VOLVO S40 2000 Repair Manual

Tires3, check pressure, wear and conditionII II II I I I II I
Check power steering fluid level I I I I I
Body
Power antenna (clean) L L L L L L
Trunk/hood, hinges and latches L L L
Cabin air filter (see page 108
) R R R R R R
1) Replace at 105,000 miles (168,000 km)
2) Brake fluid should be changed at owner request every second year or 30,000 miles (48,000 km). The fluid
should be replaced once a year or every 15,000 miles (24,000 km) when driving under extremely hard
conditions (mountain driving, etc.).
3) Rotate tires at owner request.
The following items should be checked weekly by the driver (it takes only a few minutes):
Engine oil level, brake fluid level, radiator coolant level, operation of all lights, horns, windshield wipers, tire
pressure (all five tires), windshield washer fluid level
The following should also be carried out at regular intervals:
Washing (check all drain holes), polishing, cleaning
pg. 108 Servicing
Air cleaner
Replace the air cleaner cartridge with a new one every 30,000 miles (48,000 km). The cartridge should be replaced
more often when driving under dirty and dusty conditions. The filter cannot be cleaned and therefore should always be
replaced with a new one.
Timing belt
For proper functioning of the vehicle and its emission control systems, the timing belt and tensioner must be replaced
every 105,000 miles (168,000 km). Engine damage will occur if the belt fails.
Fuel system cap, tank and lines and connections
The effectiveness of the fuel system to contain hydrocarbons is dependent largely on a leakfree system. Check for
proper sealing of the fuel filler cap which contains "O" ring type 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
Lamp ("Check Engine") may indicate a fault. However, your vehicle's performance will not be affected. Use only
Volvo original or approved fuel filler caps.
Fuel (line) filter
For proper functioning of the vehicle and its emission control systems, the fuel line filter should be replaced at 105,000
miles (168,000 km). The filter is replaced as one complete unit. Replace more frequently if contaminated fuel is
introduced into the tank (or if there is reason to suspect that this has occurred).
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PCV system
The orifice nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be
inspected at 60,000 miles (96,000 km) and thereafter, at 30,000 mile (48,000 km) intervals.
Cabin air filter
Replace the cabin air filter with a new one according every 15,000 miles (24,000 km). Volvo recommends replacing
the filter more often if the car is driven under dirty and dusty conditions. The filter cannot be cleaned and therefore
should always be replaced with a new one.
pg. 109 Engine compartment
Engine compartment S40/V40
1 Power brakes
2 -
3 Brake fluid reservoir
4 Fusebox
5 Air cleaner
6 Battery
7 Oil dipstick, automatic transmission
8 Radiator
9 Oil filter
10 Charcoal canister (under fender)
11 Oil dipstick, engine
12 Generator
13 Windshield/headlight washer fluid reservoir
14 Power steering pump
15 Power steering fluid reservoir
16 Oil filler cap, engine
17 Expansion tank, coolant
18 Windshield wiper motor
19 Chassis number
A ABS
B Air conditioning compressor
C Condenser, air conditioning
D Accumulator, air conditioning
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WARNING!
The coolant fan may start or continue to operate (for up to 6 minutes) after the engine has been switched off.
pg. 110 Fuel/emissions systems
Fuel system
The fuel system is allelectronic and is microprocessorcontrolled. It can continually compensate for variation in engine
load, speed and temperature to give the best economy and power. A mass air flow sensor measures the inducted air. In
this way the system can make instantaneous adjustments for changes in air temperature or density, thus always
assuring the best economy with the lowest possible exhaust emissions.
Heated oxygen sensor
This is an emission control system designed to reduce emissions and improve fuel economy. The heated oxygen sensor
monitors the composition of the exhaust gases leaving the engine. The exhaust gas analysis is fed into an electronic
module. This adjusts the airfuel ratio to provide optimum conditions for combustion and efficient reduction of the three
major pollutants (hydrocarbons, carbon monoxide and oxides of nitrogen (NOx) by a threeway catalytic converter.
Secondary Air Injection (certain models)
This system adds air to the hot exhaust gases as they are expelled from the engine. This causes a secondary
combustion of residual hydrocarbons and carbon monoxide, resulting in lower emissions levels in the exhaust gases.
Crankcase ventilation
The engine is provided with positive crankcase ventilation which prevents crankcase gases from being released into the
atmosphere. Instead, the crankcase gases are admitted to the intake manifold and cylinders.
Evaporative control system
The car is equipped with an evaporative control system which prevents gasoline vapor from being released into the
atmosphere.
The system consists of a fuel tank with filler pipe and cap, a rollover valve, a Fill Limit Vent Valve (FLVV), vapor
vent lines, a charcoal canister, a purge line, a purge control valve and engine connections.
In addition, there is a pressure sensor connected to the fuel tank and a filter -protected Canister Close Valve (CCV) on
the atmospheric side of the canister, for system diagnosis.
The gasoline vapor is channeled through the rollover valve and the FLVV via the vapor vent lines into the charcoal
canister, where it is
stored. When the engine is started, the gasoline vapor is drawn from the charcoal canister to the engine's air intake
system and into the combustion process.
NOTE:
· If the fuel filler cap is not closed tightly or if the engine is running when the car is refueled, the Malfunction Indicator
Lamp may indicate a fault.
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· During a transitional period, a small number of service stations may still have fuel nozzles that are not compatible
with the fuel filler neck on cars equipped with the evaporative control system (ORVR) mandated by the U.S.
Environmental Protection Agency and the California Air Resources Board. If you experience difficulties in refueling
your vehicle, please ask the gas station attendant for assistance.
CAUTION:
Fuel must not be siphoned from the fuel tank. This will damage the Evaporative control system.

Contents | Top of Page
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2 0 0 0
VOLVO
S & V 40
Chapter 9 - Specifications
pg. 119 Specifications
Specifications
This chapter contains facts and figures pertaining to the technical specifications of your car. Oil/fluids specifications
120
Engine specifications121
Cooling/fuel/distributor ignition systems122
Front/rear suspensions122
Transmission, Capacities, Vehicle loading123
Electrical system/bulbs124
Weights125
Road assistance126
pg. 120 Oil/fluid specifications
Oil quality
Meeting API specification SJ, SJ/CF, or SJ/Energy Conserving.
For best fuel economy and engine protection, consult with your authorized Volvo retailer for recommended oils. Oil
with a different quality rating may not provide adequate engine protection.
Synthetic oils complying with oil quality requirements are recommended for: driving in areas of sustained temperature
extremes (hot or cold), when towing a trailer over long distances or for prolonged driving in mountainous areas.
Extra oil additives must not be used unless advised by an authorized Volvo retailer.
Viscosity (stable ambient temperatures):
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Engine oilQuality:
Meeting API specification SG or
SH Capacity (incl. filter)
: 5.7 US qts (5.4
liters)
Automatic transmission
fluid Quality:
ATF Dexron III and Mercon 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+ Capacity: 0.42 US qts. (0.4 liters)
All specifications are subject to change without notice.
pg. 121 Engine
Engine
Liquidcooled gasoline, 4-cylinder, inline engine. Aluminum alloy cylinder block with castiron 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. Fullflow 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 T2
Output 160 hp at 5100 rpm (118 kw at 5100 rpm)
Max torque 170 ft. lbs. at 1800-4800 rpm (230 Nm at 1800-4800 rpm)
Number of cylinders 4
Bore 3.27" (83 mm)
Stroke 3.54" (90 mm)
Displacement 1.95 liters
Compression ratio 9.0:1
Number of valves 16
All specifications are subject to change without notice.
pg. 122 Specifications
Cooling system
Type: Positive pressure, closed system
Thermostat begins to open at 186° F (90° C)
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Coolant: Volvo original coolant/antifreeze
Capacity: 6 US qts. (5.7 liters)
Fuel system
The engine is equipped with a multipoint fuel injection system.
Distributor ignition system
Firing order: 13-4-2
Distributor ignition setting: Not adjustable
Spark plugs: Champion RC8PYP or equivalent
Spark plug gap: 0.03" (0.75 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.
Replacing spark plugs
The spark plugs should be changed according to your service program in your Warranty booklet. However, city
driving or fast highway driving may necessitate changing after 15,000 miles (24,000 km) of driving. When installing
new plugs, be sure to fit the right type and use correct torque, see "Specifications". When changing the plugs, check
that the suppressor connectors are in good condition. Cracked or damaged connectors should be replaced. When
changing the spark plugs, clean the terminals and the rubber seals.
Front suspension
Spring strut suspension with integrated shock absorbers and control arms linked to the support frame. Powerassisted
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: 2,1 mm + - 0,7 mm
Toe-in measured on tire sides: 2,6 mm + - 0,8 mm
Rear suspension
Multilink individual rear wheel suspension with longitudinal support arms, double link arms and track rods.
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Toe-in measured on the tire sides: 2,6 mm + - 0,8 mm
pg. 123 Specifications
Power transmission
Automatic transmission: AW 50-42
4speed 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 2.76:1
Reduction ratios
1st gear 3.61:1
2nd gear 2.06:1
3rd gear 1.37:1
4th gear 0.98:1
Reverse 3.96:1
Capacities
Fuel tank : 16 US gal. (60 liters)
Cooling system : 6 US qts. (5,7 liters)
Engine oil (incl. filter) : 5.7 US qts. ( 5.4 liters)
Automatic transmission : 8 US qts (7.6 liters)
Power steering fluid : 1.05 US qts (1 liters)
Washer fluid reservoir : 3.9 US qts. (3.75 liters)
Brake system : 0.42 US qts (0.4 liters)
Vehicle loading
The tires on your Volvo should perform to specifications at all normal loads when inflated as recommended on the tire
information label. The label is located on the inside of the fuel filler flap. The label lists both tire and vehicle design
limits. Do not load your car beyond the load limits indicated.
WARNING!
Improperly inflated tires will reduce tire life, adversely affect vehicle handling and can possibly lead to failure
resulting in loss of vehicle control without prior warning.
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All specifications are subject to change without notice.
pg. 124 Specifications
Electrical system
12 Volt, negative ground.
Voltagecontrolled generator. Singlewire system with chassis and engine used as conductors.
Battery
Voltage: 12 Volt, capacity: 600 A/100 min
The battery contains corrosive and poisonous acids. It is of the utmost importance that old batteries are disposed of
correctly. Your Volvo retailer can assist you in this matter.
Generator
Rated output: 120 A
BulbsBulb US no.Power Socket No/bulbs
Headlights High beam55W H7 2
Low beam 55W H7 2
Parking lights and
Turn signals, front 3457NA26/7W/30/2.2cp W2.5 16q 2
Turn signals, rear 115621W/32cp BA 15 s 2
Side direction indicators -5W W 2.1x9.5 d 2
Tail lights 675W/4cp BA 15 s 4
Brake lights 115621W/32cp BA 15 s 2
Backup lights 115621W/32cp BA 15 s 2
Rear fog light 115621W/32cp BA 15 s 1
Front fog lights H355 W PK22.5 2
License plate light (S40) -5 W W 2.1x9.5 d 2
License plate light (V40) -5 W SV8.5 2
Door step courtesy lights -10W SV8.5 2
Trunk light -5 W SV 8.5 1
Vanity mirror lights -1.2 W SV5.5 2
Front courtesy lights -5 W SV5.5 2
Rear reading lights -5 W W 2.1x9.5 d 2
All specifications are subject to change without notice.
pg. 125 Specifications
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DimensionsLength S40/V40 176.4 in. (448 cm)
Width S40/V40 67.7 in. (172 cm)
Height S40/V40 55.5 in. (141 cm)
Wheel base S40/V40 100.4 in. (255 cm)
Track, front S40/V40 57.1 in. (145 cm)
Track, rear S40/V40 57.9 in. (147 cm)
Turning circle: S40/V40 34.1 ft. (11.2 m)
Cargo capacity: S40 (rear seat up) 39.8 in. (101 cm)
S40 (rear seat down) 68.5 in. (174 cm)
V40 (rear seat up) 40.2 in. (102 cm)
V40 (rear seat down) 68.9 in. (175 cm)
Max width of load opening 27.6 in. (67 cm)
Max height of load opening 20.1 in. (51 cm)
Weights Gross Vehicle Weight (GVW):
S40 4180 lbs (1896 kg)
V40 4340 lbs (1969 kg)
Capacity Weight:
S40 841 lbs (382 kg)
V40 837 lbs (380 kg)
Permissible axle weight, front:
S40 2093 lbs (950 kg)
V40 2093 lbs (950 kg)
Permissible axle weight, rear:
S40 1885 lbs (856 kg)
V40 1916 lbs (870 kg)
Permissible axle weight total:
S40 3921 lbs (1780 kg)
V40 3964 lbs (1800 kg)
Curb weight:
S40 2996 lbs (1360 kg)
V40 3040 lbs (1380 kg)
The max permissible axle loads or the gross vehicle weight must not be exceeded.
Max roof load * 220 lbs (100 kg)
Max trailer weight
(w/o brakes) 1100 lbs (500 kg)
(with brakes) 2000 lbs (908 kg)
Max tongue weight ** 110 lbs (50 kg)
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