🏷️ Basic Information

Make:

Volvo

Model:

S40

Year:

2003

Generation Code:

First Generation (P1)

Generation Years:

2004-2012 (Global, US market began 2004.5)

Chassis Code:

MS

👋 Introduction

Vehicle Segment:

Compact Executive Sedan / Compact Car

Target Audience:

Individuals and families seeking a safe, well-built, and stylish European compact vehicle.

Key Competitors:

BMW 3 Series, Audi A4, Mercedes-Benz C-Class, Acura TSX, Infiniti G35, Saab 9-3, Volkswagen Passat

Volvo Brand Attributes:

Safety focus, Scandinavian design, build quality, comfort, innovative features for the time.

S40 Specific Features:

Unique 'floating' center console design, comfortable seating, robust chassis.

📋 Manual Details

Languages Covered:

English

Estimated Page Count:

Approximately 350-450 pages (typical for this model year)

Manual Type:

Owner's Manual

Digital Format:

PDF

📖 Manual Coverage

Powertrain Systems:

Engine operation, cooling system, fuel system, exhaust system, ignition system

Drivetrain Systems:

Automatic and Manual Transmission operation, AWD system (if applicable), clutch operation

Chassis Systems:

Braking system (ABS, EBD), Steering system, Suspension system, Wheel and Tire information

Electrical Systems:

Lighting system, dashboard indicators and warnings, fuses, basic battery care

Comfort And Convenience:

Climate control (HVAC), audio system, power windows and locks, seating adjustments, interior lighting, sunroof operation

Passive Safety:

Airbag system operation, seatbelt usage and pre-tensioners, child seat installation (ISOFIX/LATCH)

Active Safety:

ABS, Traction Control System (TCS) / Dynamic Stability Control (DSTC) operation

Operation Procedures:

Starting and stopping the engine, driving techniques, using the gear selector, parking brake operation, cruise control usage

Maintenance Procedures:

Checking and topping up fluids (oil, coolant, brake fluid, windshield washer fluid), tire pressure checks, basic cleaning, bulb replacement (exterior/interior)

Troubleshooting Guides:

Understanding dashboard warning lights, basic troubleshooting for common minor issues (e.g., battery drain, non-starting conditions)

Emergency Procedures:

What to do in case of breakdown, tire changing (spare tire location and usage), jump starting, towing information

Depth Of Information:

Comprehensive operator guidance, routine checks, and basic maintenance procedures. Does not cover advanced diagnostics or full component replacement.

📊 Manual Specifications

PDF Quality:

High-resolution, searchable text, printable

Printability:

Designed for clear printing on standard home or office printers

Binding Type Digital:

N/A (Digital PDF)

Paper Type Digital:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code And Type:

B4204S3 (2.0L Inline-4, Naturally Aspirated) or B5244S4 (2.4L Inline-5, Naturally Aspirated), B5244S6 (2.4L Inline-5, Naturally Aspirated with higher output) or B5254T2 (2.5L Inline-5 Turbocharged - T5 models)

Horsepower Range:

136 hp (2.0L) to 218 hp (2.5L T5 Turbo)

Torque Range:

136 lb-ft (2.0L) to 236 lb-ft (2.5L T5 Turbo)

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended for turbo models)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Bore X Stroke:

Varies by engine (e.g., 2.4L: 81.0 mm x 93.15 mm)

Compression Ratio:

Varies by engine (e.g., 2.4L NA: 10.5:1, 2.5L Turbo: 9.5:1)

Valvetrain:

DOHC (Dual Overhead Camshafts), 4 valves per cylinder

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission (M56)

Optional Transmission:

5-speed Geartronic Automatic Transmission (AW55-50SN)

All Wheel Drive:

Available on certain models (e.g., AWD variants with 2.4L and 2.5L engines), typically using a Haldex-based system.

Geartronic Functionality:

Allows manual selection of gears for more driver control

📐 Dimensions

Length:

Approx. 171.7 inches (4361 mm)

Width:

Approx. 70.4 inches (1788 mm)

Height:

Approx. 55.9 inches (1420 mm)

Wheelbase:

Approx. 103.0 inches (2616 mm)

Cargo Volume:

Approx. 12.9 cubic feet (365 liters)

Curb Weight:

Approx. 3000-3300 lbs (1360-1497 kg), depending on engine and equipment

🛡️ Safety Features

NHTSA Front Impact Rating:

5-Star (for driver and front passenger)

IIHS Side Impact Rating:

Good (for models equipped with side airbags)

Anti Lock Brakes:

Standard (ABS)

Traction Control:

Optional / Standard on higher trims (TCS or DSTC)

Electronic Brake Force Distribution:

Standard (EBD)

Airbag System:

Standard front airbags, optional side airbags (SIPS), optional inflatable side curtain airbags (IC)

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners and load limiters

💡 Technology Features

Audio System:

Optional premium sound systems by Dynaudio, CD player with AM/FM radio, optional satellite radio prep.

Navigation System:

Optional factory-installed GPS navigation system (often with a smaller, lower-resolution screen compared to modern systems).

Cruise Control:

Standard

Phone Integration:

Optional Bluetooth hands-free system (may be an accessory or later addition depending on market and trim).

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, depending on driving conditions and oil type used.

Timing Belt Replacement:

Not applicable for these models; they use a timing chain.

Major Service Intervals:

Refer to manual for specific mileage/time intervals for spark plugs, cabin air filter, engine air filter, transmission fluid, etc. (e.g., spark plugs around 60,000-100,000 miles).

Engine Oil Specification:

SAE 0W-30 or 5W-30, meeting ACEA A5/B5 specifications (e.g., Castrol EDGE Professional A5/B5 0W-30).

Coolant Specification:

Volvo Part No. 31439824 (or equivalent), a green ethylene glycol-based coolant, mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 3 or DOT 4

Transmission Fluid Automatic:

AW-1 (JWS 3309) or equivalent, e.g., Mobil ATF 3309

Common Wear Items:

Front suspension components (control arms, ball joints), rear shock absorbers, exhaust hangers, fuel pump modules, some electronic sensors (e.g., camshaft position sensor).

Engine Specific Concerns:

PCV system issues leading to oil leaks or rough running, coil-on-plug failures on ignition system, oil separator issues.

Transmission Specific Concerns:

Solenoid issues in automatic transmissions (especially early AW55-50SN models), clutch wear on manuals.

📚 Vehicle History

Volvo Heritage:

Renowned for safety, robust engineering, and distinctive Scandinavian design principles.

S40 P1 Generation:

This generation marked a significant shift in design and platform from previous Volvo compacts, sharing its P1 platform with the Volvo V50, C70, and Ford Focus/Mazda 3.

Manufacturing Locations:

Ghent, Belgium; Uddevalla, Sweden

Production Period:

2003 (Model Year 2004.5 onwards in North America)

🏆 Awards & Recognition

Safety Awards:

Consistently received high safety ratings from organizations like NHTSA and IIHS for its robust construction and advanced safety features for its time.

Consumer Reports Typical Rating:

Variable, often praised for safety and driving dynamics but sometimes criticized for reliability compared to Japanese competitors.

Emissions Standards:

Meets ULEV (Ultra Low Emission Vehicle) or PZEV (Partial Zero Emission Vehicle) standards in certain markets, depending on engine and configuration.