ghent, Belgium
🏆 Awards & Recognition
Recognitions
Safety Awards:
Consistent high safety ratings from IIHS and NHTSA for Volvo models of this era, reflecting strong safety engineering.
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