2003 VOLVO S40 engine

2 0 0 3
VOLVO
S40 & V40
This manual deals with the operation and care of your Volvo.
Welcome to the worldwide family of Volvo owners. We trust that you will enjoy many years of safe driving in your
Volvo, an automobile designed with your safety and comfort in mind. To help ensure your satisfaction with this
vehicle, we encourage you to familiarize yourself with the equipment descriptions, operating instructions and
maintenance requirements/recommendations in this manual. We also urge you and your passengers to wear seat belts
at all times in this (or any other) automobile. And, of course, please do not operate a vehicle if you may be affected by
alcohol, medication or any impairment that could hinder your ability to drive.
Your Volvo is designed to meet all applicable safety and emission standards, as evidenced by the certification labels
attached to the driver's door opening and on the left wheel housing in the engine compartment.
For further information please contact your retailer, or:
In the USA:
Volvo Cars of North America
Customer Relations
P.O. Box 914
Rockleigh, New Jersey 07647-0914
800-458-1552
In the Canada:
Volvo Cars of Canada. Ltd.
175 Gordon Baker Road
Willowdale, Ontario M2H 2N7
800-663-8255
We also invite you to visit our home page on the Internet at:
http://www.volvocars.com
Contents
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Contents
Chapter 1 - Occupant safety
Chapter 2 - Instruments, switches and controls
Chapter 3 - Body and interior
Chapter 4 - Starting and driving
Chapter 5 - Wheels and tires
Chapter 6 - In case of an emergency
Chapter 7 - Car care
Chapter 8 - Volvo Service
Chapter 9 - Specifications
Chapter 10 - Audio systems
Index
Back Cover
General information
Important
Before you operate your car for the first time please familiarize yourself with the engine oil consumption
information and refueling recommendations on pages 62 and 63
. You should also be familiar with the
information in the first four chapters of this manual.
Information contained in the balance of the manual is extremely useful and should be read after operating the
vehicle for the first time.
The manual is structured so that it can be used for reference. For this reason, it should be kept in the car for
ready access.
Do not export your Volvo to another country before investigating that country's applicable safety and exhaust
emission requirements. In some cases it may be difficult or impossible to comply with these requirements.
Modifications to the emission control system(s) may render your Volvo not certifiable for legal operation in the
U.S., Canada and other countries.
All information, illustrations and specifications contained in this manual are based on the latest product
information available at the time of publication. Please note that some vehicles may be equipped differently,
depending on special legal requirements and that optional equipment described in this manual may not be
available in all markets.
Volvo reserves the right to make model changes at any time, or to change specifications or design, without
notice and without incurring obligation.
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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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Volvo's environmental activities are based on a holistic view, which means we consider the overall environmental
impact of a product throughout its complete life cycle. In this context, design, production, product use, and recycling
are all important considerations.
In production, Volvo has partly or completely phased out several chemicals including freons, lead chromates,
naphtanates, asbestos, mercury and cadmium; and reduced the amount of chemicals used in our plants 50% since 1991.
In use, Volvo was the first in the world to introduce into production a three-way catalytic converter with a Lambda
sond, now called oxygen sensor, in 1976. The current version of this highly efficient system reduces emissions of
harmful substances (CO, HC, NOx) from the exhaust pipe by approximately 95% and the search to eliminate the
remaining emissions continues. Volvo is the only automobile manufacturer to offer CFC-free retrofit kits for the air
conditioning system for all models as far back as the M/Y 1975 240. Advanced electronic engine controls, refined
purification systems and cleaner fuels are bringing us closer to our goal.
After Volvo cars and parts have fulfilled their use, recycling is the next critical step in completing the life cycle. The
metal content is about 75% of the total weight of a car, which makes the car among the most recycled industrial
products. In order to have efficient and well controlled recycling, many Volvo variants have printed dismantling
manuals, indicating the weight and material of individual components. For Volvo, all homogeneous plastic parts
weighing more than 1.7 oz. (50 grams) are marked with international symbols that indicate how the component is to be
sorted for recycling.
In addition to continuous environmental refinement of conventional gasoline-powered internal combustion engines,
Volvo is actively looking at advanced technology alternative-fuel vehicles.
When you drive a Volvo, you become our partner in the work to lessen the car's impact on the environment.
To reduce your vehicle's environmental impact, you can:
Maintain proper air pressure in your tires. Tests have shown decreased fuel economy with improperly inflated tires
Follow the recommended maintenance schedule in your Warranty and Service Records Information booklet.
Drive at a constant speed
See an authorized Volvo retailer as soon as possible for inspection if the check engine (malfunction indicator) lamp
illuminates, or stays on after the vehicle has started
Properly dispose of any vehicle related waste such as used motor oil, used batteries, brake pads, etc.
When cleaning your car, use Volvo's own car care products, all of which have systematically been adapted to the
environment
For additional information regarding the environmental activities in which Volvo Cars of North America, LLC. and
Volvo Car Corporation are involved, visit our Internet Home Page at:
http://www.volvocars.com

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The entire process, including inflation and deflation of the airbags, takes approximately two-tenths of a second.
WARNING!
As its name implies, SRS is designed to be a SUPPLEMENT to - not a replacement for - the three-point belt
system. For maximum protection, wear seat belts at all times. Be aware that no system can prevent all possible
injuries that may occur in an accident.
When installing any optional equipment, make sure that the SRS system is not damaged. Do not attempt to service
any component of the SRS yourself. Attempting to do so may result in serious personal injury. If a problem arises,
take your car to the nearest authorized Volvo retailer for inspection as soon as possible.
pg. 5 Volvo SRS
A self -diagnostic system incorporated into the sensor monitors the SRS, SIPS and IC-system. If a fault is detected, the
"SRS" warning light will illuminate. The light is included in the warning/indicator light cluster in the instrument panel.
Normally, the SRS warning lamp should light up when the ignition is switched on and should go out after 5 seconds or
when the engine is started. Check that this light is functioning properly every time the car is started.
The following items are monitored by the self -diagnostic system:
Sensor unit
SRS wiring
Inflators
WARNING!
Never drive an SRS equipped car with your hands on the steering wheel pad / airbag housing.
No objects, accessory equipment or stickers may be placed on, attached to or installed near the SRS cover in the
center of the steering wheel, the SRS cover above the glove compartment or the area affected by airbag deployment.
If the SRS warning light stays on after the engine has started or if it comes on while you are driving, drive the car to
the nearest authorized Volvo retailer for inspection as soon as possible.
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If this light comes on while driving, the coolant temperature is too high. Stop the engine and check the coolant level in
the expansion tank. See page 117.
3 Odometer
4 Speedometer
The longer the knob is turned, the faster the setting will change.
5 Trip odometer
This indicator measures shorter distances. The last digit indicates 1/10 mile/kilometer.
6 Button for setting clock/resetting trip odometer
In both cases, the ignition must be switched on
Clock: Without pressing the button, turn it clockwise to advance the clock, or counterclockwise to set the clock back.
Trip odometer: Press the button to reset the trip odometer.
7 Tachometer
Reads thousands of engine rpm. The needle should never be in the solid red range.
8 Clock, Trip Computer/Ambient temperature
NOTE: See page 27- 29
for information on the trip computer.
9 Low fuel level warning light
When this light comes on, there are approximately 1.9 US gal. (7 liters) of fuel remaining in the tank.
10 Fuel gauge
Fuel tank capacity: 16 US gallons (60 liters).
When refuelling the fuel gauge needle will not register until the volume of gasoline in the tank exceeds 3.2 US gal. (12
liters).
pg. 21 Indicator and warning lights
1 Turn signal, left
2 Turn signal, right
3 Low washer fluid level
4 Brake light* failure warning
5 Turn signals - trailer (certain models)
6 Front fog lights on
7 Door open
8 Rear fog light on
9 Seat belt warning
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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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