Vehicle Segment:
Compact Executive Car (often referred to as a premium compact hatchback).
Key Competitors:
Audi A3, BMW 3 Series Compact, Mercedes-Benz A-Class, Volkswagen Golf.
Brand Philosophy:
Volvo's reputation for safety and build quality carried through to this model, offering a premium feel and robust engineering.
Buyer Profile:
Individuals and families seeking a safe, reliable, and comfortable compact vehicle with a touch of Scandinavian design and premium features.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Regions Covered:
Global (North America, Europe, Asia, etc. - based on factory documentation)
Trim Levels Covered:
All trim levels (e.g., Base, Luxury, Sport, Turbo variants)
Estimated Page Count:
Hundreds (specific count not provided, but described as 'complete official full factory service repair manual')
Type:
Workshop Service Repair Manual
Digital Format:
PDF Download
Powertrain:
Engine mechanical, engine management, fuel system, cooling system, exhaust system, transmission (manual and automatic), clutch, driveshafts, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (ABS, discs, drums), wheels and tires.
Electrical:
Charging system, starting system, ignition system, lighting, instruments and gauges, body electrical, climate control, audio systems, power accessories, engine control unit (ECU) diagnostics, wiring diagrams.
Body:
Body structure, exterior panels, interior trim, doors, windows, seats, HVAC (Heating, Ventilation, and Air Conditioning) system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, belt inspection and replacement.
Repair:
Engine component repair/replacement, transmission overhaul, brake system repairs, suspension component replacement, electrical system troubleshooting and repair, body panel repair.
Troubleshooting:
Systematic diagnosis of common and uncommon faults, diagnostic trouble codes (DTCs), electrical system troubleshooting with detailed wiring diagrams.
Depth:
Comprehensive, covering from basic maintenance to complete disassembly and reassembly, including detailed diagnostic procedures and specifications.
Engine Options:
Various 4-cylinder inline engines (petrol and diesel). Common petrol engines include B4164S (1.6L), B4184S (1.8L), B4204S (2.0L), and B5204S (2.0L Turbo - T4 variant). Common diesel engines include D4192T (1.9L TD/TDI).
Power Output Range:
Approximately 90 hp (1.9 D) to 200 hp (2.0 T4 Turbo).
Torque Output Range:
Approximately 140 Nm (1.6L) to 300 Nm (2.0 T4 Turbo).
Injection Type:
Multi-point fuel injection (MPI) for petrol engines, Common Rail Direct Injection (CRDi) for later diesel models.
ECU Type:
Bosch Motronic, Lucas/Visteon, or Siemens engine control units depending on engine and year.
Type:
5-speed Manual Transmission (e.g., M56).
Type:
4-speed Automatic Transmission (e.g., AW50-42LE).
Clutch Type:
Hydraulically operated single dry plate clutch.
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check manual for specific viscosity and GL rating).
Automatic Transmission Fluid:
JWS 3309 / Type T-IV (for AW50-42LE)
Length:
Approx. 4480 mm (176.4 in)
Width:
Approx. 1710 mm (67.3 in)
Height:
Approx. 1410 mm (55.5 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Curb Weight Range:
Approx. 1250 kg - 1400 kg (depending on engine and equipment).
Euro Ncap Rating:
4 Stars (for models tested in the late 1990s/early 2000s - specific V40 rating may vary, but consistent with Volvo's safety focus).
ABS:
Anti-lock Braking System (standard on most variants).
Traction Control:
Optional on some models.
Airbags:
Front airbags (driver and passenger) standard. Optional side airbags on some later models.
Seat Belts:
Three-point inertia-reel seatbelts with pretensioners for all seating positions.
Structure:
Reinforced Safety Cage, Side Impact Protection System (SIPS).
Audio System:
Factory fitted cassette or CD players, often with auxiliary inputs or CD changers available on higher trims or as options. Brands like Clarion or Alpine were common.
Navigation:
Optional factory-fitted or dealer-installed navigation systems were available on some models.
Cruise Control:
Standard or optional depending on trim level.
Phone Integration:
Some later models featured integrated Bluetooth or pre-wiring for car phones as optional equipment.
Oil And Filter Change:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (check specific model year/engine for precise intervals).
Timing Belt Replacement:
For non-interference engines, interval is typically around 100,000 km or 5 years. For interference engines (e.g., some 2.0L and turbo variants), interval is crucial and around 60,000-80,000 km or 4-5 years.
Engine Oil Specification:
API SJ, SL or ACEA A3/B3, A3/B4. Viscosity grades commonly 5W-30, 5W-40, 10W-40, 10W-30 (refer to manual for specific engine requirements).
Coolant Specification:
Volvo VCS (Volvo Coolant Concentrate) or equivalent G48 (ethylene glycol-based with organic additives), mixed 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4.
Common Problems:
ABS sensor failures, ignition coil pack issues (especially on earlier models), fuel pump failure, vacuum hose leaks, aging rubber components (bushings, hoses), climate control unit malfunctions, window regulator failures.
Timing Belt Risk:
Critical for interference engines; failure can cause catastrophic engine damage. Regular replacement is essential.
Volvo Safety Legacy:
Built upon Volvo's long-standing reputation for pioneering automotive safety features, including the three-point seatbelt and safety cage design.
Platform Origin:
Based on the same platform as the Volvo S40 sedan and V40 estate (which replaced the 460 and 440 respectively). The V40 was a compact five-door hatchback.
Production Period:
1995-2004
Manufacturing Sites:
Primarily manufactured in Ghent, Belgium, and Kalmar, Sweden.
