engine VOLVO S40 2008 Service Manual

Do not connect the jumper cable to any part of the fuel system or to any moving parts. Avoid touching hot
manifolds.
Batteries generate hydrogen gas, which is flammable and explosive.
Battery fluid contains sulfuric acid. Do not allow battery fluid to contact eyes, skin, fabrics or painted surfaces. If
contact occurs, flush the affected area immediately with water. Obtain medical help immediately if eyes are affected.
Never expose the battery to open flame or electric spark.
Do not smoke near the battery.
Failure to follow the instructions for jump starting can lead to personal injury.
Do not touch the jumper cables during the attempt to start the vehicle. This could cause sparks.
154 06 Starting and driving
Towing a trailer
General information
Volvo recommends the use of Volvo trailer hitches that are specially designed for the vehicle.
CAUTION
Models equipped with the B5244S7 engine (engine code 39, which is the 6th and 7th digits from the left in your
vehicle's VIN number, see page 249
for the location of the VIN plate), may not be used to tow trailers or vehicles of
any kind. This could cause damage to the vehicle's emission control systems.
Maximum trailer weights recommended by Volvo are:
Trailers without brakes: 1,540 lbs (700 kg).
Trailers with brakes: 2,000 lbs (900 kg) Observe the legal requirements of the state/province in which the vehicles
are registered.
The maximum recommended hitch tongue load is 165 lbs (75 kg).
All Volvo models are equipped with energy-absorbing shock-mounted bumpers. Trailer hitch installation should not
interfere with the proper operation of this bumper system.
Trailer towing does not normally present any particular problems, but take into consideration:
Increase tire pressure to recommended full. See the chapter "Wheels and tires."
When your vehicle is new, avoid towing heavy trailers during the first 620 miles (1,000 km).
Maximum speed when towing a trailer: 50 m.p.h. (80 km/h).
Engine and transmission are subject to increased loads. Therefore, engine coolant temperature should be closely
watched when driving in hot climates or hilly terrain. Use a lower gear and turn off the air conditioner if the
temperature gauge needle enters the red range.
If the automatic transmission begins to overheat, a message will be displayed in the information display.
Avoid overload and other abusive operation.
Hauling a trailer affects handling, durability, and economy.
It is necessary to balance trailer brakes with the towing vehicle brakes to provide a safe stop (check and observe
state/local regulations).
Do not connect the trailer's brake system directly to the vehicle's brake system.
More frequent vehicle maintenance is required.
Remove the ball and drawbar assembly when the hitch is not being used.
Volvo recommends the use of synthetic engine oil when towing a trailer over long distances or in mountainous
areas.
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WARNING
Bumper-attached trailer hitches must not be used on Volvos, nor should safety chains be attached to the bumper.
Trailer hitches attaching to the vehicle's rear axle must not be used.
Never connect a trailer's hydraulic brake system directly to the vehicle brake system, nor a trailer's lighting system
directly to the vehicle lighting system. Consult your nearest trained and qualified Volvo service technician for correct
installation.
When towing a trailer, the trailer's safety wire must be correctly fastened to the hole or hook provided in the
trailer hitch on the vehicle. The safety wire should never be fastened to or wound around the drawbar ball.
155 06 Starting and driving
Towing a trailer
NOTE
When parking the vehicle with a trailer on a hill, apply the parking brake before putting the gear selector in Park
( P ) or in reverse on models with a manual transmission. Always follow the trailer manufacturer's recommendations
for wheel chocking.
If you use the manual (Geartronic) shift positions while towing a trailer, or if the vehicle is equipped with a
manual transmission, make sure the gear you select does not put too much strain on the engine (using too high a
gear).
The drawbar assembly/trailer hitch may be rated for trailers heavier than the vehicle is designed to tow. Please
adhere to Volvo's recommended trailer weights.
Avoid driving with a trailer on inclines exceeding 15%.
156 06 Starting and driving
Detachable trailer hitch
Installing the ball holder
1. If necessary, remove the cotter pin from the locking bolt and slide the locking bolt out of the hitch assembly.
2. Slide the ball holder into the hitch assembly.
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3. Align the hole in the ball holder with the one in the hitch assembly.
4. Slide the locking bolt through the hitch assembly/ball holder.
5. Insert the cotter pin in the hole at the end of the locking bolt.
Removing the ball holder
1. Remove the cotter pin from the locking bolt and slide the locking bolt out of the ball holder/hitch assembly.
2. Pull the ball holder out of the hitch assembly.
NOTE
A cover for the hitch assembly is also included in the kit.
157 06 Starting and driving
Transporting loads
Loading the car
Your vehicle's load-carrying capacity is affected by factors such as:
the number of passengers
tire inflation
the amount of optional or accessory equipment installed
the amount of cargo
See the chapter "Wheels and tires" for more detailed information.
Before loading the car, turn off the engine, and apply the parking brake when loading or unloading long objects. The
gear selector can be inadvertently knocked out of position by long cargo, causing the car to move.
Keep the following in mind when loading the vehicle:
Load the cargo in the cargo area against the rear seat backrest.
Load heavy cargo as low as possible.
Center wide loads.
Secure all cargo with restraining straps anchored to the load securing eyelets.
Cover sharp edges on the load.
Seats can be folded down and head restraints removed to extend the cargo compartment. See page 107.
WARNING
Remember that an object weighing 44 lbs (20 kg) produces a force of 2,200 lbs (1,000 kg) in a head-on collision
at 30 m.p.h. (50 km/h)!
When the rear backrest(s) are folded down, the vehicle should not be loaded to a level higher than 2 in. (5 cm)
below the upper edge of the rear side windows. Objects placed higher than this level could impede the function of
the Volvo Inflatable Curtain.
Load carriers (accessory)
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The system is activated automatically when the vehicle is started. The indicator light in the button in the center console
illuminates.
The front park assist system is active from the time the engine is started until the vehicle exceeds a speed of
approximately 10 mph (15 km/h). It is also active when the vehicle is backing up.
Rear park assist is active when the engine is running and reverse gear has been selected.
Rear park assist
The distance monitored behind the vehicle is approximately 5 ft (1.5 m). The signal comes from the rear speakers.
The system must be deactivated when towing a trailer, carrying bicycles in a rear-mounted carrier, etc, which could
trigger the rear park assist system's sensors.
NOTE
Rear park assist is deactivated automatically when towing a trailer if Volvo genuine trailer wiring is used.
Front park assist
The distance monitored in front of the vehicle is approximately 2.5 ft (0.8 m). The audible signal comes from the audio
system's front speakers.
It may not be possible to combine auxiliary headlights and front park assist since these lights could trigger the system's
sensors.
163 06 Starting and driving
Park assist (option/accessory)
Activating/deactivating park assist
The system is activated automatically when the vehicle is started.
If the vehicle is equipped with both front and rear park assist , press the park assist button on the center console
(see the illustration) to temporarily turn off (deactivate) the systems. The indicator light in the button will go out when
the system has been switched off.
If the vehicle is equipped with rear park assist only , a message will be displayed when reverse gear is selected
showing if the system is on or off. Press EXIT to turn rear park assist off, or ENTER to turn the system on.
Park assist will be automatically reactivated the next time the engine is started, or if the button is pressed (the
indicator light in the button will illuminate).
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2 0 0 8
VOLVO S40
190 08 Car care
Washing and cleaning the car 192
Paint touch up196
191 08 Car care
192 08 Car care
Washing and cleaning the car
Washing the car
The following points should be kept in mind when washing and cleaning the car:
The car should be washed at regular intervals since dirt, dust, insects and tar spots adhere to the paint and may cause
damage. To help prevent corrosion, it is particularly important to wash the car frequently in the wintertime when salt
has been used on the roads.
Avoid washing your car in direct sunlight. Doing so may cause detergents and wax to dry out and become abrasive.
To avoid scratching, use lukewarm water to soften the dirt before you wash with a soft sponge, and plenty of sudsy
water.
Bird droppings : Remove from paintwork as soon as possible. Otherwise the finish may be permanently damaged.
A detergent can be used to facilitate the softening of dirt and oil.
A water-soluble grease solvent may be used in cases of sticky dirt. However, use a wash place equipped with a
drainage separator.
Dry the car with a clean chamois and remember to clean the drain holes in the doors and rocker panels.
Tar spots can be removed with kerosene or tar remover after the car has been washed.
A stiff-bristle brush and lukewarm soapy water can be used to clean the wiper blades. Frequent cleaning of the
windshield and wiper blades improves visibility considerably and also helps prolong the service life of the wiper
blades.
Wash off the dirt from the underside (wheel housings, fenders, etc).
In areas of high industrial fallout, more frequent washing is recommended.
After cleaning the engine, the spark plug wells should be inspected for water and blown dry if necessary.
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NOTE
When washing the car, remember to remove dirt from the drain holes in the doors and sills.
Exterior components
Volvo recommends the use of special cleaning products, available at your Volvo retailer, for cleaning colored plastic,
rubber, or ornamental components such as chromed strips on the exterior of your vehicle. The instructions for using
these products should be followed carefully.Solvents or stain removers should not be used.
CAUTION
Avoid waxing or polishing plastic or rubber components
Polishing chromed strips can wear away or damage the surface
Polishes containing abrasive substances should not be used
193 08 Car care
Washing and cleaning the car
NOTE
During high pressure washing, the spray mouthpiece must never be closer to the vehicle than 13" (30 cm). Do not
spray into the locks.
Dirt, snow, etc., on the headlights can reduce lighting capacity considerably. Clean the headlights regularly, for
example when refueling.
When washing or steam cleaning the engine, avoid spraying water or steam directly on the electrical components
or toward the rear side of the engine. Special moonroof cautions:
Always close the moonroof and sun shade before washing your vehicle.
Never use abrasive cleaning agents on the moonroof.
Never use wax on the rubber seals around the moonroof
Automatic washing - simple and quick
We do NOT recommend washing your car in an automatic wash during the first six months (because the paint will not
have hardened sufficiently). 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.
CAUTION
Before driving into an automatic car wash, turn off the optional rain sensor to avoid damaging the windshield
wipers.
Make sure that side view mirrors, auxiliary lamps, etc, are secure, and that any antenna(s) are retracted or
removed. Otherwise there is risk of the machine dislodging them.
Chromed wheels : Clean chrome-plated wheels using the same detergents used for the body of the vehicle.
Aggressive wheel-cleaning agents can permanently stain chrome-plated wheels.
WARNING
When the car is driven immediately after being washed, apply the brakes several times in order to remove any
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moisture from the brake linings.
Engine cleaning agents should not be used when the engine is warm. This constitutes a fire risk.
Exterior lighting
Condensation may form temporarily on the inside of the lenses of exterior lights such as headlights, fog lights, or
taillights. This is normal and the lights are designed to withstand moisture. Normally, condensation will dissipate after
the lights have been on for a short time.
Polishing and Waxing
Normally, polishing is not required during the first year after delivery, however, waxing may be beneficial.
Before applying polish or wax the vehicle 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 a dull surface.
A wide range of polymer-based 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.
194 08 Car care
Washing and cleaning the car
Do not polish or wax your vehicle in direct sunlight (the surface of the vehicle should not be warmer than 113° F
(45° C).
CAUTION
Volvo does not recommend the use of long-life or durable paint protection coatings, some of which may claim to
prevent pitting, fading, oxidation, etc. These coatings have not been tested by Volvo for compatibility with your
vehicle's clear coat. Some of them may cause the clear coat to soften, crack, or cloud. Damage caused by application
of paint protection coatings may not be covered under your vehicle's paint warranty.
Upholstery care
Fabric
Clean with soapy water or a detergent. For more difficult spots caused by oil, ice cream, shoe polish, grease, etc., use a
clothing/fabric stain remover. Consult your Volvo retailer.
Interior plastic components
Cleaning interior plastic components should be done with a cleaning agent specially designed for this purpose. Consult
your Volvo retailer.
Alcantera™ suede-like material
Suede -like upholstery can be cleaned with a soft cloth and mild soap solution.
Leather care
Volvo's leather upholstery is manufactured with a protectant to repel soiling. Over time, sunlight, grease and dirt can
break down the protection. Staining, cracking, scuffing, and fading can result.
Volvo offers an easy-to-use, non-greasy leather care kit formulated to clean and beautify your vehicle's leather, and to
renew the protective qualities of its finish. The cleaner removes dirt and oil buildup. The light cream protectant
restores a barrier against soil and sunlight.
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2 0 0 8
VOLVO S40
198 09 Maintenance and servicing
Volvo maintenance 200
Maintaining your car201
Hood203
Engine compartment204
Engine oil205
Fluids206
Wiper blades208
Battery209
Replacing bulbs211
Fuses220
199 09 Maintenance and servicing
200 09 Maintenance and servicing
Volvo maintenance
General
Volvo advises you to follow the maintenance program outlined in the Warranty and Service Records Information
booklet. This maintenance program contains inspections and services necessary for the proper function of your vehicle.
The maintenance services contain several checks that require special tools and training, and therefore must be
performed by a qualified technician. To keep your Volvo in top condition, specify time-tested and proven Genuine
Volvo Parts and Accessories.
The Federal Clean Air Act - U.S.
The Federal Clean Air Act requires vehicle manufacturers to furnish written instructions to the ultimate purchaser to
assure the proper servicing and function of the components that control emissions. These services, which are listed in
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Each time the car is refueled:
Check the engine oil level
Clean the windshield, windshield wipers, headlights, and taillights
Monthly:
Check cold tire pressure in all tires. Inspect the tires for wear.
Check that engine coolant and other fluid levels are between the indicated "min" and "max" markings.
Clean interior glass surfaces with a glass cleaner and soft paper towels.
Wipe driver information displays with a soft cloth.
Visually inspect battery terminals for corrosion. Corrosion may indicate a loose terminal connector, or a battery near
the end of its useful service life. Consult a trained and qualified Volvo service technician for additional information.
As needed:
Wash the car, including the undercarriage, to reduce wear that can be caused by a buildup of dirt, and corrosion that
can be caused by salt residues.
Clean leaves and twigs from air intake vents at the base of the windshield, and from other places where they may
collect.
NOTE
Complete service information for qualified technicians is available online for purchase or subscription at
www.volvotechinfo.com
.
202 09 Maintenance and servicing
Maintaining your car
Emission inspection readiness
What is an Onboard Diagnostic System (OBD II)?
OBD II is part of your vehicle's computerized engine management system. It stores diagnostic information about your
vehicle's emission controls. It can light the Check Engine light (MIL) if it detects an emission control "fault." A "fault"
is a component or system that is not performing within an expected range. A fault may be permanent or temporary.
OBD II will store a message about any fault.
How Do States Use OBD II for Emission Inspections?
Many states connect a computer directly to a vehicle's OBD II system. The inspector can then read "faults." In some
states, this type of inspection has replaced the tailpipe emission test.
How Can My Vehicle Fail OBD II Emission Inspection ?
Your vehicle can fail OBD II emission inspection for any of the following reasons.
If your Check Engine (MIL) light is lit, your vehicle may fail inspection.
If your vehicle's Check Engine light was lit, but went out without any action on your part, OBD II will still have a
recorded fault. Your vehicle may pass or fail, depending on the inspection practices in your area.
If you had recent service that required disconnecting the battery, OBD II diagnostic information may be incomplete
and "not ready" for inspection. A vehicle that is not ready may fail inspection.
How Can I Prepare for My Next OBD II Emission Inspection ?
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If your Check Engine (MIL) light is lit - or was lit but went out without service, have your vehicle diagnosed and, if
necessary, serviced by a qualified Volvo technician.
If you recently had service for a lit Check Engine light, or if you had service that required disconnecting the battery,
a period of driving is necessary to bring the OBD II system to "ready" for inspection. A half-hour trip of mixed stop-
and -go/highway driving is typically needed to allow OBD II to reach readiness. Your Volvo retailer can provide you
with more information on planning a trip.
Maintain your vehicle in accordance with your vehicle's maintenance schedule.
203 09 Maintenance and servicing
Hood
Opening the hood
To open the hood:
1. Pull the lever located under the left side of the dash to release the hood lock.
2. Lift the hood slightly.
3. Press up the release control located under the front edge of the hood (at the center) up to the right, and lift the hood.
WARNING
Check that the hood locks engage properly when closed.
204 09 Maintenance and servicing
Engine compartment
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