VOLVO S40 2004 Service Manual
Manufacturer: VOLVO, Model Year: 2004, Model line: S40, Model: VOLVO S40 2004Pages: 89, PDF Size: 2.05 MB
Page 41 of 89
and should never be rotated from one side of the vehicle to the other.
pg. 83 Wheels and tires
Uniform tire quality grading
ALL PASSENGER CAR TIRES MUST CONFORM TO FEDERAL SAFETY REQUIREMENTS IN
ADDITION TO THESE GRADES
TREADWEAR
The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions
on a specified government test course. For example, a tire graded 150 would wear one and one half (1 1/2) times as
well on the government course as a tire graded 100. The relative performance of tires depends upon the actual
conditions of their use, however, and many depart significantly from the norm due to variation in driving habits,
service practices and differences in road characteristics and climate.
TRACTION
The traction grades, from highest to lowest, are AA, A, B, and C, as measured under controlled conditions on specified
government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance.
WARNING!
The traction grade assigned to this tire is based on braking (straight-ahead) traction tests and does not reflect
cornering (turning) traction.
TEMPERATURE
The temperature grades are AA (the highest), A, B, and C, representing the tire's resistance to the generation of heat
and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel.
Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive
temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car
tires must meet under the Federal Motor Safety Standard No. 109. Grades B and A represent higher levels of
performance on the laboratory test wheel than the minimum required by law.
UNIFORM TIRE QUALITY GRADING
LOCATING THE GRADE
Quality grades can be found where applicable on the tire sidewall between tread shoulder and maximum section width.
Treadware 200 Traction AA Temperature A
WARNING!
The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive
speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible
tire failure.
pg. 84 Spare tire
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Special Spare
The spare tire in your car is called a "Special Spare". It has the following designation: 125/90 R15 96M.
Recommended tire pressure (see the bottom line of the decal on the fuel filler door) should be maintained irrespective
of which position on the car the Special Spare tire is used.
In the event of damage to this tire, a new one can be purchased from your Volvo retailer.
CAUTION: The car must not be driven with wheels of different dimensions or with a spare tire other than the one that
came with the car. The use of different size wheels can seriously damage your car's transmission.
WARNING!
Current legislation prohibits the use of the "Special Spare" tire other than as a temporary replacement for a punctured
tire. In other words, it must be replaced as soon as possible by a standard tire. Roadholding, etc., may be affected
with the "Special Spare" in use. Do not, therefore, exceed 50 mph (80 km/h).
CAUTION: We recommend that you switch the DSA system off whenever you use the "Special Spare" tire that does
not match the diameter of your other tires. See page 30
.
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2 0 0 4
VOLVO
S40 & V40
Chapter 6 - In case of an emergency
pg. 85 In case of an emergency
In case of an emergency
Even if you maintain your car in good running condition, there is always the possibility that something might go wrong
and prevent you from driving, such as a punctured tire, blown fuse or bulb, etc. For additional information, see section
"ON CALL Road Assistance" in chapter 9
.
Tool kit, Jack
86
Tire changing87
Replacing bulbs89
Replacing fuses95
Replacing wiper blades98
In case of emergency99
Manually closing the moonroof100
pg. 86 Tool kit, Jack
Tool kit and jack
The tool kit and jack are under the carpet in the cargo space floor, next to the spare wheel.
Contents of tool kit
1. Combined screwdriver/socket wrench
2. Lug wrench
3. Crank (for the jack)
4. Gloves
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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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Get all the passengers to move to a safe place outside the car.
Close all doors.
Block the wheels remaining on the ground with wooden blocks, stones or something similar.
With the car still on the ground, use the lug wrench to loosen the wheel lugs 1/2 - 1 turn. Position the lug wrench so
that you apply force in a downward direction. Never lift up on the lug wrench to loosen or tighten lugs.
Turn the bolts counterclockwise to loosen. If necessary, press down on the lug wrench with your foot to loosen the
lugs.
CAUTION:
The car must not be driven with wheels of different dimensions or with a spare tire other than the one that came
with the car. The use of different size wheels can seriously damage your car's transmission.
pg. 88 Wheel changing
Attaching the jack
There are two jack attachment points located on each side of the car. These attachment points are marked by arrows on
the outside of the cover over the bottom sill (see illustration).
Check that the doors are closed and stay closed all the time the car is jacked up.
Position the jack under the two notches closest to the wheel to be changed.
Attach the crank to the jack (A).
Attach the lug wrench (B) to the crank.
Raise the jack by cranking it clockwise. Be sure the jack engages the attachment point correctly.
The base of the jack must be flat on a level, firm, non-slippery surface. Before raising the car, check that the
jack is still correctly positioned in the attachment point.
Raise the car until the wheel to be changed is lifted off the ground.
Unscrew the wheel bolts completely and carefully remove the wheel so as not to damage the thread on the studs.
WARNING!
The jack must be correctly placed in the jack attachment.
Installing the wheel
Clean the contact surfaces on the wheel and hub.
Lift the wheel and place it on the hub.
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Install the wheel lugs and tighten handtight.
Using the lug wrench. Tighten crosswise until all lugs are snug.
Lower the vehicle to the ground and alternately tighten the lugs crosswise to 81 ft. lbs. (110 Nm).
Install the wheel cover (where applicable).
CAUTION:
Correct tightening torque on wheel lugs must be observed. The wheel lugs should never be greased or lubricated.
Extended, chromed wheel lugs must not be used with steel rims, as they make it impossible to fit the hub caps.
pg. 89 Replacing bulbs
Removing high/low beam headlight bulbs
Your car is fitted with separate high and low beam bulbs.
Switch off the lights and remove the ignition key.
Open the hood.
Pull off the rubber cover from the rear of the bulb unit to be replaced.
Release the retaining spring and withdraw the connector/bulb from the headlight unit. Pull the bulb out of the
connector.
NOTE: Never touch the glass of a bulb with your fingers: this could leave traces of grease or oil on the glass which
then evaporate and may damage the reflector.
pg. 90 Replacing bulbs
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Installing high/low beam headlight bulbs
Insert the new bulb in the headlight unit
Reconnect the connector and wiring.
Press the retaining spring over the connector/bulb until it clicks into position.
Reinstall the rubber cover at the rear of the headlight unit.
Put the hard plastic cover in place above the headlight housing and press the tab down to secure the cover.
NOTE: Never touch the glass of a bulb with your fingers: this could leave traces of grease or oil on the glass which
then evaporate and may damage the reflector.
pg. 91 Replacing bulbs
Front direction indicators and parking lights
Removing the bulb:
Loosen the screw (A) between the headlight and direction indicator housings (max. 2 complete turns
counterclockwise), using the screwdriver supplied in the tool kit.
Press clip (D) and move the direction indicator housing forward.
With the wiring still attached, turn bulb holder slightly counterclockwise and withdraw it from the lamp housing.
Pull the bulb to remove.
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Replacement
Insert a new bulb in the holder.
Re-insert the bulb holder in the lamp housing and turn it clockwise until it clicks into place.
Press the lamp housing into place.
Make sure than locating pin (B) fits into the hole in the fender and slotted hole (C) around the screw.
Tighten the screw.
pg. 92 Replacing bulbs
Replacement of rear light bulbs - S40
All the bulbs in the rear light unit are replaced from inside the trunk
Procedure:
Switch off the lights and remove the ignition key.
Turn the clip 90° and pull it out. Fold the panel in the boot towards the middle so as to get access to the bulb
holders.
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 panel.
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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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Insert screwdriver, turn and pull downward
Front courtesy lights
Switch off the ignition.
Insert a flat screwdriver and turn carefully to loosen the glass lens.
Replace the bulb and press the glass lens back into place.
Insert a screwdriver and turn
Rear reading lights
Switch off the ignition.
Insert a screwdriver and turn to loosen the lens unit.
Replace the bulb and press the lens unit back into place.
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