
CALIFORNIA  Proposition  65 Warning
WARNING! Engine exhaust, some of its  constituents, and  certain vehicle components contain  or emit chemicals
known to the state of California to cause cancer, and  birth defects or other reproductive harm.
 
 In addition, certain
fluids contained in vehicles and  certain products  of component  wear  contain  or emit chemicals known to the State
of California to cause cancer, and  birth defects or other reproductive harm.
Shiftlock
When your car is parked, the gear selector is locked in the (P)ark position. To release the selector from  this  position,
turn the ignition key  to position II (or start the engine), depress the brake pedal, press the button on the front  of the
gear selector knob and  move the selector from  (P)ark.
If it is necessary to manually  override the shiftlock system:
 Turn  the starting (ignition) key  to position I
 Press firmly on the "SHIFTLOCK OVERRIDE" button located at the base of the gear selector
 While  holding the override button down, press the button on the front  of the gear selector
 Move the selector from  the ( P)ark position.
Keylock
When you switch off the ignition, the gear selector must  be  in the (P)ark position before the key  can be  removed.
Anti-lock Brake System (ABS)
The ABS  system in your car performs a  self -diagnostic test when the vehicle first reaches the speed of approximately
4 mph (6 km/h). The brake pedal will pulsate several times and  a  sound may be  audible  from  the ABS  control module.
This is normal.
Fuel filler door
When you lock the doors, the fuel filler  door also locks, with a  delay of 10 minutes. When all doors are unlocked, the
fuel filler  door is also unlocked. Your key,  keyless  remote, and  the door lock button in the driver's door control pod
will all unlock the fuel filler  door. To open  the unlocked fuel filler  door, press at the forward edge of the door. See
pages 42
 for information about locking and  unlocking features.
© 2002 Volvo Cars of North America LLC.  
Volvo and the environment
Volvo is committed to the well being of our customers. As a  natural part of this  commitment, we care about the
environment in which  we all live. Caring for the environment means an  everyday involvement in reducing our
environmental impact.
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10 High beams on 
11 Fault in SRS system 
12 Brake circuit not working (brake fluid level  too low) and  EBD 
13 Battery  charge failure 
14 Parking brake applied  
15 Low oil pressure 
16 ABS  (anti-lock brakes)  malfunction 
17 Automatic transmission: position W,  4 or 3 or L 
18 Malfunction  indicator light 
19 Immobilizer  on 
20 Service Reminder  Indicator 
21 DSA  (option) 
22 High coolant  temperature warning light 
23 Low fuel warning light
Starting check 
After a  few seconds, all lights except 16 and  19 will go out. Once the engine starts, these lights will also go out.
* Indicates failure of a  brake light, not failure of the braking system (see item 12).
pg. 22 Warning lights
The warning lights described on pages 22 and 23 should never stay on when driving
When the ignition key  is turned on and  before the engine starts, all of the warning lights should go on to test the
function of the bulbs. Should a  light not go off after the engine has started, the system indicated should be  inspected.
However, the parking brake reminder light will not go off until the parking brake has been fully released.
 Supplemental Restraint System (SRS)
If the light comes on (or stays on after the vehicle has started), the SRS diagnostic system has detected a  fault. Drive to
an  authorized Volvo retailer for an  inspection of the system. See  the SRS section for more information. 
Oil pressure warning light
If the light  comes on while driving,  stop the car and then stop the engine immediately and check  the engine oil
level . See  page 114.
 If the light stays on after restart, have the car towed  to the nearest authorized Volvo retailer. After
hard driving, the light may come on occasionally when the engine is idling. This is normal, provided it goes off when
the engine speed is increased.
 Parking  brake reminder light
This light will be  on when the parking brake (hand brake) is applied.  The parking brake lever is situated between the
front  seats.
Canadian models are equipped with this  warning light: 
WARNING!
If the fluid level  is below  the lowest MIN  mark in the brake fluid reservoir: DO  NOT DRIVE. Tow the car to a
Volvo retailer and  have the brake system checked and  any  leakage repaired.
Brake failure warning light
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If the light  comes on while driving or  braking, stop immediately, open the hood and check  the brake fluid  level
in the reservoir. See  page 116 for reservoir position. 
If the control lamp still  stays on, the EBD (Electronic  Brakeforce  Distribution) is not working. 
Drive to your Volvo retailer. See  ABS  control lamp and  also page 73.
 
Canadian models are equipped with this  warning light: 
Bulb failure warning light
The light will come on if one  of the brake light bulbs are defective when the brake pedal is pressed. 
Check the fuse and  bulb. See  sections "Replacing bulbs" and  "fuses".
pg. 23 Warning lights, Daytime Running  Lights
 DSA  (option) 
Dynamic Stability Assistance
This is a  system which  helps keep the drive wheels from  spinning.  The light flashes  if the road surface  is slippery, the
wheels are spinning  and  the system is working. 
The control light comes on if a  fault occurs in the DSA  system. It also comes on if the system is switched off via the
switch. 
For more information see page 30.
 Service Reminder Light
This light will come on according  to preset service intervals  or after 750 hours of driving or after 12 months,
whichever occurs first. It is a  reminder to the driver that the service interval has been exceeded. The light will stay on
for 2 minutes after start until reset by the servicing retailer.
Anti-lock Brake system (ABS)
If the warning lamp lights up there is a  malfunction of the ABS  system (the standard braking system will however
function). The vehicle should be  driven to a  Volvo retailer for inspection. 
See  page 73
 for additional information.
Malfunction Indicator Lamp  
On-Board Diagnostics II (OBDII):  As you drive, a  computer called "OBDII" monitors your car's engine,
transmission, electrical and  emission systems. The CHECK ENGINE light will light up if the computer senses a
condition that potentially may need correcting. When this  happens, please have your car checked by a  Volvo retailer as
soon as possible.
A CHECK ENGINE light may have many causes. Sometimes,  you may not notice  a  change in your car's behavior.
Even so, an  uncorrected condition could hurt fuel economy, emission cleanliness, and  driveability. Extended driving
without correcting the cause could even damage other components in your car.
Canadian models are equipped with this  warning light: 
NOTE : If the fuel filler  cap is not closed tightly or if the engine is running when the car is refueled, the Check Engine
Lamp may indicate a  fault. However, your vehicle's performance will not be  affected. Use only Volvo original or
approved fuel filler  caps.
Daytime Running Lights:
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2 0 0 3 
VOLVO
S40 & V40
Chapter 4 - Starting and driving
pg. 61 Starting and driving
Starting and driving
This section on starting and  driving contains items such as starting the engine, operating the gear selector, towing,
trailers, etc.  Fuel requirements, Refueling
62
Driving economy64
Starting the engine65
Automatic transmission66
Points to remember68
Emergency towing70
Vehicle towing information71
Jump  starting, Proposition  65 Battery Warning72
Brake system, ABS73
Electronic Brake-Force  Distribution (EBD)74
Winter driving, Before a long distance trip75
Detachable trailer hitch, installing/removing76
Trailer towing78
pg. 62 Fuel  requirements
Deposit control (detergent) gasoline  
Volvo recommends the use of detergent gasoline to control engine deposits. Detergent  gasoline is effective in keeping
injectors  and  intake  valves clean. Consistent use of deposit control gasolines will help ensure good driveability and
fuel economy. If you are not sure whether the gasoline contains deposit control additives, check with the service
station operator.
Unleaded fuel  
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Timing belt 
For proper functioning of the vehicle and  its  emission control systems, the timing belt and  belt tensioner must  be
replaced  every 105,000 miles (168,000 km). Engine damage will occur if the belt fails.
PCV system
(on turbocharged models) 
The nipple in the intake  manifold and  the filter  at the end  of the PCV  hose in the air cleaner  should be  inspected and
cleaned at 105,000 miles (168,000 km) and  thereafter, again at 150,000 mile (240,000 km) intervals.
Spark plugs  
The spark plugs should be  replaced  every 45,000 miles (72,000 km) under normal driving conditions. City driving or
fast  highway  driving may necessitate replacement  sooner.
Under normal driving conditions, spark plugs require no maintenance between replacement  intervals.  When installing
new plugs, be  sure to use the right type and  to tighten them correctly. When changing the plugs, clean the terminals
and  rubber seals.  Also check that the suppressor connectors are in good condition. Cracked or damaged connectors
should be  replaced.
pg. 111 Engine compartment
Engine  compartment S40/V40
1 Power brakes 
2 Brake fluid reservoir 
3 Fusebox 
4 Engine air cleaner  
5 Battery  
7 Radiator  
8 Oil filter  
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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Fuel system 
The engine is equipped with a  multipoint fuel injection system.
Distributor ignition system  
Firing  order: 1-3-4-2 
Distributor ignition setting:  Not adjustable 
Spark plugs:  Champion RC8PYP or equivalent 
Spark plug gap: 0.0315" (0.80 mm) 
Tightening torque: 18.4 ft. lbs. (25 Nm)
WARNING!
The distributor ignition system operates at very high voltages. Special  safety precautions must  be  followed to
prevent injury. Always turn the ignition off when:
 Replacing distributor ignition components e.g.  plugs, coil, etc.
 Do not touch any  part of the distributor ignition system while the engine is running. This may result in unintended
movements and  body injury.
All specifications are subject to change without notice.
Front  suspension  
Spring strut suspension with integrated shock absorbers and  control arms  linked to the support frame. Power assisted
rack and  pinion steering. Safety type steering column. 
The alignment specifications apply to a  car at curb weight (without passengers or cargo). 
Toe-in measured on the wheel rims: 1.4 mm +/- 0.2 mm 
Toe-in measured on tire sides: 2.0 mm +/- 0.4 mm
Rear suspension  
Multilink individual rear wheel suspension with longitudinal support arms,  double link arms  and  track rods.
Toe-in measured on the tire sides: 2.6 mm +/- 0.8 mm
pg. 125 Specifications
Power transmission  
Automatic transmission: AW 55-50 
5-speed automatic  electronically  controlled gearbox comprising a  hydraulic torque converter with a  lockup function;
planetary gear, integrated final drive. Operation via a  floor  mounted gear selector lever. Drive shafts with symmetrical
joint location. Overdrive.
Final drive ratio  2.44:1 
Reduction ratios  
1st gear 4.77:1 
2nd gear 3.00:1 
3rd gear 1.96:1 
4th gear 1.32:1 
5th gear 1.02:1 
Reverse 3.23:1
Capacities  
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2 0 0 3 
VOLVO
S40 & V40
INDEX
pg. 143 - 145 Index
A
ABS 23
,73
Adjustable steering wheel34
Advanced user Mode (AUM) - radio141
Air conditioning37
Air distribution36
Air filter  - engine110
Air vents35
Airbag (SIPS)8
Airbag (SRS)4
Alarm43
Anti-lock Brake System  (ABS)23,73
Anti-theft code130
Antifreeze75,117
Ashtrays33
Audio system HU -415131
Audio system HU -615132
Audio systems129
AUM - Advanced user Mode - radio141
Automatic car washing104
Automatic transmission67,68,69,125
Automatic transmission fluid122
Auxiliary socket33
B
Battery75
,126
Battery  maintenance119
Booster cushion11
Brake failure warning light22
Brake fluid116,122
Brake fluid warning light22
Brake system73,74
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