Volvo S40 & V40 Petrol 1996-2004 Haynes Service Repair Manual

Free download Volvo S40 & V40 Petrol 1996-2004 Haynes Service Repair Manual PDF scr1

Volvo S40 & V40 Petrol 1996-2004 Haynes Service Repair Manual covers S40 Saloon & V40 Estate, including T4 & special/limited editions.

  • DOES NOT cover new S40 / V50 range introduced Mar 2004, Diesel or bi-fuel models.

Engines Covered:

  • 1.6 Litre (1588 cc) DOHC and variable valve timing
  • 1.8 Litre (1731 cc) DOHC
  • 1.8 Litre (1783 cc) DOHC variable valve timing
  • 1.8 Litre (1834 cc) Mitsubishi-designed DOHC direct-injection (GDI)
  • 1.9 Litre (1855 cc) DOHC turbo variable valve timing turbo
  • 2.0 Litre (1948 cc) DOHC variable valve timing
  • 2.0 Litre (1948 cc) DOHC turbo variable valve timing

Transmissions covered:

  • M3P 5 speed manual
  • M5p 5-speed manual
  • M5M42 or F5M45 5-speed manual
  • M56L2 5-speed manual
  • M56H 5-speed manual
  • AW 50-42 4-speed automatic
  • AW 55-50 5-speed automatic


The Volvo S40/V40 was introduced into the UK in May of 1996 as a replacement for the 400 series. The S40/V40 range was developed jointly with Mitsubishi, and is built along with its sister car, the Mitsubishi Carisma, at the NedCar plant in Holland. At its launch, the S40 Saloon and V40 Estate models were available with a choice of either 1.8 litre (1731 cc) or 2.0 litre (1948 cc) petrol engines, with either a 5-speed manual transmission or a 4-speed automatic. Both engines were newly-designed 16-valve double overhead camshaft (DOHC) units.

All models have fully-independent front and rear suspension, and are equipped with antilock disc brakes all round.

In early 1997. a 1.6 litre (1588 cc) version of the petrol engine was introduced, initially in Saloon models only. Towards the end of 1997, two turbocharged petrol engines were also introduced; the high-powered 1855 cc engine (fitted to the T4 model) and a low-pressure turbo version of the 1948 cc engine.

In March 1998, the first models with the Mitsubishi-designed 1.8 litre (1834 cc) GDI engine were introduced, while in early 1999, the first diesel models (not covered in this manual) were added to the range. Also in 1999, the 1.6 and 1.8 litre engines (except the GDI engine) gained variable valve timing, and a consequent boost in power – the 1.8 litre unit also grew slightly in capacity at this time, from 1731 cc to 1783 cc.

The range received a major facelift in May 2000, with new lights and bumpers, suspension revisions, 2.0 litre variable valve timing engines, and a new 5-speed automatic transmission. A further facelift in April 2002 resulted in a new-look Volvo radiator grille and other minor changes.

Provided that regular servicing is carried out in accordance with the manufacturer’s recommendations, the S40A/40 should prove reliable and economical. The engine compartment is well-designed, and most of the items requiring frequent attention are easily accessible.

Your Volvo S40 & V40 manual

The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence.

Free download Volvo S40 & V40 Petrol 1996-2004 Haynes Service Repair Manual PDF scr2


  • Living with Your Volvo S40 & V40
  • Roadside Repairs
  • Weekly Checks
  • Lubricants & Fluids
  • Tyre Pressures
  • Routine Maintenance & Service
  • Engine In-Car Repair Procedures – Except GDI
  • Engine In-Car Repair Procedures (GDI)
  • Engine Removal & Overhaul Procedures
  • Cooling, Heating & Ventilation Systems
  • Fuel System – Except GDI Engine
  • Fuel System – GDI Engine
  • Exhaust & Emission Control Systems
  • Starting & Charging Systems
  • Ignition System
  • Clutch
  • Manual Transmission
  • Automatic Transmission
  • Driveshafts
  • Braking System
  • Suspension & Steering
  • Bodywork & Fittings
  • Body Electrical Systems
  • Wiring Diagrams

There is a Haynes manual for most popular domestic and import cars, trucks, and motorcycles. By conducting complete tear-downs and rebuilds, the Haynes staff has discovered all die problems owners will find in rebuilding or repairing their vehicle. Documenting the process in hundreds of illustrations and clear step-by-step instructions makes every expert tip easy to follow. From simple maintenance to trouble-shooting and complete engine rebuilds, it’s easy wire Haynes.

Language: English
File: PDF
Size: 28.9 Mb
Free download Volvo S40 & V40 Petrol 1996-2004 Haynes Service Repair Manual PDF