2004 Volvo V40 Service and Repair Manual

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Factory-Grade Data

2004 Volvo V40 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 Wagon 4-Door
  • 2.0T Wagon 4-Door
  • Base Wagon 4-Door

Engines covered

  • 1.9L 1948CC l4 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

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Payment methods

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  • Bancontact
  • Google Pay
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  • Visa

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Vehicle Safety Data

2004 Volvo V40 Recalls & Complaints

NHTSA #03V42400024/10/2003Component: FUEL SYSTEM, GASOLINE

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

NHTSA #04V49300014/10/2004Component: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM:HOSES, LINES/PIPING, AND

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

NHTSA #03V28400001/08/2003Component: EQUIPMENT:OTHER:LABELS

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

TSB #11032671

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

TSB #11027173

This is a Technical Journal. Vehicle type and platform identification.

TSB #11020437

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

TSB #11016002

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

TSB #11015994

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

TSB #11014113

This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory

TSB #11014112

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

TSB #11009811

This is a Technical Journal: Software Upgrade / Download Guide. If one control unit is upgraded and not all, it may result in various problems.

Showing the 8 most recent of 153 technical service bulletins on file with NHTSA.

20050523Component: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC:HOSES, LINES/PIPING, Crash reported

ON APRIL 13, 2005 AT APPROXIMATELY 4 PM, I WAS BACKING MY V40 VOLVO 2004 WAGON OUT OF A PARKING SPACE AT THE KOSSMAN GARAGE, LIBERTY AVENUE,PITTSBURGH, PA, GOING SLOWLY BECAUSE IT WAS A TIGHT SPACE, W

20160624Component: SERVICE BRAKES

TL* THE CONTACT OWNS A 2004 VOLVO V40. WHILE DRIVING 15 MPH, THE BRAKES MALFUNCTIONED. THE CONTACT DEPRESSED THE BRAKE PEDAL TO THE FLOORBOARD IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS NOT DIAGNOS

20080207Component: AIR BAGS:SIDE/WINDOW

THE DRIVER'S SIDE AIRBAG HAS FAILED FOR NO APPARENT REASON. THE COST OF REPAIR WILL BE AROUND $900.00 THE CAR WAS PURCHASED 4 YEARS AGO. THAT IS A VERY COSTLY REPAIR FOR A RELATIVELY YOUNG VEHICLE.

20050722Component: STRUCTURE

DT: CONSUMER STATES WHEN THERE IS A SUN GLARE ON THE DASHBOARD THERE ISN'T ENOUGH ILLUMINATION. THE CONSUMER WAS UNABLE TO SEE THE INSTRUMENTS ON THE DASHBOARD. THE CONSUMER TOOK THE VEHICLE TO THE

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