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2004 Volvo S40 Service and Repair Manual
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$29.99 USD
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Covers all 2004 S40 trims — LSE Sedan 4-Door, Base Sedan 4-Door, 2.0T Sedan 4-Door +2 more ·
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2004 Volvo S40 Service and Repair Manual
Regular price
$29.99 USD
Unit price
2004 Volvo S40 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.
Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.
What’s included
- Step-by-step repair procedures and service information
- Specifications and reference data (where provided)
- Wiring diagrams and electrical sections
- Powertrain, brakes, steering, suspension, HVAC and more
Trims covered
- LSE Sedan 4-Door
- Base Sedan 4-Door
- 2.0T Sedan 4-Door
- i Sedan 4-Door
- T5 Sedan 4-Door
Engines covered
- 1.9L 1948CC l4 GAS DOHC Turbocharged
- 2.4L 2435CC l5 GAS DOHC Naturally Aspirated
- 2.5L 2521CC 154Cu. In. l5 GAS DOHC Turbocharged
- 2.5L 2521CC l5 GAS DOHC Turbocharged
Index / Table of contents
- Body
- Brakes
- Chassis Electrical
- Driveline
- Engine Cooling
- Engine Electrical
- Engine Mechanical
- Engine Performance & Emission Controls
- Fuel System
- General Information & Identification
- Heating, Ventilation, & Air Conditioning
- Hybrid & Electric Vehicle Systems
- Steering
- Suspension
- Transmission, Clutch, & Transfer Case
- Wiring Diagrams
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
Consequence
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy
DEALERS WILL INSTALL A V-CLAMP TO THE FUEL RAIL. OWNER NOTIFICATION BEGAN ON JANUARY 28, 2004. OWN
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
Consequence
IF THIS OCCURS, MORE BRAKE PEDAL FORCE MAY BE REQUIRED TO STOP THE VEHICLE AND/OR MAY EXPERIENCE A R
Remedy
DEALERS WILL INSPECT, AND IF NECESSARY, REPLACE THE VACUUM HOSE. THE RECALL BEGAN ON NOVEMBER 29, 2
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence
AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy
VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE
CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE
Consequence
THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
Remedy
OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUC
This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.
This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval. Curren
This is a Technical Journal. Vehicle type and platform identification.
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i
This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C
Showing the 8 most recent of 115 technical service bulletins on file with NHTSA.
I GOT NEW CAR IN NOV 2003 OF THE YEAR 2004 MODEL. IT FEELS LIKE ONE HAS TO PUT FOOT ON BRAKES ALL THE WAY TO APPLY. IT IS PROGRESSIVELY GETTING WORSE. IN DEC 2005, WHILE EXISTING FROM HIGHWAY WE MEET
I GOT NEW CAR IN NOV 2003 OF THE YEAR 2004 MODEL. IT FEELS LIKE ONE HAS TO PUT FOOT ON BRAKES ALL THE WAY TO APPLY. IT IS PROGRESSIVELY GETTING WORSE. IN DEC 2005, WHILE EXISTING FROM HIGHWAY WE MEET
TL*THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING LESS THAN 50 MPH, THE CONTACT CRASHED INTO THE REAR OF THE PRECEDING VEHICLE. THE PASSENGER SIDE AIR BAG DEPLOYED, BUT THE DRIVER'S SIDE AIR BAG D
ON OCTOBER 4TH I WAS INVOLVED IN A CAR ACCIDENT IN WHICH A DRIVER HIT MY CAR ON THE DRIVER'S SIDE PUSHING MY CAR DOWN A PTH IN THE WOODS IN FAIRFAX, VA. MY AIRBAGS DID NOT DEPLOY ALTHOUGH THE SENSORS
DURING A FRONTAL DRIVERS SIDE CRASH THE DRIVERS SIDE AIRBAG DID NOT DEPLOY CAUSING INJURY TO THE DRIVER. HOWEVER THE PASSENGER SIDE AIRBAG DID DEPLOY, BUT NO PASSENGERS WERE PRESENT AT THE TIME OF THE
Showing the 5 most serious of 75 complaints filed with NHTSA.
Other Years of the Volvo S40
2012 Volvo S40 Service and Repair Manual2011 Volvo S40 Service and Repair Manual2010 Volvo S40 Service and Repair Manual2009 Volvo S40 Service and Repair Manual2008 Volvo S40 Service and Repair Manual2007 Volvo S40 Service and Repair Manual2006 Volvo S40 Service and Repair Manual2005 Volvo S40 Service and Repair Manual2003 Volvo S40 Service and Repair Manual2002 Volvo S40 Service and Repair Manual2001 Volvo S40 Service and Repair Manual2000 Volvo S40 Service and Repair Manual1999 Volvo S40 Service and Repair Manual