Target Audience:
DIY enthusiasts and professional technicians seeking comprehensive repair information for the Volvo S40 (2002 model year)
Value Proposition:
Provides detailed, factory-level repair and maintenance information at a fraction of the cost of official dealership manuals or professional repair services.
Content Structure:
Step-by-step instructions, hundreds of photos and illustrations, detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, enlarged insets, numbered table of contents.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system
Drivetrain:
Transmission (automatic and manual), driveshafts, differentials
Chassis:
Suspension (front and rear), steering system, braking system
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation, body electronics
Body And Interior:
Body panels, doors, windows, seats, HVAC system
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Repair:
Component removal and installation, engine rebuild, transmission repair, suspension overhaul, brake service
Troubleshooting:
Diagnostic procedures, common fault diagnosis, electrical system troubleshooting
Specifications:
Torque specifications, clearances, fluid capacities, electrical component data
Depth:
Full factory level, suitable for professional mechanics and experienced DIYers, covering complete disassembly and reassembly
Printability:
Printable without restriction, entire manual or selected pages
Binding:
Not applicable (digital download)
Paper Quality:
Not applicable (digital download)
Delivery:
Instant digital download via link on checkout page
Engine Options:
Likely includes naturally aspirated and turbocharged variants of Volvo's B4204S (2.0L 4-cylinder) and B5244S2 (2.4L 5-cylinder) engines. Turbocharged variants might include the B4204T or B5244T series.
Horsepower Torque Range:
Varies by specific engine. For example, the 2.0L may produce around 136 hp, while the 2.4L may offer around 140 hp. Turbocharged versions would have higher outputs.
Fuel Delivery:
Electronic Fuel Injection (EFI)
ECU Type:
Likely Bosch Motronic or similar advanced engine control unit (ECU)
Catalytic Converter:
Equipped with a three-way catalytic converter system
Transmission Type Standard:
Likely a 5-speed manual transmission for most variants.
Transmission Type Optional:
Likely a 4-speed automatic transmission (e.g., AW55-50SN) for many models.
Transmission Features:
Gear ratios, clutch specifications, automatic transmission fluid (ATF) type and capacity, electronic control of automatic transmissions.
NHTSA Rating:
Information not readily available for this specific year and model's detailed NHTSA rating, but Volvo typically prioritizes safety.
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA)
Stability Control:
Likely equipped with Electronic Stability Program (ESP) or Traction Control System (TCS)
Airbags:
Front airbags, side airbags, potentially inflatable curtain airbags (IC)
Body Structure:
Volvo's signature reinforced safety cage design
Audio System:
Factory premium sound system options likely included CD player, radio, and potentially a separate amplifier. Options for cassette players may also exist.
Cruise Control:
Standard cruise control functionality
Optional Features:
Limited connectivity options by modern standards; potential for factory-fitted hands-free phone systems in some higher trims.
Oil Change Interval:
Typically 10,000 miles or 12 months, whichever comes first, depending on driving conditions (refer to manual for specifics).
Timing Belt Interval:
For applicable engines, typically around 60,000-100,000 miles or 5-7 years. Crucial to confirm with the manual.
Engine Oil Specification:
Likely SAE 5W-30 or 5W-40 synthetic oil meeting Volvo's specific VCC approval (e.g., VCC 95200357).
Coolant Specification:
Volvo's long-life coolant, typically a 50/50 mix of ethylene glycol and deionized water, often blue or green in color.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Automatic Transmission Fluid:
Specific Dexron III/VI compatible fluid or Volvo's proprietary ATF (e.g., JWS 3309).
Common Wear Items:
Suspension components (bushings, ball joints, struts), ignition coils (especially on turbocharged models), ABS sensors, HVAC blower motor resistors, power steering leaks.
Electrical Gremlins:
Occasional issues with door modules, window regulators, and instrument cluster LEDs.
Volvo Safety Focus:
Volvo has a long-standing reputation for pioneering automotive safety innovations.
S40 Development:
The S40 (and its V40 wagon sibling) was developed in partnership with Mitsubishi, sharing a platform (and often production facilities) with the Mitsubishi Carisma.
Production Period:
The first generation S40/V40 was produced from 1995 to 2004.
Manufacturing Location:
Primarily manufactured in Ghent, Belgium, and sometimes in the Netherlands.
