engine VOLVO S40 2008 Workshop Manual

1. Cooling system expansion tank
2. Power steering fluid reservoir (concealed behind the headlight)
3. Dipstick - engine oil
4. Radiator
5. Cooling fan
6. Washer fluid reservoir
7. Engine oil filler cap
8. Brake/clutch fluid reservoir
9. Battery
10. Relay/fuse box
11. Air cleaner
WARNING
The cooling fan may start or continue to operate (for up to 6 minutes) after the engine has been switched off.
205 09 Maintenance and servicing
Engine oil
Changing engine oil and oil filter
See page 253
for oil specifications. Refer to the Warranty and Service Records Information booklet for information on
the oil change intervals.
Volvo recommends Castrol.
NOTE
Volvo does not recommend the use of oil additives.
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Synthetic oil is not used when the oil is changed at the normal maintenance intervals except at owner request and
at additional charge. Please consult a trained and qualified Volvo service technician.
Checking and adding oil
The oil level should be checked every time the vehicle is refueled. This is especially important during the period up to
the first scheduled maintenance service
The car should be parked on a level surface when the oil is checked.
If the engine is warm , wait for at least 10-15 minutes after the engine has been switched off before checking the oil.
Checking the oil
1. Pull out the dipstick and wipe it with a lint-free rag.
2. Reinsert the dipstick, pull it out, and check the oil level.
3. Add oil if necessary. If the level is close to the MIN mark, add approximately 1 US quart (1 liter) of oil.
4. Run the engine until it reaches normal operating temperature.
5. Switch off the engine and wait for at least 10-15 minutes and recheck the oil level. If necessary, add oil until the
level is near the MAX mark.
NOTE
Not checking the oil level regularly can result in serious engine damage if the oil level becomes too low.
Oil that is lower than the specified quality can damage the engine.
Always add oil of the same type and viscosity as already used.
Never fill oil above the MAX mark. This could cause an increase in oil consumption.
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206 09 Maintenance and servicing
Fluids
WARNING
Do not allow oil to spill onto or come into contact with hot exhaust pipe surfaces
NOTE
Volvo uses different systems to indicate a low oil level or pressure. Some models have an oil pressure sensor, in
which case a warning symbol (see page 54
) is used to indicate low oil pressure. Other models have an oil level
sensor, in which case the driver is alerted by the warning symbol in the center of the instrument panel and a text in
the information display. Some models use both systems. Contact an authorized Volvo retailer for more information.
Washer fluid
The washer fluid reservoir is located in the engine compartment and holds approximately 6.8 US qts (6.5 liters).
During cold weather, the reservoir should be filled with windshield washer solvent containing antifreeze.
Coolant
Normally, the coolant does not need to be changed. If the system must be drained, consult a trained and qualified
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Volvo service technician.
NOTE
Do not top off with water only. This reduces the rust-protective and antifreeze qualities of the coolant and has a
lower boiling point. It can also cause damage to the cooling system if it should freeze. Top off with Volvo Genuine
Coolant/Antifreeze only (a 50/50 mix of water and antifreeze).
207 09 Maintenance and servicing
Fluids
CAUTION
The cooling system must always be kept filled to the correct level, and the level must be between the MIN and
MAX marks. If it is not kept filled, there can be high local temperatures in the engine which could result in damage.
Different types of antifreeze/coolant may not be mixed. Check coolant regularly!
WARNING
Never remove the radiator cap while the engine is warm. Wait until the vehicle cools. If it is necessary to top off the
coolant when the engine is warm, unscrew the expansion tank cap slowly so that the overpressure dissipates.
Brake fluid
The brake fluid should always be between the MIN and MAX marks on the side of the reservoir. Check, without
removing the cap, that there is sufficient fluid in the reservoir.
Fluid type: DOT 4+ boiling point >536°F (280°C), P/N 9437433
Replace: The fluid should be replaced according to the intervals specified in the Warranty and Service Records
Information booklet. When driving under extremely hard conditions (mountain driving, etc), it may be necessary to
replace the fluid more often. Consult your Volvo retailer. Always entrust brake fluid changing to a trained and
qualified Volvo service technician.
Power steering fluid
The fluid level is checked at each service interval.
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Driving habits and conditions, climate, the number of starts, etc., all affect the service life and function of the battery.
In order for your battery to perform satisfactorily, keep the following in mind:
Check the fluid level in each cell in the battery every 24 months or every 15,0001 miles (24,000 km), whichever is
sooner. The fluid should be at the level shown in the illustrations above (A). Do not overfill.
1More frequently in warm climates.
Use a screw driver to open the caps or cover and a flashlight to inspect the level.
If necessary, add distilled water. The level should never be above the indicator (A).
The fluid level should be checked if the battery has been recharged.
After inspection, be sure the cap over each battery cell or the cover is securely in place.
Check that the battery cables are correctly connected and properly tightened.
Never disconnect the battery when the engine is running, or when the key is in the ignition. This could damage the
vehicle's electrical system.
The battery should be disconnected from the vehicle when a battery charger is used directly on the battery.
WARNING
PROPOSITION 65 WARNING!
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of
California to cause cancer and reproductive harm. Wash hands after handling.
210 09 Maintenance and servicing
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Battery
Battery symbols
Battery replacement
Removing the battery
1. Switch off the ignition and remove the key.
2. Wait at least 5 minutes after switching off the ignition before disconnecting the battery so that all information in the
vehicle's electrical system can be stored in the control modules.
3. Remove the cover over the battery.
4. Disconnect the battery negative (ground) cable.
5. Disconnect the positive cable.
6. Remove the front side of the battery box with a screwdriver.
7. Release the clamp holding the battery.
8. Lift out the battery.
Installing a new battery
1. Put the battery in place in the engine compartment.
2. Install the battery's retaining clamp.
3. Reinstall the front side of the battery box.
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Replacing bulbs
Vanity mirror lighting
1. Insert a screwdriver under the center of the lower edge of the mirror, turn it, and carefully pry up the lugs at the
edge.
2. Move the screwdriver under the edge on the left and right-hand sides (near the black rubber sections) and pry
carefully to release the lower edge of the mirror.
3. Pry carefully and lift out the entire mirror and the cover.
4. Remove the defective bulb and replace it with a new one.
5. To reinstall the mirror, begin by pressing the three lugs at the upper edge of the mirror back into place.
6. Press the three lower lugs back into place.
220 09 Maintenance and servicing
Fuses
Replacing fuses
There are relay/fuse boxes located in the engine compartment and the passenger compartment.
If an electrical component fails to function, this may be due to a blown fuse. The easiest way to see if a fuse is blown
is to remove it.
To do so:
1. Pull the fuse straight out. If a fuse is difficult to remove, special fuse removal tools are located on the inside of the
fuse box covers.
2. From the side, examine the curved metal wire in the fuse to see if it is intact.
3. If the wire is broken, insert a new fuse of the same color and amperage (written on the fuse).
If fuses burn out repeatedly, have the electrical system inspected by a trained and qualified Volvo service technician.
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WARNING
Never use metal objects or fuses with higher amperage than those stated on the following pages. Doing so could
seriously damage or overload the vehicle's electrical system.
221 09 Maintenance and servicing
Fuses
Fuse box in the engine compartment
The fuse box in the engine compartment has positions for 36 fuses.
Fuses 1-18 are relays/circuit breakers and should only be removed or replaced by an authorized Volvo service
technician.
Fuses 19-36 may be changed at any time when necessary.
Several extra fuses and a fuse removal tool to assist in removing/replacing fuses can be found on the underside of the
fuse box cover in the engine compartment.
222 09 Maintenance and servicing
Fuses
Fuse box in the passenger compartment
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The fuse box in the passenger compartment is located under the glove compartment.
To access the fuses:
1. Remove the upholstery covering the fuse box by first pressing in the center pins in the mounting clips approximately
0.5 in (1cm) with a small screwdriver and then pulling the pins out.
2. Turn both retaining screws (2) counterclockwise until they release.
3. Fold down the fuse box (3) half way. Pull it toward the seat until it stops. Fold it down completely. The fuse box can
be unhooked completely.
4. Replace the blown fuse.
5. Close the fuse box in reverse order.
6. Pull the center pins fully out of the mounting clips, secure the upholstery with the mounting clips and press the pins
into the mounting clips again. The mounting clips then expand, holding the upholstery in position.
223 09 Maintenance and servicing
Fuses
Fuses in the engine compartment
224 09 Maintenance and servicing
Fuses
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VOLVO S40
246 11 Specifications
Label information 248
Dimensions and weights250
Engine oil253
Engine specifications255
Electrical system256
Volvo programs259
247 11 Specifications
248 11 Specifications
Label information
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