Volvo V40 Owner's manual

S40/V40 Phase II
(July 2000)

Volvo S40
October 2001

Volvo V40
October 2001

Volvo S40 Sport Lux - 2003 model
May 2002

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Overview Taking just a quick glance, the casual observer would be
forgiven for thinking that the latest examples of Volvo's
compact S40 saloon and V40 estate should be filed under the
` minor facelift' category.
Externally at least, the visual changes are restricted to
new bumpers and front wings, revised lights and new alloy
wheels. But underneath the skin, large scale modifications
more than justify the Phase II tag the models have been given.
This is far more than a facelift...
Taking three years to develop, the comprehensive
changes are designed to make the popular midrange cars
more dynamic to drive and even safer, as well as offering
better value. The changes will broaden their appeal to a wider
audience.
Primary changes include a totally revised chassis with a
l onger wheelbase and new front suspension incorporating a
wider track. The result gives dramatically improved comfort
and handling characteristics.
There's a raft of changes under the bonnet, too, with two
new common-rail diesel engines, a new 2.0-litre 200 bhp turbo
for the T4 and changes to the 2.0T li ght pressure turbo which
give more power and torque and improved fuel economy. A
new five speed automatic transmission, similar to that found in
the V70, is also available on selected models.
I nside there are changes to the dashboard, better seats
and new fabrics plus comprehensive improvements in standard
equipment levels. Every S40/V40 has air conditioning as
standard along with remote central locking, electric front
windows and electrically operated and heated door mirrors.
Even more significant are the safety improvements:
Volvo's Inflatable Curtain (IC) head protection system has
been adopted across the range. This is in addition to dual
stage front airbags, WHIPS whiplash protection, SIPS side
i mpact protection and ISOFIX child safety seat fixings. Already
one of the safest cars on the road - and the only model in its
class to win four stars in the independent Euro NCAP tests - '
the Phase II S 40/V40 takes passenger safety to new heights.
Exhaustive testing has also formed an integral part of the
programme, with test vehicles having been driven the equiv-
alent of 60 times around the globe, in 15 different countries
across three continents - Europe, North America and
Australia. The cars were subject to extremes of temperatures
from sub zero (-30 deg C) to scorching heat (+45 deg C).

Overview
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Remarkably, considering the comprehensive changes
continued
made across the range, prices for the new S40/V40 remain
the same as for the outgoing model, making them a conspic-
uously better value package.
"These cars feel new. They are more comfortable, they
are quieter, the engines have been upgraded and they are
even more powerful. It feels as though the cars have grown;' _.,
says Project Leader Cock Moret.
Added together, the changes should cement the model's
place in the heart of the UK car buyer. Last year, Volvo sold
22,810 examples in the UK, making it more popular than rivals
such as the Nissan Primera, Toyota Avensis, Honda Accord
and Audi A4.
" We are confident that the changes made to the S40
saloon and V40 estate will not only ensure the models stay
popular with existing owners, but will also widen their appeal
considerably;' said Gerry Keaney, Managing Director, Volvo
Car UK. "There is little doubt that the improvements in safety,
the new engines and advances in comfort and handling, not to
mention the better value proposition, make the Phase II
S40/V40 serious) strop. contenders"
Key points
Wider front track
Longer wheelbase
New revised front and rear suspension settings
Bigger tyres
New five speed automatic option
Extensively revised engines
T4 Turbo up from 1.9-litres to 2.0-litres
Two new common-rail diesels
Greater safety, with IC, dual stage airbags and ISOFIX fittings
Dashboard revisions
Subtle exterior changes
More standard equipment
New colours, upholstery and alloy wheels
Prices unchanged
Better value

Design concept Right from their original introduction in 1995, the Volvo S40
and V40 won critical acclaim for design and styling, which
culminated in the accolade of the 'Most Beautiful Estate Car
i n the World', an annual Italian award.
Critics acclaimed the skill with which Volvo contrived to
combine dynamic and youthful elements within a classically
elegant shape, blending many Volvo styling cues - such as
the V-shaped bonnet and powerful chrome grille - in a modern
package.
I ndeed, the cars were the first indicators of Volvo's new
design language, as can now be seen in models such as
C70, S80 and the new V70. But nothing stands still and the
ti
me has come for the originator of the new look to move with
the times.
" We felt it was time to make some minor adjustments to
the appearance of the S40 and V40, something to make them
more ready to challenge the competition in the new millennium;'
says Englishman Peter Horbury, Volvo's head of design.
"I would say that the cars now appear to be more homog-
eneous and have a closer relationship with our larger cars.
" Our ambition, however, was not to create a new
appearance but simply to create a new sensation, a sense
of freshness. As the cars have a strong design with a clear
i dentity, we chose only to make subtle changes."
As a result, the external changes can largely be found in
the details, such as the front and rear bumpers, revised front
wings, headlights and indicators. The new front bumper
assembly has been redesigned with new protective inlays
while the front spoiler's air intake has also been redesigned,
taking its inspiration from the designs used on Volvo's
R-line models.
Clear glass is used for the standard fixed-focus double
headlamps while the indicators and foglamps have also
been redesigned. At the rear, the tail lights now have clearer
glass while the panel between the lights has been restyled to
create a more integrated impression.
From the side, freshly styled wheels, new side mould-
i ngs and larger side marker lights help give the impression
that the car is physically larger than before.
What hasn't changed is the sheer practicality of the
design: the good aerodynamic characteristics (S40, 0.31 Cd;
V40, 0.32Cd) which help to minimise crosswind sensitivity
and wind noise, as well as reducing fuel consumption; the
wide opening doors for ease of access - the front doors open
to an angle of no less than 66 deg; and the gas struts on both
the boot lid and tailgate which couple with a low loading
height to make luggage easy to load.
Changes inside the car are perhaps more obvious, and
underscore the visual link with Volvo's larger models. The
dashboard has been given a comprehensive facelift to offer
better ergonomics and functionality. Dominating the centre
of the dash, the revised audio system bears as strong
resemblance to the units in the V70 and S80.
The centre tunnel console has also been completely
redesigned and is taller than before and far more versatile. It
features a larger storage compartment with a coinholder and
12 volt power socket and also doubles as an armrest for driver
and front seat passenger. Another new feature is a useful
waste bin for rear passengers - ideal for the kids' sweet
wrappers.
Two new upholstery trims have been developed for the
Phase II models, one a plush fabric, the other a leather and
fabric combination. Extra padding in the seat themselves
helps produce a sportier shape offering greater support and
comfort, while a new lighter interior colour option -
Oak/Arena, borrowed from the S80 and V70 - adds an extra
air of class to the cabin.
As ever, the luggage area has a cargo net options and
clever restraint system, which uses an inertia reel belt to hold
bulky items in place. Load space in the V40 can be extended

Design concept by folding the rear seats and to make the operation as easy
continued
as possible, the centre rear three point seat belt is fully
i
n-tegrated into the seat back and folds with the seat.
Comfort is assured by orthopaedically designed seats
with adjustable lumbar control and variable height settings.
The steering wheel is also adjustable for rake to ensure every
driver can find the ideal driving position. Air conditioning is
standard on all Phase II models, and incorporates a dust and
pollen filter which removes impurities from the air before it
enters the cabin.
Engine and road noise has been reduced partly due to
the new front suspension and tyres, but also thanks to
i
mproved noise insulation between the engine compartment
and cabin. The engines themselves are also quieter than their
predecessors.
CHASSIS Customers have always enjoyed the sporting behaviour of the
Suspension front-wheel drive S40/V40, but feedback has shown that
some would prefer a little more comfort. Rather than simply
soften the suspension and compromise the car's handling
and road holding, however, Volvo's chassis project team has
spent three years re-engineering the chassis to provide extra
comfort with sharp handling.
"The customers are always right;' says Project Leader
Cock Moret, "but we did not want to improve the comfort at
the expense of the roadholding!"
As a result, the entire front suspension has been
upgraded, with new McPherson struts, new lower wishbones
and a redesigned steering assembly. Revised geometry and
redesigned control arms allow the springs and dampers to
work more freely and effectively. Dampers have been
softened for better ride characteristics while the springs are
stiffer for even better road holding.
Modified front wings have enabled a larger wheel and
tyre combination to be fitted, with the old 195155 tyres being
replaced by 195160 tyres for greater comfort.
Rear suspension is a largely unchanged fully independent
multi-link system with trailing arms, upper and lower camber
control links and a toe control link which provides passive rear
steering to help handling and stability.
The changes to the front end have lengthened the
wheelbase by 12 mm and the front track by 16 mm - two
changes that also do their bit towards improving the driving
experience. The result is car that is notably more comfortable,
especially over poor road surfaces, but one that has lost none
of its high levels of grip, its strong cornering ability and its
excellent directional stability.
Steering is a precise rack and pinion system with power Brakes &
assistance,
while the braking system has discs all round, steering
ventilated
at the front and with an anti-lock system as
standard. Also standard is EBD, or electronic brake distribu-
tion,
which constantly distributes braking power between
front
and rear wheels to ensure maximum retardation
regardless of road conditions or the load carried.

ENGINES &
TRANSMISSIONS
Engines
Principle under bonnet news concerns far reaching changes to
both turbocharged petrol engines, the arrival of two new four
cylinder common rail turbo diesels in place of the old 95 bhp
turbo diesel and an advanced new 1.8-litre direct injection
petrol engine.
Central to both new diesels is the advanced common rail
fuel distribution system in which the diesel fuel is distributed
under very high pressure via a single `common' fuel line or `rail'.
The main benefit of common rail technology is that fuel distri-
bution can be controlled very precisely resulting in far more
complete combustion. This reduces emissions and
maximises the engine's performance and efficiency. Common
rail technology also practically eliminates diesel's characteristic
knocking noise.
Both 8 valve diesels displace 1870cc and develop 102
and 115 bhp respectively, the higher power output being
due to the addition of an i ntercooler. As well as being notably
smoother and more powerful than the engine they replace, the
new turbo diesels are far more fuel efficient, with a
combined cycle fuel consumption figure of 52.3 mpg
compared with the outgoing engine's 50.4 mpg. Both produce
a low 142 grams of CO2 per km.
I n performance terms, the 102 bhp version has a top
speed potential of 115 mph and takes 12 seconds to reach 62
mph from rest, while its more powerful sister tops 121 mph and
cuts the 0-62 mph dash to 10.5 seconds. Their arrival - the
more powerful version will be available from early summer with
the second version due in the autumn - is expected to boost
considerably the cars' appeal to the important fleet market.
All the four cylinder petrol units in S40/V40 - bar a new
direct injection petrol 1.8 - are members of Volvo's RN family
of four, five and six cylinder engines. The basic design of the RN
engine range embraces an aluminium block and twin cam head
with four valves per cylinder and centrally mounted spark plugs.
On both turbocharged versions of the S40/V40 , the engines
also feature continuously variable valve timing (CVVT) which
helps optimise the combustion process and improves emission
l evels.
CVVT technology permits the camshafts to be turned by
up to 20 degrees, making it possible to vary the timing between
the inlet and outlet phases of the unit. By closing the inlet valves
earlier in relation to the opening of the outlet valves, higher
torque is generated at lower speeds.
When full performance is not being used on the open
road, maximum overlap is used, meaning the exhaust valves do
not close until the inlet valves are already open. When this hap-
pens, some of the exhaust fumes are drawn back into
the cylinder at the same time as the fresh fuel-air mixture is
i njected, allowing the engine to run more fuel efficiently.
CVVT also has cold start benefits as by opening the
exhaust valves earlier than usual, fuel can afterburn in the ex-
haust system and so heat the catalytic converter more quickly.
The choice of pent-roof combustion chambers allows the
use of large diameter valves while the shape of the
chambers themselves helps create a tumbling motion in the
mixture during the intake stroke. This makes the combustion
process more efficient and leads to good fuel economy,
high part-load stability, high specific performance and low
exhaust emissions.
I n the light pressure 2.0T , modifications have boosted
power to 165 bhp from 160 bhp as well as raising torque to
177 lb ft from 169 lb ft. The result is better economy, with the
combined cycle consumption figure rising to 34 mpg.
Performance figures include an impressive 137 mph top
speed, with 0-62 mph taking just 8.5 seconds.
Providing even more dramatic performance, the turbo-
charged T4 has been increased in size from 1.9 to 2.0-litres
and as well as embracing CVVT technology, now features a
more efficient twin scroll turbocharger.
Although neither power nor torque figures have changed

- 200 bhp and 221 lb ft - the engine feels quite different in
character, being more responsive with less obvious turbo lag
than before. Fuel consumption has also improved to 31.7 mpg
over the combined cycle, while top speed is an exceptional 146
mph. And the T4 takes just 7.3 seconds to sprint to 62 mph
from standstill.
Of the remaining quartet of naturally aspirated four cylin-
der petrol engines, three are unchanged - the entry level 109
bhp 1.6-litre, 122 bhp 1.8-litre and 136 bhp 2.0-litre - and fea-
ture conventional multi-point fuel injection. The newest engine,
a Mitsubishi-developed 122 bhp 1.8-litre, has an advanced
direct injection system. Direct injection ensures better economy
and lower CO2 emissions.
Transmissions The slick five speed manual transmission is carried over from
the previous models, but most Phase II models will also have
the option of Volvo's latest five speed adaptive automatic, as
found on the V70 and S80.
Developed jointly with Aisin Warner, the gearbox
features complex electronics to monitor progress and road
conditions and literally adapts its gear change points to a
driver's particular style. This effectively does away with the
need for separate 'E' and 'S' driving modes, though a 'W' (for
winter) mode is retained. In the winter mode, the car starts off
i n a higher gear to prevent wheelspin on slippery surfaces.
Its
benefits are manifold. Comfort is enhanced as a
result of more precise shift control and shorter steps between
the gears, while acceleration is swifter thanks to the lower first
gear and the closer ratios. And when driving at higher speed,
the noise level is reduced as a result of the higher top gear.
The automatic transmission is available as an option on
all models except the entry level 1.6, the direct injection 1.8
petrol and both diesels.
A traction control system - DSA, or Dynamic Stability DSA
Assistance - is standard on the T4 and optionally available on
other versions.
Working in tandem with the anti-lock braking
system, DSA uses the
ABS
wheel sensors to detect wheel
spin. Once detected, the engine management system then
automatically reduces power and torque to kill the wheel spin
and restore normal grip.
The original S40/V40 was rightly regarded as one of the safest
SAFETY &
cars on the road, and was the only car in its class to score four
ENVIRONMENT
stars in the independent Euro NCAP crash test. But safety
Passive safety
never sleeps at Volvo...
Last year, Volvo introduced its innovative WHIPS
whiplash system to the range and with the Phase II comes the
extra safety afforded by the IC inflatable curtain. Previously only
available in larger Volvos, the curtain is integrated into the car's
roof lining and deploys in a side impact to offer greater
protection to the occupants' heads.
Just 25 milliseconds after impact, IC's vertical channels fill
with gas and the curtain inflates to prevent occupants in the
front and rear from colliding with the door, roof or pillar. Unlike
conventional airbags which remain inflated for only an instant,
the IC is designed to stay inflated for three seconds to provide
optimum protection and to prevent the occupants to be thrown
out of a shattered window, for example. IC forms an integral
part of SIPS, Volvo's award winning Side Impact Protection
System. SIPS comprises seat mounted side airbags, extra
steel members in the doors, pillars, sills and the floor, plus
reinforcements in the floor, roof and beneath the seats.
Naturally, S40/V40's class leading passive safety cre-
dentials includes a sturdy body shell with computer designed
energy absorbing crumple zones at the front and rear. A shock
absorbing interior has panels and fittings designed so as not to

Passive safety cause unnecessary injury in an accident, while all five seats
continued
have head restraints and three point seat belts with preten-
sioners, which tighten the belt automatically in the event of an
accident. Those on the front seats also have belt force
li
miters.
The front airbags - a passenger bag is a no cost option -
i nflate in two stages and at variable speeds depending on the
severity of the accident. In a low speed accident, the airbag will
only be activated if the driver and front passenger are not
wearing seat belts. If sensors detect an accident at marginally
higher speeds, the airbags will be inflated to 70 per cent of their
full capacity unless belts are not being worn, in which case the
bags inflate to their full capacity.
I
n a violent high speed accident, however, the bags will be
i
nflated to full 100 per cent capacity, but even in this case,
i
nflation takes place in two stages, with a split second delay
between the first and second stages which regulates the
pressure
within the bag thus minimising their impact on
occupants. To prevent unnecessary discomfort to passengers,
the airbags inflate without the use of harmful substances.
The WHIPS system is designed to offer whiplash protec-
tion in a rear end crash. In an accident, the front seat backs
move with the occupants are they are thrown forward in the
i
nitial
phase of the accident and cradle them as they are
restrained and pulled back into the seat in the second phase of
the impact. Volvo's safety engineers have played a significant
role in the development of the internationally agreed ISOFIX
child seat attachment system and the S40/V40 can be ordered
with ISOFIX fittings as standard.
Life inside the cabin is equally pleasant, thanks in part to
the standard and extremely effective filter which traps pollen
and soot particles before they can enter the car. And at the end
of its natural life, virtually the entire car can be recycled. Little
wonder that each new Volvo is backed by an environmental
declaration examined and verified by Lloyd's Register in London.
Phase II S40/V40 models benefit from improved standard Equipment
equipment levels with air conditioning standard across the
entire range. Also standard on each model are remote control
central locking, electric front windows and electrically operated
and heated door mirrors. As ever Volvo customers will be able
to create a bespoke car, using the various cost effective option
packs available for the S40/V40 to mach their personal needs.
Among the new options developed for the Phase II
models are gas discharge headlights - available here for the
first time on a Volvo - and a new compact navigation system.
Forming part of the central dashboard audio system, the
cassette deck is replaced by a small colour screen on which
graphics direct the driver to a chosen destination.
This simplified version of the acclaimed RTI system found
i n larger Volvos, is based on GPS navigation and combines the
graphic direction displays with voice guidance.
Environment
Volvo's commitment to the environment goes deeper than
l
ow exhaust emissions and good fuel economy. The entire
production process is as environmentally friendly as possible
and no harmful substances are used during production.
Like all Volvos, the S40 and V40 are covered by a comprehen
slue manufacturer warranty giving cover for three years o
60,000 miles, whichever comes sooner. In addition, there's .
three year unlimited mileage paintwork warranty and eight yea
guarantee against rust perforation. In the unlikely event of .
mechanical failure, buyers also benefit from a year free 'get-you
home' cover from the RAC.
Warranty

Questions &
answers
How many S40s and V40s have been sold to date?
World-wide, we have sold some 230,000 saloons and
300,000 estates. The figures for the UK are 41.500 and
37,600 respectively. We expect to sell around 160,000 units
world-wide this year, thanks in part to the car's successful
i ntroduction to the American market. In the UK, we plan to sell
1 3.000 during the rest of the year and some 20,000 in 2001.
The range is produced at NedCar in Belgium, jointly
with Mitsubishi. How does DaimlerChrysler's recent
i nvestment in Mitsubishi affect this arrangement?
We have a contract to produce cars at NedCar until the end
of 2004 and both Volvo and Mitsubishi are keen to continue
j oint production for as long as possible. In time. Mitsubishi and
DaimlerChrysler will take over ownership of NedCar, but this
will not affect production.
Where will the S40/V40 successor be built?
Unlike the current model, the next generation small Volvo will
not be a joint project with Mitsubishi, but will make some use
of Ford technology. It will be built at Volvo's factory in Ghent,
Belgium.
Who has made the new common rail diesel engines
found in the Phase II models?
They have been sourced from Renault, a company with a long
history of producing highly efficient midsize diesels.
Why is the new five-speed automatic not available on
all models?
I t does not suit the characteristics of all the engines. Each
version has a choice of transmission carefully developed for
that particular application.
Why are many of the environmental solutions found on
newer Volvos not included in the S40/V40?
We have made major strides in the car's environmental
performance, not least in terms of fuel consumption, but we
have been limited by the age of the platform when it comes to
major changes. Nonetheless it remains one of the cleaner cars
on the market and Lloyd's Register has verified the car's
Environmental Product Declaration.