2003 VOLVO S40 automatic transmission

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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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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Note that roof racks, ski racks, etc., increase air resistance and thereby fuel consumption.
Avoid using automatic transmission kick-down feature unless necessary.
Avoid using the air conditioning when it is not required. When engaged, the air conditioner's compressor places an
additional load on the engine. However, please note that fuel consumption is lower with the air conditioning on than it
is when driving with the air conditioning switched off and the windows down.
Utilizing the fuel consumption modes in the Trip Computer can help you "learn" how to drive more economically.
Other factors which decrease gas mileage are:
Dirty air cleaner
Dirty engine oil and clogged oil filter
Dragging brakes
Incorrect front end alignment
Some of the above mentioned items and others are checked at the standard Maintenance Service intervals.
NOTE : The automatic transmission's ( D)rive position should be used as often as possible to help improve fuel
economy.
WARNING!
It is recommended that tires of the same make and dimensions be used on all four wheels (including the use of
snow tires). Do not use bias ply tires as this will adversely alter vehicle handling characteristics. Maintain correct tire
pressure.
Do not drive with trunk lid open! A warning light in the instrument panel will indicate that the trunk is open.
Poisonous exhaust gases may enter via the open trunk lid. If the trunk lid/tailgate must be kept open for any reason,
proceed as follows:
Close the windows.
Set the ventilation system control to air flow to floor, windshield and side windows and blower control to its
highest setting.
pg. 65 Starting the engine
Starting and stopping
1. Fasten the seat belt.
WARNING!
Before starting, check that the seat, steering wheel and mirrors are adjusted properly. Make sure the brake pedal can
be depressed completely. Move the seat closer if necessary. Refer to section "front seats".
2. Make sure the gear selector is in the Park position.
3. Without touching the accelerator pedal, turn the ignition key to the starting position. Allow the starter to operate
for up to 5 seconds. Release the key as soon as the engine starts. If the engine fails to start, repeat step 3.
For cold starts at altitudes above 6000 ft (1800 meters), depress the accelerator pedal halfway and turn the key to the
starting position. Release the pedal slowly when the engine starts. Depress the brake pedal and release the parking
brake.
4. To release the gear selector from the (P)ark position, the ignition key must be in position II and the brake pedal
must be depressed.
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NOTE: Your car is equipped with a KEYLOCK system. When the engine is switched off, the gear selector must be in
the (P)ark position before the starting key can be removed from the ignition switch.
5. Select the desired gear. The gear engages after a slight delay which is especially noticeable when selecting R.
CAUTION :
The engine should be idling; never accelerate until after you feel the gear engage! Too rapid acceleration immediately
after selecting a gear will cause harsh engagement and premature transmission wear.
NOTE : Selecting P or N when idling at a standstill for prolonged periods of time will help prevent overheating of
transmission oil.
Ignition sleep mode
If the key is turned to "drive" position (see page 26
) for several minutes without the engine running, the car's starting
system will power down to "sleep" mode. To start the car, momentarily turn the key back to the "locked" position.
Then start the car as you would normally do.
WARNING!
Always place the gear selector in Park and apply the parking brake before leaving the vehicle. Never leave the car
unattended with the engine running.
Always open the garage doors fully before starting the engine inside a garage to ensure adequate ventilation. The
exhaust gases contain carbon monoxide, which is invisible and odorless but very poisonous.
CAUTION:
Never race the engine immediately after starting. Oil flow may not reach some lubricating points fast enough to
prevent engine damage.
Do not race the engine just prior to switching off!
pg. 66 Automatic transmission
Gear selector positions
P Park
The transmission must be in Park position to start the engine, and to allow removal of the key from the ignition when
you leave the car. The car should be stationary when you select P! In the position P the transmission is mechanically
locked. Always apply the parking brake when parking!
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Shift lock
In order to move the gear selector from P position to the other gear positions the key must be in driving position
(position II) and the brake pedal must be depressed. See page 99
for information on how to move the gear selector
manually in case of a dead battery.
R Reverse
The car must be at a standstill before you select Reverse gear.
N Neutral position
The N position is the neutral position. The engine can be started, but no gear is selected. Apply the parking brake when
the car is stationary with the gear selector in position N.
D Driving position
D is the normal driving position. The gear se-lector automatically shifts up and down between the transmission gears,
based on the level of acceleration and the speed. The car should be stationary when you select D from position R.
4 Low gear position
Shifting up and down between the 1st, 2nd, 3rd, and 4th occurs automatically.
Shifting up to Drive does not occur.
Position 4 can be used:
for mountain driving
for driving with trailer
to increase the engine braking
3 Low gear position
Shifting up and down between the 1st, 2nd, and 3rd occurs automatically.
The 4th and Drive gears will not be engaged.
Position 3 can be used:
for mountain driving
for driving with trailer
to increase the engine braking
L Low gear position
Choose position L if you want to drive with the 1st or 2nd gear engaged. Position L gives the best possible engine
braking effect when, for example, mountain driving.
Shifting up to 5th does not occur.
Position 4 can be used:
for mountain driving
for driving with trailer
to increase the engine braking
Downshifting protection
There is a built in protection in the transmission which prevents over revving in the engine when you select one of the
low gear positions.
pg. 67 Automatic transmission
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W - Winter/Wet Weather
Use the W button to turn the Winter/Wet Weather function on or off.
The Winter/Wet Weather function limits downshifting during acceleration, helping to reduce wheel spin. Because
downshifting is limited in W mode, performance may seem sluggish and fuel economy may be reduced.
W mode is recommended for acceleration from a standstill on rain-slicked roads.
Automatic transmission -shift gate positions
The gear selector can be moved freely between N and D. Selections of other positions are obtained by depressing the
selector knob prior to moving the selector.
Slightly depressing the selector knob allows selection of positions R, N, D, 4, 3 and L. Fully depressing the selector
knob allows selection of position P. This is also necessary when initially bringing the selector out of position P. Fully
depressing the selector knob permits shifting freely between all positions.
Kick-down
Automatic shift to a lower gear (kick-down) is achieved by depressing the accelerator pedal fully and briskly. An
upshift will be achieved when approaching the top speed for a particular gear or by releasing the accelerator pedal
slightly. Kick -down can be used for maximum acceleration or when passing at highway speeds. Avoid using the kick-
down function during the break-in period (first 1,200 miles of vehicle operation).
Transmission Lamp
If the indicator lamp (see page 21 item 18
) begins to flash, this is an indication of a fault in the automatic transmission.
The Check Engine Lamp will also light up if a fault is detected. If the transmission does not shift properly, place the
gear selector in position L. Please contact your Volvo retailer if this occurs.

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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:
JWS-3309 P/N 1161540 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+ boiling point >536°F (280°C), P/N 9437433 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 T4
Output 170 hp at 5500 rpm (127 kW at 92 rps)
Max torque 177 ft. lbs. at 1800-5000 rpm (240 Nm at 30-75 rps)
Number of cylinders 4
Bore 3.27" (83 mm)
Stroke 3.54" (90 mm)
Displacement 1.95 liters (118.9 cu. in.)
Compression ratio 9.0:1
Number of valves 16
Valve clearance mechanical
All specifications are subject to change without notice.
pg. 124 Specifications
Cooling system
Type: Positive pressure, closed system
Thermostat begins to open at 186° F (90° C)
Coolant: Volvo original coolant/antifreeze (50/50 water-antifreeze mix).
Capacity: 6 US qts. (5.7 liters)
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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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