1. Introduction
This manual provides comprehensive repair and maintenance procedures for Volvo S40 and V40 petrol models manufactured between 1996 and March 2004. It covers various aspects of vehicle servicing, from routine checks to detailed engine and system repairs, designed to assist vehicle owners in performing their own maintenance and repairs.
Figure 1.1: Front cover of the Haynes Volvo S40 & V40 Petrol Repair Manual, indicating the models and years covered.
2. Vehicle Coverage
This manual specifically covers Volvo S40 and V40 Saloons equipped with normally-aspirated petrol engines, including special and limited editions. The detailed procedures are applicable to the following engine types:
- 1.8 litre (1850cc) petrol engines
- 2.0 litre (1997cc) petrol engines
- 2.3 litre (2256cc) petrol engines
Note: This manual does not cover diesel engines or models outside the specified production years (1996 - March 2004).
3. Safety Precautions
Always prioritize safety when performing any maintenance or repair work on your vehicle. Adhere to the following general safety guidelines:
- Disconnect the battery's negative terminal before working on electrical systems to prevent accidental shorts or injury.
- Allow the engine and exhaust system to cool completely before working on hot components to avoid burns.
- Use appropriate personal protective equipment (PPE) such as safety glasses, gloves, and sturdy footwear.
- Ensure the vehicle is securely supported on jack stands on a level surface before working underneath it. Never rely solely on a jack.
- Dispose of used fluids, filters, and other components responsibly according to local environmental regulations.
Figure 3.1: An example page from the manual showing a safety warning. The text warns: "Dispose of the old filter safely; it will be highly flammable, and may explode if thrown on a fire."
4. Routine Maintenance
Regular maintenance is crucial for the longevity and reliable operation of your Volvo S40 or V40. This section outlines routine checks and servicing procedures to keep your vehicle in optimal condition.
4.1 Weekly Checks
Perform these basic checks regularly to monitor your vehicle's condition:
- Engine oil level
- Coolant level
- Brake and clutch fluid level
- Power steering fluid level
- Battery condition and fluid level (if applicable)
- Tyre condition and pressure
- Screen washer fluid level
- Wiper blades inspection
Refer to the manual for detailed instructions on performing these checks and recommended intervals.
4.2 Lubricants and Fluids
This section provides specifications for various lubricants and fluids required for your vehicle, including capacities and recommended types.
Figure 4.1: A page from the manual detailing engine oil capacities, transmission fluid types, cooling system antifreeze mixtures, and spark plug specifications. It also includes torque wrench settings for various components.
5. Engine Repairs & Overhaul
This section covers detailed procedures for engine-related repairs, adjustments, and overhaul processes for the specified Volvo S40 and V40 petrol engines.
5.1 Timing Belt Renewal
Instructions for timing belt replacement are provided, including steps for removing and installing the belt and associated components such as tensioners and pulleys.
The manual details the correct procedure for positioning the crankshaft pulley and removing the old tensioner, ensuring proper timing during reassembly.
5.2 Auxiliary Drivebelt Renewal
Procedures for replacing auxiliary drivebelts are outlined, with specific guidance for both GDI (Gasoline Direct Injection) and non-GDI engines, covering different engine configurations.
5.3 GDI Engine In-Car Repair Procedures
Specific repair steps for Gasoline Direct Injection (GDI) engines are included, such as the removal and installation of the power steering pump/air conditioning compressor drivebelt.
Figure 5.1: This image details application points for Volvo sealant on the cylinder head (upper and lower), and steps for cylinder head removal and refitting. It also shows the wiring harness layout and earth strap attachment points.
6. Cooling, Heating, and Ventilation System
This section provides instructions for maintaining and repairing the vehicle's cooling, heating, and ventilation systems, including component removal and installation.
Figure 6.1: The image illustrates steps for working on the heating/ventilation housing, including unscrewing retaining screws, unclipping outlets, and removing components for access and repair.
7. Electrical Systems and Wiring
This section includes information on the vehicle's electrical systems and detailed wiring diagrams to assist with fault finding, diagnosis, and repairs of electrical components.
Figure 7.1: The image displays a comprehensive wiring diagram for the EMS 2000 fuel injection system, indicating various components and their connections with color codes for easy identification.
8. Technical Specifications
Detailed technical specifications for the Volvo S40 and V40 models covered by this manual are provided to aid in maintenance and repair tasks.
| Category | Detail |
|---|---|
| Engine Oil Capacities (up to 1997) | 1.8 litre: 5.3 litres, 2.0 litre: 5.4 litres, 2.3 litre: 3.8 litres |
| Engine Oil Capacities (from 1998, except GDI) | 1.8 litre: 5.4 litres, 2.0 litre: 5.4 litres, 2.3 litre: 3.8 litres |
| GDI Engine Oil Capacities | 1.8 litre: 5.4 litres, 2.0 litre: 5.4 litres, 2.3 litre: 3.8 litres |
| Cooling System Capacity | 6.5 litres (non-turbo, except GDI), 6.0 litres (GDI), 5.7 litres (Turbo), 5.0 litres (Drain and refill approx.) |
| Manual Transmission Fluid | 3.4 litres (non-turbo, except GDI), 2.7 litres (GDI), 2.1 litres (Turbo) |
| Automatic Transmission Fluid | 7.7 litres (total), 2.5 litres (torque converter only), 0.8 litres (difference between MAX and MIN levels) |
| Washer Fluid Reservoir | 3.5 litres (without headlight washers), 4.5 litres (with headlight washers) |
| Fuel Tank Capacity | 60 litres |
| Antifreeze Mixture | 50% antifreeze for protection down to -37°C (5°F) |
| Spark Plug Gap | 1.4 mm (1.6 litre models), 1.4 mm (1.8 litre models), 0.8 mm (GDI), 0.7 mm (2.0 litre non-turbo), 1.4 mm (2.0 litre turbo), 0.7 mm (2.3 litre turbo) |
| Spark Plug Torque | 25 Nm (18 lbf ft) |
| Wheel Nut Torque | 110 Nm (81 lbf ft) |
| Manual Dimensions | 8.27 x 0.75 x 10.71 inches |
| Manual Weight | 1.09 pounds |
| Language | English |
| Print Length | 320 pages |
Note: Always refer to the manual for the most accurate and complete specifications for your specific vehicle variant, as details may vary.
9. Troubleshooting
The manual includes a dedicated "Fault Finder" section designed to assist users in diagnosing common issues. This section provides structured guidance on identifying problems based on symptoms and outlines step-by-step solutions to resolve them, helping to avoid unnecessary repairs.
10. Publisher Information
This repair manual is published by Haynes, a recognized provider of automotive repair information known for its detailed, step-by-step guides.
- Publisher: J H Haynes & Co Ltd
- Publication Date: June 5, 2015
- ISBN-10: 1785210440
- ISBN-13: 978-1785210440
- Language: English
For further assistance or inquiries regarding the content of this manual, please refer to the contact information provided within the manual itself or visit the official Haynes website.
