2004 VOLVO V4 brake

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!
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 selector 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
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tire damage.
Wear indicator
The tires have a so-called "wear indicator" in the form of a number of narrow strips running across or parallel to the
tread. When approx. 1/16" (1.6 mm) is left on the tread, these strips become visible and indicate that the tire should be
replaced.
Tires with less than 1/16" (1.6 mm) tread have a very poor grip in rain or snow.
When replacing worn tires, it is recommended that the tire be identical in type (radial) and size as the one being
replaced. Using a tire of the same make (manufacturer) will prevent alteration of the driving characteristics of the
vehicle.
To improve tire economy:
Maintain correct tire pressure. See the tire pressure label on the inside of the fuel filler door.
Drive smoothly: avoid fast starts, hard braking and tire screeching.
Tire wear increases with speed.
Correct front wheel alignment is very important.
Unbalanced wheels impair tire economy and driving comfort.
If the wheels are rotated, they should be kept on the same side of the car so that they revolve in the same direction
as prior to rotation.
Hitting curbs or potholes can damage the tires and/or wheels permanently.
Flat spots
All tires become warm during use. After cooling, when the vehicle is parked, the tires have a tendency to distort
slightly, forming flat spots. These flat spots can cause vibrations similar to the vibrations caused by unbalanced wheels.
They do, however, disappear when the tire warms up. The degree to which flat spots form depends on the type of cord
used in the tire. Remember that, in cold weather, it takes longer for the tire to warm up and consequently longer for the
flat spot to disappear.
pg. 81 Wheels and tires
Snow chains
Snow chains can be used on your Volvo with the following restrictions:
Snow chains should be installed on front wheels only. Use only Volvo approved snow chains.
Snow chains may only be mounted on approved snow tires 185/65 R15. Consult your Volvo retailer.
If accessory, aftermarket or "custom" tires and wheels are installed and are of a size different than the original tires
and wheels, chains in some cases CANNOT be used. Sufficient clearances between chains and brakes, suspension and
body components must be maintained.
Some strap on type chains will interfere with brake components and therefore CANNOT be used.
Consult your Volvo retailer for additional snow chain information.
CAUTION:
Check local regulations regarding the use of snow chains before installing.
Always follow the chain manufacturer's installation instructions carefully. Install chains as tightly as possible and
retighten periodically.
Never exceed the chain manufacturer's specified maximum speed limit. (Under no circumstances should that limit
be higher than 30 mph (45 km/h)).
Avoid bumps, holes or sharp turns when driving with snow chains.
The handling of the vehicle can be adversely affected when driving with chains. Avoid fast or sharp turns as well as
locked wheel braking.
Snow tires, studded tires *
Tires for winter use:
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The screwdriver is combined with the socket wrench. The tools can be alternated by pulling the shaft out of the handle
and re-inserting the opposite end of the shaft into the handle.
Removing the jack
Remove the spare tire out. Loosen the jack slightly by turning the axle (1) and remove it from the retaining clip.
Replacing the jack
Put the jack in the clip and turn axle (1) until the jack is securely in place.
Replace the tools in the same place.
WARNING!
The jack (see the following pages) must be correctly placed in the jack attachment.
Be sure the jack is on a firm, level, non-slippery surface.
Never allow any part of your body to be extended under a car supported by a jack.
Use the jack intended for the car when replacing a wheel. For any other job, use stands to support the side of the
car being worked on.
Apply the parking brake and put the gear selector in position P.
Block the wheels standing on the ground, use rigid wooden blocks or large stones.
The jack should be kept well-greased.
Use gloves
pg. 87 Tire changing
Changing a tire
Engage the parking brake.
Put the gear selector in (P)ark.
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Replacement of rear light bulbs - V40
All the bulbs in the rear light unit are replaced from inside the cargo area.
Procedure:
Switch off the lights and remove the ignition key.
Open the cover in the panel
Push catches A and B in and remove the bulb holder. The bulbs are held in the bulb holder.
Leave the connector and cables connected to the bulb holder.
Remove the bulb by pressing it inwards and turning it a few degrees counterclockwise.
Insert a new bulb into the bulb holder and replace the holder. Check that the bulb works and refit the cover.
1 Tail light (rear parking light) 5W
2 Direction indicator 21W
3 Brake light 21W
4 Tail light 5W
5 Backup light 21W
6 Rear fog light (Left side only) 21W
pg. 93 Replacing bulbs
Side direction indicator
1. Slide the lens forward and pull out the rear edge.
2. Pull out the entire lens/bulb unit.
3. With the lens toward you, turn the bulb holder 1/4 turn (the wires should not be disconnected from the holder) and
pull out the bulb holder from the lens unit.
4. Pull the old bulb straight out and press a new one into place.
5. Replace the entire unit in the reverse order.
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toward the rear side of the engine.
After cleaning the engine, the spark plug wells should be inspected for water and blown dry if necessary.
Suitable detergents
Special car washing detergents should be used. A suitable mixture is about 2.5 fl. oz. (8.5 cl) of detergent to 2.6 US
gal. (10 liters) of warm water. After washing with a detergent the car should be well rinsed with clean water.
WARNING!
When the car is driven immediately after being washed, apply the brakes several times in order to remove any
moisture from the brake linings.
Engine cleaning agents should not be used when the engine is warm. This may constitute a fire risk.
NOTE: When washing the car, remember to remove dirt from the drain holes in the doors and sills. Painted Bumpers:
Wash the painted bumpers with the same cleaning agent used on the rest of the car. Never clean the bumpers with
gasoline or paint thinner. Difficult spots can be removed with denatured alcohol. To avoid scratches, do not dry the
bumpers with paper.
pg. 104 Automatic car washing, Polishing and waxing
Automatic washing - simple and quick
Brushless car washes are recommended. An automatic wash is a simple and quick way to clean your car, but it is
worth remembering that it may not be as thorough as when you yourself go over the car with sponge and water.
Keeping the underbody clean is most important, especially in the winter. Some automatic washers do not have
facilities for washing the underbody.
Before driving into an automatic wash, make sure that side view mirrors, auxiliary lamps, etc., are secure, otherwise
there is risk of the machine dislodging them. You should also lower the antenna (sedans).
We do NOT recommend washing your car in an automatic wash during the first six months because the paint
will not have hardened sufficiently.
Polishing and waxing
Normally, polishing is not required during the first year after delivery. However, waxing is recommended.
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: Machine buffing is not recommended.
pg. 105 Cleaning the upholstery
Cleaning the upholstery
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2 0 0 4
VOLVO
S40 & V40
Chapter 8 - Volvo Service
pg. 107 Volvo Service
Service - an investment
An investment which will pay dividends in the form of improved reliability, durability and resale value. Label information
108
Maintenance service, Warranty, Vehicle Event Data109
Emissions maintenance110
Engine compartment111
Fuel/emissions systems112
Lubrication113
Engine oil114
Power steering fluid, Brake fluid reservoir116
Coolant, drive belt117
Washer fluid reservoir118
Battery maintenance, Proposition 65 Battery Warning119
pg. 108 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
(underside of hood)
3 Loads and Tire Pressures
(on inside of fuel filler door)
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The fuel filter should be replaced at 105,000 miles (168,000 km). The filter is replaced as a complete unit. Replace
more frequently if contaminated fuel is introduced into the tank, or if there is reason to suspect that this has occurred.
Fuel system, including filler cap, tank, lines and connections
The ability of the fuel system to contain hydrocarbons depends upon a leak-free system. Inspect fuel lines every
30,000 miles (48,000 km). Check for proper sealing of the fuel filler cap which contains "O" ring 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 (Malfunction indicator) may indicate a fault. However, your vehicle's performance will not be affected. Use only
Volvo original or approved fuel filler caps.
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 Fuse box
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
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Engine oilQuality: Meeting minimum ILSAC specification GF-2, including
ACEA A1, API SJ, SJ/CF and SJ/Energy Conserving.
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
liter)
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)
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
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