2005 VOLVO S40 service

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. 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.
WARNING!
If your vehicle is involved in an accident, unseen damage may affect its driveability and safety.
Introduction
WARNING!
CALIFORNIA proposition 65
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.
Volvo and the environment
Volvo is committed to the well being of its 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. 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.
Volvo was the first in the world to introduce into production a three-way catalytic converter with a Lambda sond, now
called the heated 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 of all models as far back as the 1975 model 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.
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Drive at a constant speed whenever possible.
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.
Introduction
PremAir®
The surface of the radiator in the engine compartment is treated with a special coating called Premair*. This coating
works as a catalytic converter, converting most of the ground level ozone passing through the radiator into oxygen,
thereby reducing harmful ground-level ozone.
* PremAir is a registered trademark of Engelhard Corporation.
Contents
Contents
Chapter 1 - Instrument overview
Chapter 2 - Safety
Chapter 3 - Instruments and controls
Chapter 4 - Climate
Chapter 5 - Interior
Chapter 6 - Locks and alarm
Chapter 7 - Starting and driving
Chapter 8 - Wheels and tires
Chapter 9 - Vehicle care
Chapter 10 - Maintenance and servicing
Chapter 11 - Audio
Chapter 12 - Specifications
Index
Supplement - VALET OR SERVICE LOCKING
Supplement - ACCESSORY 18-INCH TIRE PRESSURES
Supplement - SAFETY - AIRBAG LABELS
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Keep your windshield and headlights clean.
Replace wiper blades when they start to leave streaks.
Take into account the traffic, road, and weather conditions, particularly with regard to stopping distance.
Reporting safety defects in the U.S.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Volvo Cars
of North America. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your retailer, or Volvo Cars of North America. To contact NHTSA, you
may either call the Auto Safety Hotline toll-free at 1- 800-424-9393 (or 202-366-0123 in Washington, D.C. area) or
write to: NHTSA, U.S. Department of Transportation, Washington D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.
Volvo strongly recommends that if your vehicle is covered under a service campaign, safety or emission recall or
similar action, it should be completed as soon as possible. Please check with your local retailer or Volvo Cars of North
America, LLC if your vehicle is covered under these conditions. NHTSA can be reached at:
http://www.nhtsa.dot.gov
or by phone at:
pg. 13 Occupant safety
1-888-DASH-2-DOT (1-888-327- 4236) (toll free)
1-800-424-9393 (toll free)
1-202-366-0123 (in the Washington DC area)
pg. 14 Seat belts
Seat belts
Using seat belts
Not wearing a seat belt is like believing "It'll never happen to me!" Volvo, the inventor of the three-point seat belt,
urges you and all occupants of your vehicle to wear seat belts and ensure that children are properly restrained, using an
infant, car or booster seat determined by age, weight and height.
Volvo also believes no child should sit in the front seat of a vehicle.
Most states and provinces make it mandatory for occupants of a vehicle to use seat belts.
So, urging you to buckle up is not just our recommendation. The few seconds it takes to buckle your seat belt may one
day allow you to say "It's a good thing I was wearing my seat belt."
The outboard seat belts are equipped with tensioners that reduce slack in the belts.
These tensioners are triggered in situations where the airbags deploy. The front seat belts also include a tension
reducing device which, in the event of a collision, limits the peak forces exerted by the seat belt on the occupant.
WARNING!
Never use a seat belt for more than one occupant. Never wear the shoulder portion of the belt under the arm, behind
the back or otherwise out of position. Such use could cause injury in the event of an accident. As seat belts lose
much of their strength when exposed to violent stretching, they should be replaced after any collision, even if they
appear to be undamaged.
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NOTE: When the ignition is switched on, the OWS indicator light will go on for up to 10 seconds while the system
performs a self -diagnostic test and then go out.
However, if a fault is detected in the system:
The OWS indicator light will stay on
The safety system warning light (see page 22) will come on and stay on
The message PASS. AIRBAG OFF SERVICE URGENT will be displayed in the information display.
WARNING!
If a fault in the system is detected and indicated as explained above, be aware that the passenger's side front airbag
will not deploy in the event of a collision. In this case, the safety systems and Occupant Weight Sensor should be
inspected by an authorized Volvo retailer as soon as possible.
pg. 20 Front airbags (Supplemental Restraint System - SRS)
WARNING!
Never try to open, remove, or repair any components in the OWS system. This could result in system malfunction.
Maintenance or repairs should only be carried out by an authorized Volvo service technician.
WARNING!
Keep the following points in mind with respect to the OWS system. Failure to follow these instructions could
adversely affect the system's function and result in serious injury to the occupant of the front passenger's seat:
The full weight of the front seat passenger should always be on the seat cushion. The passenger should never lift
him/herself off the seat cushion using the armrest in the door or the center console, by pressing the feet on the floor,
by sitting on the edge of the seat cushion, or by pressing against the backrest in a way that reduces pressure on the
seat cushion. This could cause OWS to disable the front, passenger's side airbag.
The front passenger's seat should not be modified in any way. This could reduce pressure on the seat cushion, which
might interfere with the OWS system's function.
No objects should be placed under the front passenger's seat. This could interfere with the OWS system's function.
WARNING!
No objects that add to the total weight on the seat should be placed on the front passenger's seat. If a child is seated
in the front passenger's seat with any additional weight, this extra weight could cause the OWS system to enable the
airbag, which might cause it to deploy in the event of a collision, thereby injuring the child.
The seat belt should never be wrapped around an object on the front passenger's seat. This could interfere with the
OWS system's function.
The front passenger's seat belt should never be used in a way that exerts more pressure on the passenger than
normal. This could increase the pressure exerted on the weight sensor by a child, and could result in the airbag being
enabled, which might cause it to deploy in the event of a collision, thereby injuring the child.
pg. 21 Front airbags (Supplemental Restraint System - SRS)
When do the front airbags deploy?
The front airbags are designed to deploy during certain frontal or front -angular collisions, impacts, or decelerations,
depending on the crash severity, angle, speed and object impacted. The airbags may also deploy in certain non-frontal
collisions where rapid deceleration occurs. The SRS sensors are designed to react to both the impact of the collision
and the inertial forces generated by it, and to determine if the intensity of the collision is sufficient for the seat belt
tensioners and/or airbags to be deployed. If the airbags have been deployed, we recommend the following:
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vehicle is started.
WARNING!
If the safety system warning light stays on after the engine has started or if it comes on while you are driving, drive
the vehicle to the nearest authorized Volvo retailer for inspection as soon as possible.
There is no maintenance to perform on the SRS yourself. The month and year shown on the decal on the door pillar
indicate when you should contact your Volvo retailer for specific servicing or replacement of airbags and seat belt
tensioners. This service must be performed by an authorized Volvo retailer. WARNING!
If your vehicle has been subjected to flood conditions (e.g. soaked carpeting/ standing water on the floor of the
vehicle) or if your vehicle has become flood-damaged in any way, do not attempt to start the vehicle or put the key
in the ignition before disconnecting the battery (see below). This may cause airbag deployment which could result in
personal injury. Have the vehicle towed to an authorized Volvo retailer for repairs.
Automatic transmission:
Before attempting to tow the vehicle, use the following procedure to override the shiftlock system to move the gear
selector to the neutral position.
Switch off the ignition for at least 10 minutes and disconnect the battery
Wait at least one minute.
Insert the key in the ignition and turn it to position II.
Press firmly on the brake pedal.
Move the gear selector from (P)ark to the (N)eutral position. See page 111 for information on manually overriding
the shiftlock system.
pg. 23 Front airbags (Supplemental Restraint System - SRS)
SRS text on passenger's dash
Should you have any questions about the SRS system, please contact your authorized Volvo retailer or Volvo
Customer Support:
In the USA In Canada
Volvo Cars of North America, LLC Volvo Cars of Canada Ltd.
Customer Care Center Customer Care Center
P.O. Box 914 175 Gordon Baker Rd.
Rockleigh, New Jersey 07647-091 North York, Ontario M2H 2N7
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1-800-458-15521-800-663-8255
SRS text on outside of both sun visors
SRS text on inside of both sun visors
WARNING!
Children must never be allowed in the front passenger's seat. Volvo recommends that ALL occupants (adults and
children) shorter than 4 feet 7 inches (140 cm) be seated in the back seat of any vehicle with a passenger -side front
airbag. See 35
for guidelines.
Occupants in the front passenger's seat must never sit on the edge of the seat, sit leaning toward the instrument panel
or otherwise sit out of position.
The occupant's back must be as upright as comfort allows and be against the seat back with the seat belt properly
fastened.
Feet must be on the floor, e.g. not on the dash, seat or out of the window.
pg. 24 Front airbags (Supplemental Restraint System - SRS)
WARNING!
No objects or accessory equipment, e.g. dashboard covers, may be placed on, attached to, or installed near the SRS
hatch (the area above the glove compartment) or the area affected by airbag deployment (see the illustration on page
17).
There should be no loose articles, e.g. coffee cups, on the floor, seat, or dashboard area.
Never try to open the SRS cover on the steering wheel or the passenger's side dashboard. This should only be done
by an authorized Volvo service technician. Failure to follow these instructions can result in injury to the vehicle
occupants.

Contents | Top of Page
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14. Temperature gauge
The gauge indicates the temperature of the engine cooling system. If the temperature is abnormally high and the needle
enters the red zone, a message is shown in the display. Bear in mind that extra lamps in front of the air intake reduce
the cooling capacity at high outside temperatures and high engine loads.
15. Indicator and warning symbols
1. Models with All Wheel Drive have a tank volume of 15 US gallons (57 liters).
Models with engine code 39 have a fuel tank capacity of 14.5 US gallons (55 liters). This code is the 6th and 7th digits
from the left in your vehicle's VIN number. See page 184
for the location of the VIN plate.
pg. 39 Indicator and warning symbols
Function check
The indicator and warning symbols light up when you turn the ignition key to the driving position (position II) before
starting. This shows that the symbols are functioning. When the engine starts, all symbols go out. If the engine is not
started within 5 seconds, all of the symbols except CHECK ENGINE and
will go out. Certain symbols may not
have their functions illustrated, depending on the car's equipment. The PARK BRAKE symbol will not go out until the
parking brake has been released.
Symbols in the center of the instrument panel
Warning symbol
The red warning symbol lights up to indicate a fault that could affect the car's driveability. A text explaining the nature
of the fault will also be shown in the information display. This symbol may also light up in combination with other
indicator or warning symbols.
If the red warning symbol lights up:
1. Stop the car as soon as possible in a suitable location.
2. Read the message in the information display.
3. Follow the instructions provided, or contact an authorized Volvo Retailer or workshop.
Information symbol
The yellow information symbol lights up to alert the driver to a message in the information display. This symbol may
also light up in combination with other indicator or warning symbols.
NOTE: The car can still be driven after the information symbol has come on. The car can be driven for 1-2 weeks
after service-related information has been displayed.
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6. Generator warning light
If the light comes on while the engine is running, have the charging system checked by an authorized Volvo
workshop.
7. Brake failure warning light
If this light comes on while driving or braking, stop the car as quickly as possible in a safe place, open the
hood, and check the brake fluid level in the reservoir. See page 148
for the location of the reservoir.
Canadian models are equipped with this symbol .
WARNING!
If the fluid level is below the MIN mark in the reservoir or if a "Brake failure - Service urgent" message is displayed
in the information display: DO NOT DRIVE. Have the car towed to an authorized Volvo retailer and have the brake
system inspected.
pg. 42 Symbols on the right side of the instrument panel
If the BRAKE and ABS warning lights come on at the same time, this could indicate a fault in the brake system.
In this case:
1. Stop the car in a suitable place and switch off the engine.
2. Restart the engine.
3. If both warning lights go off, no further action is required and the car can be driven.
4. If both lights remain on after the engine has been restarted, switch off the engine again and check the brake fluid
level. See page 148
for the location of the reservoir.
Door open warning
The driver will be alerted if one of the doors, the hood, or the trunk lid are open or ajar.
At low speeds
If the car is moving at a speed of less than approximately 4 m.p.h. (7 km/h), the Information symbol in the
instrument panel will light up and a message will be shown in the information display indicating which door(s), etc is
not completely closed.
At higher speeds
If the car is moving at a speed above approximately 4 m.p.h. (7 km/h), the Warning symbol in the
instrument panel will light up and a message will be shown in the information display indicating which door(s), etc is
not completely closed.
Hood and trunk
If the hood and/or trunk lid is not completely closed, the Information symbol in the instrument panel will
light up and a message will be displayed, regardless of the vehicle's speed.
pg. 43 Information display
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