The service and repair manual for the 2004 Volvo S40 — 1.9L I4 and 2.4L I5 and 2.5L I5 engines, 5 trims. Matched to this exact model year, so the specifications and sequences are the ones Volvo published for your car, not figures carried over from a neighbouring year.
01 / FitmentWhat this manual covers
| Model year | 2004 |
|---|---|
| Engines | 1.9L I4 — 119 cu in, DOHC, turbocharged 2.4L I5 — 149 cu in, DOHC 2.5L I5 — 154 cu in, DOHC, turbocharged |
| Trims | LSE Sedan 4-Door · Base Sedan 4-Door · 2.0T Sedan 4-Door · i Sedan 4-Door · T5 Sedan 4-Door |
| Federal record | 4 recalls · 75 complaints · 115 technical service bulletins (refreshed 2026-08-21) |
02 / InsideSample pages from the 2004 S40 manual
03 / ContentsSections in the manual
- Quick Lookups 165
- General Information 1,454
- Accessories & Equipment 7,565
- Heating, Ventilation & A/C (HVAC) 2,054
- Body & Frame 4,337
- Maintenance 51
- Brakes 2,156
- Restraints 1,925
- Drivelines & Axles 270
- Steering 322
- Electrical 3,408
- Suspension 1,290
- Engine Mechanical 1,853
- Transmission 2,563
- Engine Performance 8,624
- Torque 177
- Pa) at 800
- RPM (Max 700
04 / Known issuesRecalls on federal record for the 2004 S40
- Fuel System, Gasoline · 03V424000Fuel leakage in the presence of an ignition source could result in a fire.
- Service Brakes, Hydraulic — power assist › vacuum › hoses, lines/piping, and · 04V493000If this occurs, more brake pedal force may be required to stop the vehicle and/or may experience a r.
- Equipment — electrical › navigational system(global positioning system) · 10V566000An overheated battery could lead to a fire.
- Equipment — other › labels · 03V284000This does not meet the requirements of the standard.
Owners have filed 75 complaints and Volvo has issued 115 technical service bulletins for the 2004 S40. The manual carries the manufacturer's diagnostic and repair procedures behind these systems.
FAQQuestions about the 2004 S40 manual
Is this manual specific to the 2004 S40?
Yes. It is the OEM manual matched to the 2004 model year, covering the 1.9L I4 and 2.4L I5 and 2.5L I5 across the LSE Sedan 4-Door, Base Sedan 4-Door, 2.0T Sedan 4-Door, i Sedan 4-Door, T5 Sedan 4-Door trims. Specifications and procedure sequences are the ones Volvo published for this year.
What 2004 S40 problems does it help with?
4 recalls are on federal record for the 2004 S40, covering fuel system, gasoline, service brakes, hydraulic, equipment. The manual carries the manufacturer's diagnostic and repair procedures for those systems; the recall repairs themselves are done free by Volvo dealers.
Does it include 2004 S40 wiring diagrams?
Yes — the complete wiring diagrams for the 2004 build, alongside repair procedures, specifications and diagnostics.
Is it a subscription?
No. $29.99 once and the manual is yours. It is a digital manual — nothing ships; access details arrive by email after checkout and it works on any device.
RelatedOther S40 years and 2004 Volvo models
2010 S40 · 2009 S40 · 2008 S40 · 2007 S40 · 2006 S40 · 2005 S40 · 2003 S40 · 2002 S40 · 2001 S40 · 2000 S40 · 1999 S40 · all 14 years
2004 Volvo C70 · 2004 Volvo S60 · 2004 Volvo S80 · 2004 Volvo S90 · 2004 Volvo V40 · 2004 Volvo V70 · 2004 Volvo V90 · 2004 Volvo VHD · 2004 Volvo VN · 2004 Volvo VNL · 2004 Volvo VNM · 2004 Volvo WX · every 2004 model