The Volvo S40, produced from 1995 to 2004 on the P1 platform, represents Volvo's commitment to safety, durability, and Scandinavian design in the compact executive sedan segment. This model, often seen as a successor to the 440/460 series, offers a blend of refined interiors, ergonomic focus, and robust engineering, making it a popular choice for professionals and families seeking comfort and security. It features a naturally aspirated 2.0-liter inline 4-cylinder engine (B4204S) producing 115 PS, with front-wheel drive and a choice of a 5-speed manual or a 4-speed automatic transmission. Volvo's inherent reputation for safety is evident in features like a reinforced safety cage, crumple zones, standard front airbags, and three-point seatbelts with pretensioners, alongside active safety systems such as front ventilated disc brakes with standard ABS on most models.
This comprehensive workshop service repair manual is designed for both do-it-yourself enthusiasts and experienced mechanics, covering all essential aspects of the Volvo S40. It provides detailed information on powertrain systems including the engine, transmission, and drivetrain, as well as chassis components like suspension, steering, and brakes. The manual also delves into the complete electrical system, bodywork, and interior systems, offering extensive maintenance schedules, step-by-step repair procedures, and troubleshooting guides for common and uncommon issues. With hundreds of illustrations and factory-level detail, this manual equips users with the knowledge to effectively maintain and repair their vehicle, ensuring its longevity and optimal performance.
Platform:
Hyundai Elantra (XD)
Segment:
Compact Executive Sedan
Target Audience:
Professionals, families seeking safety and comfort
Key Competitors:
Audi A3, BMW 3 Series Compact (E36/5), Mercedes-Benz C-Class (W202), Volkswagen Golf GTI
Brand Identity:
Volvo's reputation for safety, durability, and comfortable interiors
Design Philosophy:
Scandinavian design, focus on ergonomics and passenger safety
Primary Markets:
North America, Europe
Region Specific Variants:
Includes information pertinent to models sold globally
Estimated Pages:
Hundreds (exact count not specified, but described as comprehensive)
Type:
Workshop Service Repair Manual
Purpose:
Do-it-yourselfer and experienced mechanic
Delivery Method:
Digital Download
Powertrain:
Engine, transmission, drivetrain, exhaust system
Chassis:
Suspension, steering, brakes, wheels and tires
Electrical:
Complete electrical system, wiring diagrams, troubleshooting
Body:
Body panels, interior trim, climate control, safety systems (airbags, seatbelts)
Maintenance:
Scheduled maintenance, fluid changes, filter replacements
Repair:
Step-by-step repair procedures for all major components
Troubleshooting:
Diagnosis and resolution of common and uncommon faults
Diagnostics:
Diagnostic procedures, fault codes, and electrical system diagnostics
Depth:
Comprehensive factory-level detail, including full disassembly and reassembly
Illustrations:
Hundreds of photos and illustrations, including enlarged insets
Guidance:
Detailed substeps, notes, cautions, and warnings
Searchability:
Assumed searchable due to PDF format (though not explicitly stated)
Printability:
Printable without restriction
Print Options:
Print entire manual or select pages
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Software Requirement:
Adobe PDF Reader
Engine Code:
B4204S (2.0L)
Engine Type:
Inline 4-cylinder, naturally aspirated
Displacement:
1948 cc (2.0 Liters)
Bore X Stroke:
82.7 mm x 93.2 mm
Compression Ratio:
10.3:1
Horsepower:
115 PS (113 hp; 85 kW) at 5500 rpm
Torque:
170 Nm (125 lb-ft) at 4000 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (95 RON recommended)
Other Engines:
1.8L Turbo (B18FT, 115hp), 1.8L Turbo (B18FT, 160hp), 2.0L Turbo (B204FT, 163hp), 2.0L Turbo (B204FT, 200hp - T5)
Type:
4-speed Automatic (AW50-42LE)
Drivetrain:
Front-Wheel Drive (FWD)
Clutch:
Hydraulically operated, single dry plate
Length:
4478 mm (176.3 in)
Height:
1398 mm (55.0 in)
Wheelbase:
2619 mm (103.1 in)
Curb Weight:
Approx. 1300 kg (2866 lbs) for 2.0L model
Gross Vehicle Weight Rating:
Varies by model and equipment
Trunk Volume:
Approx. 450 liters (15.9 cu ft)
Historic Ratings:
While NHTSA/IIHS ratings for the 1996 model specifically are scarce, Volvo vehicles of this era generally performed well in crash tests due to the brand's strong safety focus.
Brakes:
Front ventilated discs, rear solid discs; ABS standard on most models
Traction Control:
Optional on some models
Airbags:
Driver and front passenger airbags standard
Seat Belts:
Three-point inertia-reel seatbelts with pretensioners
Body Structure:
Reinforced safety cage, crumple zones
Audio System:
Factory fitted radio/cassette or CD player with optional amplifier and speaker upgrades.
Climate Control:
Manual air conditioning, optional automatic climate control on higher trims.
Cruise Control:
Standard or optional depending on trim level.
Exterior Features:
Body-colored door handles and mirrors, power-adjustable heated exterior mirrors.
Oil Change:
Every 15,000 km (9,000 miles) or 12 months, whichever comes first
Air Filter Replacement:
Every 30,000 km (18,000 miles) or 24 months
Spark Plug Replacement:
Every 60,000 km (36,000 miles) for standard plugs, longer for platinum/iridium
Timing Belt Replacement:
Every 90,000 km (54,000 miles) or 5 years (crucial for interference engines)
Engine Oil:
API SJ or ACEA A3/B3, viscosity SAE 5W-40 or 10W-40 (refer to manual for specific climate/engine)
Coolant:
Volvo long-life coolant (G48/VCX) or equivalent ethylene glycol-based coolant with anti-corrosion additives
Transmission Fluid Auto:
AW-1 or equivalent ATF (refer to manual for specific type)
Common Problems:
Ignition coil failure, ABS sensor issues, minor oil leaks from engine seals, wear on suspension components (bushings, ball joints), blower motor resistor failure.
Preventative Measures:
Regularly check timing belt condition and replace proactively; ensure proper engine cooling system maintenance to prevent overheating.
Heritage:
Volvo AB, a Swedish manufacturer founded in 1927, known for its emphasis on safety, reliability, and robust engineering.
Predecessors:
Successor to the Volvo 440/460 series, representing a more modern design and platform.
Generation:
First generation (P1 platform, internally known as the 'Peter' project). Later replaced by the second generation S40 (MS platform) in 2004.
Production Period:
1995-2004
Manufacturing Locations:
Ghent, Belgium; Kalmar, Sweden
Safety Awards:
While specific awards for the 1996 S40 are not widely publicized, Volvo as a brand consistently received accolades for its safety innovations and commitment, influencing its market perception.
