2004–2010 Volvo S40 (New Style) Parts Manual (P/N 30716315-4)

• Covers the 2004-2010 Volvo S40 (New Style), with catalog distinctions for 2004-07 and 2008-10 applications, 2.4L and 2.5L engines, FWD and AWD, and SULEV/non-SULEV emissions equipment where applicable.
• Provides exploded views, OEM part numbers, application notes, and labor-time entries for the front and rear bumpers, grille, hood, fenders, doors, lamps, glass, roof, sunroof, and structural body panels.
• Breaks down the ABS/brake system, front and rear suspension, front and rear drive axles, steering gear and pump, steering column, wheels, and related hardware for parts identification and collision-repair estimating.
• Maps the engine/transmission mounts, engine under cover, air cleaner, cooling components, oil coolers, exhaust, 2.5L turbocharger/intercooler equipment, emissions hardware, and fuel tank.
• Details the air bag system, occupant-detection components, instrument panel, center console, seats, seat belts, interior trim, battery, alternator, ignition, navigation, wiper system, and exterior lighting.
• Includes 25 PDF pages with R&I/R&R labor allowances, included and excluded operations, refinishing notes, A/C refrigerant-capacity data, underhood dimensions, paint-code location, clear-coat identification, and application-specific part listings.

Parts and Estimating Coverage

This is a collision repair parts and labor estimating reference for the second-generation S40, with printed pages 1556-1580 reproduced in a 25-page PDF. It is best suited to collision estimators, body repair technicians, parts departments, and experienced owners who already know how to interpret exploded views, OEM part numbers, and R&I/R&R notation. It is not a general mechanical repair manual.

The illustrations pair numbered components with part descriptions, application breaks, part numbers, and labor entries. That makes the catalog useful when building a repair estimate or identifying brackets, retainers, moldings, covers, sensors, clips, and adjacent components that may not be obvious until disassembly. Application notes distinguish equipment such as halogen versus xenon/HID lamps, headlamp washers, fog lamps, parking sensors, sport-package trim, power or manual seat hardware, sunroof equipment, and different exterior colors.

Representative exploded-view plates include the air bag system, front suspension and wheel hardware, front drive axle and steering gear, 2.5L turbocharger/intercooler assembly, instrument panel and center console, and rear suspension and drive axle. Exterior sections extend beyond bolt-on panels to the front inner structure, cowl and dash, rocker/pillars/floor, side body, rear body, roof, quarter glass, and back window. Door pages separate sheet metal, hardware, glass, and interior trim so repair planning can follow the actual assembly layers.

Labor Notes and Scope Limits

The labor information is written for replacement with new OEM undamaged parts on an undamaged vehicle. Entries identify operations such as air bag system disable/enable, brake-system bleeding, windshield removal and replacement, adhesive cleanup, bumper refinishing, and suspension assembly R&R, but they do not provide executable step-by-step repair instructions. Many entries refer to separate “Procedure Explanation” pages; those pages are not included in this PDF.

The catalog flags two estimate-critical cautions. Certain suspension fasteners must be replaced after they are loosened or removed, while air bag work is tied to a separate SRS special-caution procedure. It also states that windshield R&R does not include calibration or programming, so those operations must be considered separately when required. Ignoring these notes can leave required hardware or restraint-system work out of the repair plan.

Electrical coverage is limited to component location, exploded assemblies, and parts data; this PDF does not contain wiring diagrams, connector-pin diagnostics, fault codes, or troubleshooting flowcharts. It also does not contain engine or transmission overhaul procedures, torque tables, four-wheel-alignment instructions, headlamp-aiming procedures, or full A/C evacuation and recharge steps. For live SRS, brake, suspension, or refrigerant work, use the appropriate Volvo service procedures and approved shop equipment in addition to this catalog.