
NOTE: Never touch the glass of a bulb with your fingers: this could leave traces of grease or oil on the glass which
then evaporate and may damage the reflector.
Side marker lamp replacement
Slide the lamp insert backward and pull out. Try to loosen the lamp insert with your fingers if possible. Otherwise use
a stiff piece of plastic or wood to protect the paint. Turn the bulb holder counter-clockwise and pull out. Replace with
a new bulb. Press in the bulb holder and twist clockwise. Reinstall the lamp insert by pressing it into the bodywork.
pg. 89 Replacing bulbs
Front direction indicators and parking lights
Removing the bulb:
· Loosen the screw (A) between the headlight and direction indicator housings (max. 2 complete turns
counterclockwise), using the screwdriver supplied in the tool kit.
· Press clip D and move the direction indicator housing forward.
· With the wiring still attached, turn bulb holder slightly counterclockwise and withdraw it from the lamp housing.
· Pull the bulb to remove.
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NOTE: When touching up the car, it should be clean and dry. The surface temperature should be above 60° F (15° C).
Scratches on the surface
If the stone chip has not penetrated down to the metal and an undamaged layer of paint remains, the touchup paint can
be applied as soon as the spot has been cleaned.
Deep scratches
1. Place a strip of masking tape over the damaged surface. Pull the tape off so that any loose flakes of paint adhere to
it.
2. Thoroughly mix the primer and apply it with a small brush.
When the primer surface is dry, the paint can be applied using a brush. Mix the paint thoroughly; apply several thin
paint coats and let dry after each application.
3. If there is a longer scratch, you may want to protect surrounding paint by masking it off.
pg. 101 Washing
Washing the car
· The car should be washed at regular intervals since dirt, dust, insects and tar spots adhere to the paint and may cause
damage.
NOTE: It is particularly important to wash the car frequently in the wintertime to prevent corrosion, when salt has
been used on the roads.
· When washing the car, do not expose it to direct sunlight. Use lukewarm water to soften the dirt before you wash
with a sponge, and plenty of water, to avoid scratching.
· Bird droppings: Remove from paintwork as soon as possible. Otherwise the finish may be permanently damaged.
· A detergent can be used to facilitate the softening of dirt and oil.
· A water-soluble grease solvent may be used in cases of sticky dirt. However, use a wash place equipped with a
drainage separator.
· Dry the car with a clean chamois and remember to clean the drain holes in the doors and rocker panels.
· The power radio antenna (sedans) must be dried after washing.
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Before applying polish or wax the car must be washed and dried. Tar spots can be removed with kerosene or tar
remover. Difficult spots may require a fine rubbing compound.
After polishing use liquid or paste wax.
Several commercially available products contain both polish and wax.
Waxing alone does not substitute for polishing of a dull surface.
A wide range of polymer-based car waxes can be purchased today. These waxes are easy to use and produce a long-
lasting, high-gloss finish that protects the bodywork against oxidation, road dirt and fading.
Note: Polishing removes oxidized paint from the surface. This is normal. Therefore, when polishing, it may be noticed
that traces of paint color remain on the polishing cloth. This is also normal.
Note: Machine buffing is not recommended.
pg. 103 Cleaning the upholstery
Cleaning the upholstery
The fabric can be cleaned with soapy water or a detergent. For more difficult spots caused by oil, ice cream, shoe
polish, grease, etc., use a clothing/fabric stain remover.
The plastic in the upholstery can be cleaned with a soft cloth and mild soap solution.
Leather upholstery/suede-like upholstery (Alcantera™) can be cleaned with a soft cloth and mild soap solution.
For more difficult spots, Volvo offers a leather care kit.
Under no circumstances should gasoline, naphtha or similar cleaning agents be used on the plastic or the leather
since these can cause damage.
Clean only with lukewarm water and mild soap solution.
Cleaning floor mats
The floor mats should be vacuumed or brushed clean regularly, especially during winter when they should be taken out
for drying. Spots on textile mats can be removed with a mild detergent. Make sure the carpets are properly secured in
the fixation points on the floor.
Bear in mind
· Take extra care when removing stains such as ink or lipstick since the coloring can spread.
· Use solvents sparingly. Too much solvent can damage the seat padding.
· Start from the outside of the stain and work toward the center.
pg. 104
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2 0 0 1
VOLVO
S40 & V 40
Chapter 8 - Volvo Service
pg. 105 Volvo Service
Service - an investment
An investment which will pay dividends in the form of improved reliability, durability and resale value. Label information
106
Maintenance service, Warranty107
Maintenance schedule108
Servicing110
Engine compartment111
Fuel/emissions systems112
Lubrication113
Engine oil114
Power steering fluid, Brake fluid reservoir116
Coolant, drive belt117
Washer fluid reservoir118
Battery maintenance119
Proposition 65 Battery Warning119
pg. 106 Label information
1 Vehicle Emission Control Information
Your Volvo is designed to meet all applicable emission standards, as evidenced by the certification label on the
underside of the hood. For further information regarding these regulations, please consult your Volvo retailer.
2 Vacuum hose routing
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Tires3, check pressure, wear and conditionII II II I I I II I
Check power steering fluid level I I I I I
Body
Power antenna (clean) L L L L L L
Trunk/hood, hinges and latches L L L L L L
Cabin air filter (see page 110
) R R R R R R
1) Replace at 105,000 miles (168,000 km)
2) Brake fluid should be changed at owner request every second year or 30,000 miles (48,000 km). The fluid
should be replaced once a year or every 15,000 miles (24,000 km) when driving under extremely hard
conditions (mountain driving, etc.).
3) Rotate tires at owner request.
The following items should be checked weekly by the driver (it takes only a few minutes):
Engine oil level, brake fluid level, radiator coolant level, operation of all lights, horns, windshield wipers, tire
pressure (all five tires), windshield washer fluid level
The following should also be carried out at regular intervals:
Washing (check all drain holes), polishing, cleaning
pg. 110 Servicing
Engine air filter
Replace the engine air filter cartridge with a new one every 30,000 miles (48,000 km). The cartridge should be
replaced more often when driving under dirty and dusty conditions. The filter cannot be cleaned and therefore should
always be replaced with a new one.
Timing belt
For proper functioning of the vehicle and its emission control systems, the timing belt and tensioner must be replaced
every 105,000 miles (168,000 km). Engine damage will occur if the belt fails.
Fuel system cap, tank and lines and connections
The effectiveness of the fuel system to contain hydrocarbons is dependent largely on a leakfree system. Check for
proper sealing of the fuel filler cap which contains "O" ring type seals.
NOTE: If the fuel filler cap is not closed tightly or if the engine is running when the car is refueled, the Check Engine
light ("Check Engine") may indicate a fault. However, your vehicle's performance will not be affected. Use only Volvo
original or approved fuel filler caps.
Fuel (line) filter
For proper functioning of the vehicle and its emission control systems, the fuel line filter should be replaced at 105,000
miles (168,000 km). The filter is replaced as one complete unit. Replace more frequently if contaminated fuel is
introduced into the tank (or if there is reason to suspect that this has occurred).
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PCV system
The orifice nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be
inspected at 60,000 miles (96,000 km) and thereafter, at 30,000 mile (48,000 km) intervals.
Cabin air filter
Replace the cabin air filter with a new one according every 15,000 miles (24,000 km). Volvo recommends replacing
the filter more often if the car is driven under dirty and dusty conditions. The filter cannot be cleaned and therefore
should always be replaced with a new one.
pg. 111 Engine compartment
Engine compartment S40/V40
1 Power brakes
2 Brake fluid reservoir
3 Fusebox
4 Air cleaner
5 Battery
7 Radiator
8 Oil filter
9 Charcoal canister (under fender)
10 Engine oil dipstick
11 Generator
12 Windshield/headlight washer fluid reservoir
13 Power steering pump
14 Power steering fluid reservoir
15 Engine oil filler cap
16 Coolant expansion tank
17 Windshield wiper motor
18 Chassis number
A ABS
B Air conditioning compressor
C Air conditioning condenser
D Air conditioning accumulator
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2 0 0 1
VOLVO
S40 & V 40
Chapter 9 - Specifications
pg. 121 Specifications
Specifications
This chapter contains facts and figures pertaining to the technical specifications of your car. Oil/fluids specifications
122
Engine specifications123
Cooling/fuel/distributor ignition systems124
Front/rear suspensions125
Transmission, Capacities, Vehicle loading125
Electrical system/bulbs126
Dimensions/weights127
ON CALL road assistance128
pg. 122 Oil/fluid specifications
Oil quality
Meeting minimum ILSAC specification GF-2, including ACEA A1, API SJ, SJ/CF and SJ/Energy Conserving.
Depending on your driving habits, premium or synthetic oils may provide superior fuel economy and engine
protection. Consult your Volvo retailer for recommendations on premium or synthetic oils. Oil additives must not be
used unless advised by an authorized Volvo retailer.
Volvo recommends use of oil with a quality rating equal to or higher than ILSAC GF-2. Equivalent and better oils
include ACEA A1, API SJ, SJ/CF, and SJ/Energy conserving. Lower quality oils may not offer the same fuel
economy, engine performance, or engine protection.
Viscosity (stable ambient temperatures):
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Engine oilQuality:
Meeting minimum ILSAC specification GF-2, including
ACEA A1, API SJ, SJ/CF and SJ/Energy Conserving. Capacity (incl. filter)
: 5.7
US qts (5.4 liters).
Capacity (excl. filter) : 5.3
US qts (5.0 liters)
Automatic
transmission
fluid Quality:
ATF Dexron III and Mercon Capacity:
8 US qts. (7.6
liters)
Power steering
fluid Quality:
ATF oil Capacity:
1.05 US qts. (1
liters)
Brake fluid Quality: DOT 4+ Capacity:
0.42 US qts.
(0.4 liters)
All specifications are subject to change without notice.
pg. 123 Engine
Engine
Liquid-cooled, gasoline, inline, 4-cylinder, turbocharged engine. Aluminum alloy cylinder block with cast-iron
cylinder liners cast directly into the block. Aluminum alloy cylinder head with double overhead camshafts and separate
intake and outlet channels.
Engine lubrication is provided by an eccentric pump driven from the crankshaft. Full-flow type oil filter. Exhaust
emission control is accomplished by multiport fuel injection, a heated oxygen sensor and a three-way catalytic
converter. Designation: Volvo B 4204 T3
Output 162 hp at 5100 rpm (121 kw at 5100 rpm)
Max torque 177 ft. lbs. at 1800-4800 rpm (240 Nm at 1800-4800 rpm)
Number of cylinders 4
Bore 3.27" (83 mm)
Stroke 3.54" (90 mm)
Displacement 1.95 liters
Compression ratio 9.0:1
Number of valves 16
Valve clearance mechanical
All specifications are subject to change without notice.
pg. 124 Specifications
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