Segment:
Compact Executive/Premium Compact Sedan
Target Audience:
Do-it-yourself enthusiasts and professional mechanics
Key Competitors:
BMW 3 Series (E46), Audi A4 (B6), Mercedes-Benz C-Class (W203), Acura TSX, Lexus IS (XE10)
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
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
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
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.
Coverage:
Full factory service and repair coverage, not a condensed version.
Engine Code:
B4204S3 (2.0L Naturally Aspirated)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Bore X Stroke:
81.0 mm x 95.2 mm
Horsepower:
136 hp @ 6000 rpm (approximate for B4204S3)
Torque:
187 Nm @ 4500 rpm (approximate for B4204S3)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Available Engines:
2.4L Naturally Aspirated (B5244S2), 2.5L Turbocharged (B5254T2 - T5 models)
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)
ABS:
Standard Anti-lock Braking System
Traction Control:
Optional/Standard on some trims (TRACS/DSTC)
Airbags:
Front airbags, side airbags, optional inflatable curtain airbags (IC)
Seatbelts:
Pretensioning seatbelts with load limiters
Child Safety:
ISOFIX child seat anchorage points
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).
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)
Transmission Fluid Manual:
SAE 75W-80 GL-4 or GL-5 (consult manual for exact spec)
Transmission Fluid Automatic:
AW-1 (for AW55-50SN)
Common Issues:
Ignition coil failure, ABS sensor issues, minor electrical gremlins, turbo hose leaks (on T5 models), fuel pump module issues.
Volvo Philosophy:
Emphasis on safety, durability, and Scandinavian design
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 Years:
2004-2004 (This generation ended with 2004, the second generation launched for 2005)
Manufacturing Location:
Ghent, Belgium
