Know Stuff About first generation S40s and V40s

Spac · 2020-10-07T12:26:46+00:00

The Supertouring models.These were a limited edition, presumably to capitalise on the 1998 Bathurst win. All manual T4 Phase1.5s, as best as I can tell. The...

Spac

Did a bit of investigation with half shafts today.

Nothing conclusive yet, but getting some things clearer…

The gearbox end is the same between auto and M56 - all three diameters, and spline count.

The wheel end has either of two diameters - 26mm for NA, and 27mm for Turbo. The 26mm is the same as Mitsubishi Mirage/Lancer (CB, CC, CE at least).

Turbo auto and Turbo manual (M56) are very similar in length. The manual ones are about 5mm longer, but it is hard to say for sure with the CV boots.

All of the x40 and Mitsubishi half shafts I have on hand, have M22x1.5 thread on the wheel end. Mitsu use 32mm AF nuts, Volvo use 36mm AF, but the thread is the same.

Short version is that I am pretty certain that you can use turbo auto half shafts in a turbo manual car (and vice-versa).

I kind of stopped once I discovered that the late NA manual half-shafts will join an M56 to Mitsubishi hubs - this answered my main question…

Edit: Also just worked out that NA Auto half shats should join a M56 to Mitsu hubs.

Johnno_

Sadly that WA T4 manual was T-boned in 2022.

Johnno_

"The fuel pressure regulators can leak fuel back into the intake manifold which causes hard starting (hold the throttle about one-third of the way down while cranking and it will start). It can also cause sluggish performance and poor fuel economy, but the hard starting is the most reliable sign. Replacement takes about two minutes."

Thanks for that @Spac , mine was shot. And thank you very much for the excellent write up.

More Phase Monster stuff.

I'm currently up to four or five parts that have not been compatible on my Phase 2.

Side external profile view.

Phase 1

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Smaller side indicators, a small sideskirt behind the rear wheel, a longer side protection strip that extends to the front wing (making it three pieces) and a usually grey bottom splitter on the front spoiler.

Phase 2

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Larger indicators, deletion of the small sideskirt behind rear wheel, side protection strip finishes on the front door, bottom front spoiler splitter is colour coded.

Useful to know:

I found out there are Phase 1 & 2 mudflaps, Phase 1 rear items have a large notch for the rear sideskirt, Phase 2 do not.

Side indicators are mirror copies of the diagonally opposite. LHS front as the same as RHS rear, RHS front is same as LHS rear.

Front view

Due to flak about the handling of Phase 1's, the front suspension was revised with stiffer springs and softer shocks. The Phase 2 extended the wheelbase 12mm from 2550 to 2562mm and the track was widened 18mm from 1454mm to 1472mm.

The modifications meant re-designs for front wings and spoiler. Bonnet remains the same.

Phase 1

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Wheel arches are a little more flush, notched out area for number plate, foglights (when equipped) are rectangular, no extra air dam in front spoiler, bottom splitter is in a tasteful shade of grey.

Phase 2

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Wheel arches are flared wider and the front fit of the wing fits a little different to fit in the re-designed spoiler, number plate "notch" has been smoothed out, foglights are a oblong D shape, bottom splitter is colour coded and of a different design.

Another front view of the Phase 2 front spoiler design.

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Useful to know:

Phase 1 usually have the "Waterfall" and Phase 2's the "Eggcrate" grille, however this is not a reliable indication as they get swapped around a bit.

Bottom splitters usually go to Valhalla due to impacts with speed humps and spoon drains. Items on marketplace are snapped up quickly. The centre piece of the Phase 2 is missing on lots of pics around the web. Mine is missing the whole deal.

Colour coded bumper strips, side protectors, door handles with chrome and headlamp wipers are more prevalent in Japanese, UK and US markets. Clear side indicators were another overseas option on very late phase 2s as were 17" Arcadia rims. This was most likely to clear stock before the introduction of Ford platformed S40/V50.

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johna

I've never seen an S/V40 in Australia with Arcadias. Is 17" even an available size on the tyre placard on an Australian phase 2 (someone please check)?

Not all phase 2 have the egg crate grille, only late models, unless swapped as you said. These came for MY 2003 according to some Volvo press releases I found.

Johnno_

More Phase Monster Stuff (Interior)

Inflatable curtain (IC) was introduced with the Phase 2. It runs from the front A pillar to the rear and is more for head injury prevention, it also stays inflated longer to prevent occupants being thrown out. The airbags in the seats (SIPS) were retained. I just checked my old seat with the characteristic split and the bag is in there.

Here's a shot with the headliner removed.

End result of the IC curtain is that the Phase 2 roof lining shell is a different shape to fit in the cutain. Owners who have been caught, report grab handles not lining up. Along with the head lining shell difference, A/B/C/D pillar trim & clips are different to the Phase 1s as they are made to detach easier and are shorter than Phase 1 versions.

Cockpit design & re-design.

Phase 1 Cockpit features a lower center console, window & mirror switches in centre console, large ventilation knobs, four spoke steering wheel, a different headlamp switch arrangement. A flippy door for ashtray/lighter/12V socket. The DIN2 and trip computer hpusing stayed with Phase 2 as did the glovebox.

Auto selectors are narrower, have a PRND window that pops out and the gaiter is shorter and wider than the Phase 2

Phase 2 cockpit was upgraded to fit in with 60/70/80 styling at the time. Smaller climate control knobs with squarer A/C,Demist, Recirc buttons. Headlamp switch was revised. Centre console was completely redesigned being taller and having an armrest on top. Auto assemblies are wider, have an inbuilt PRND window and even the gaiter on the auto is a longer and thinner size.

Centre console has a couple of drink holders which are OK for small cans but bang your forearm in an annoying way with 600ml bottles and normal sized drink bottles due to the slope. There a small coin holder that holds a couple of dollars. 12V socket is mounted on selector panel.

Ashtray door has been eliminated leaving an open cubby hole.

Good to know. Indicators were unchanged and flop around if not secured to the steering column

Phase 2 climate control and headlight switches get a nasty gummy finish after a few decades.

Door trims remain the same apart from the drivers side with the addition of window and mirror switches. Leather finish peels off backing over time due to the degraded foam.

There's four different types of clusters maybe some more if we include diesels and LPG overseas examples.

Phase 1 early

Phase 2 standard, I believe may have also been in Phase 1 T4s

Phase 2 Sport cluster

Phase 2 "Flash Harry" Sport cluster with the chrome rings. Only seems to pop up in Europe and the UK

johna

Good job on documenting all these details, @Johnno. Hope you don't mind me adding a few notes.

All S/V40s from MY 2003 had the updated four-dial instrument clusters.

And there were two types of those digital trip computers (I have only seen these on phase 1 T4s). They differ slightly in the measurement options - one has DIST and one has OIL (presumably temperature). Not sure which type was available when.

Johnno_

johna
Good job on documenting all these details, @Johnno. Hope you don't mind me adding a few notes.
All S/V40s from MY 2003 had the updated four-dial instrument clusters.
And there were two types of those digital trip computers (I have only seen these on phase 1 T4s). They differ slightly in the measurement options - one has DIST and one has OIL (presumably temperature). Not sure which type was available when.
https://cdn.ozvolvo.org/uploads/XOHJ3UJBKGGN/s-l1600.png

Good to know, I don't have much info on Phase 1 quirks. I was just editing my interior post as I can remember seeing an LPG cluster on a Dutch version but they weren't sold here. Diesel gauges might be different too!

The Arcadia version Phases 2's weren't sold here and 17" isn't on my sticker or logbook. However a set of Arcadias was imported in for a very nice T4 build.

johna

Just to add to the "Super Tourer" limited edition info, they were available in 2000 and all S40 or V40 T4's but could be had with manual or automatic. Engine was the B4194T2 (phase 1.5 T4 engine). Wheels were called "Ares". Available in Panama Yellow, Silver or Black only.

Johnno_

Thought I'd add this. It's the front wing panel profile for Phase 1/1.5/2

Image description

MKN

Hi everyone, and it seems I am late to the party, but I found this discussion quite fascinating.

I have a Volvo S40 P1 (1997) with huge sentimental value that I am restoring. I am doing this in South Africa. I was struggling to get parts, so I bought another Volvo S40 P1 (1998) from the UK. This vehicle is enroute to SA as I type.

The main components that I need are in the interior, such as the seats, dash etc..

It also seems the UK vehicle has a "better" engine than my one, so as a bonus, I am thinking of also taking the engine. The only difference is mine has a Manual Gearbox and the UK vehicle has an Auto Box. Would I be able to swap the engines, by just coupling the UK engine on to my Manual Gearbox.

Spac

MKN
Yes.

MKN

Spac Thanks a million, much appreciated.

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