service VOLVO S40 2008 Workshop Manual

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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4. Connect the positive cable.
5. Connect the ground cable.
6. Reinstall the cover over the battery.
NOTE
Used batteries should be properly disposed of at a recycling station or similar facility, or taken to your Volvo
retailer.
WARNING
Never expose the battery to open flame or electric spark.
Do not smoke near the battery.
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.
211 09 Maintenance and servicing
Replacing bulbs
Introduction
Before replacing bulbs in your vehicle, please keep the following points in mind:
NOTE
Never touch the glass of bulbs with your fingers. Grease and oils from your fingers vaporize in the heat and will
leave a deposit on the reflector, which will damage it.
The optional Bi -Xenon® headlight bulbs contain trace amounts of mercury. These bulbs should always be
disposed of by an authorized Volvo retailer.
Certain bulbs should only be replaced by a trained and qualified Volvo service technician:
- Courtesy (dome) lighting
- Reading lights
- Glove compartment lights
- Turn signals and courtesy lights in the side door mirrors
- High-mounted brake lights
- Bi -Xenon® headlights
- Brake lights
212 09 Maintenance and servicing
Replacing bulbs
Removing the headlight housing
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The entire headlight housing must be lifted out when replacing the high/low beam, parking light, turn signal, and side
marker bulbs. To lift out the housing:
1. Remove the key from the ignition and turn the headlight switch to position 0.
2. Open the hood.
3. Pull up the headlight housing's retaining pin (1).
4. Pull the headlight housing to one side and then forward (2).
5. Disconnect the wiring connector by pressing down clip (3) with your thumb while at the same time pulling the
connector (4) with your other hand.
6. Lift out the headlight housing and place it on a soft surface to avoid scratching the lens.
After the defective bulb has been replaced, reinsert the housing in the reverse order. Check that the retaining pin is
correctly inserted.
WARNING
Bi -Xenon® headlights (option) - due to the high voltage used by these headlights, these bulbs should only be
replaced by a trained and qualified Volvo service technician.
213 09 Maintenance and servicing
Replacing bulbs
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1. Open the hood.
2. Remove the headlight housing (see page 212
).
3. Remove the cover on the upper side of the headlight housing by turning it counterclockwise.
4. Driver's side headlight: Turn the bulb holder counterclockwise.
Passenger's side headlight: Turn the bulb holder clockwise.
214 09 Maintenance and servicing
Replacing bulbs
NOTE
The halogen high beam bulb has a different socket on vehicles equipped with Bi -Xenon® headlights. On these
models, pull the bulb straight out.
WARNING
Bi -Xenon® headlights (option) - due to the high voltage used by these headlights, the Bi -Xenon® bulbs should only
be replaced by an authorized Volvo service technician.
5. Pull out the bulb holder and replace the bulb.
6. Reinstall the bulb holder. It can only be installed in one position.
7. Reinstall the cover on the upper side of the headlight housing by turning it clockwise.
8. Reinstall the headlight housing.
Parking light bulb
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3. Grasp the edge of the panel and pull it straight out.
4. Unscrew the screw in the fog light housing and remove it.
5. Turn the bulb counterclockwise and remove it.
6. Insert a new bulb by turning it clockwise (the profile on the bulb holder will correspond with the profile in the base
of the bulb).
7. Reinsert the bulb holder. The mark TOP should be upward.
217 09 Maintenance and servicing
Replacing bulbs
Removing the taillight bulb holder
All bulbs in the taillight cluster can be replaced from the cargo area. To access the bulb holders:
1. Switch off all lights and turn the key to position 0.
2. Remove the covers in the left/right panels to access the bulb holders.
3. Disconnect the wiring connector from the affected bulb holder.
4. Press the catches together and pull out the bulb holder.
5. Replace the defective bulb.
6. Press the wiring connector back into position.
7. Press the bulb holder into place and reinstall the cover.
NOTE
If the message indicating a burned out bulb remains in the information display after the bulb has been replaced,
consult a trained and qualified Volvo service technician.
Location of taillight bulbs
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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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1FWD = Front Wheel Drive
2AWD = All Wheel Drive
3Models 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.
252 11 Specifications
Dimensions and weights
Specifications and capacities
NOTE
The transmission oil does not normally need to be changed during the service life of the vehicle. However, it may be
necessary to replace the oil if the vehicle is often driven in areas of sustained temperature extremes (hot or cold),
when towing a trailer over long distances, for prolonged driving in mountainous areas, or if the vehicle is often
driven short distances in temperatures under 40°F (5°C).
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253 11 Specifications
Engine oil
Oil specifications
Engine oil must meet the minimum ILSAC specification GF-3, API SL, or ACEA A1/B1. Lower quality oils may not
offer the same fuel economy, engine performance, or engine protection.
Volume: 6.1 US qts (5.8 liters).
Volume between the MIN and Max marks on the dipstick: approximately 1.4 US qts (1.3 liters).
Volvo recommends Castrol.
Depending on your driving habits, premium or synthetic oils may provide superior fuel economy and engine
protection. Consult your Volvo retailer or a trained and qualified Volvo service technician for recommendations on
premium or synthetic oils.
Oil additives must not be used.
NOTE
Synthetic oil is not used when the oil is changed at the normal service intervals. This oil is only used at customer
request, at additional charge. Please consult a trained and qualified Volvo service technician.
Oil viscosity (stable ambient temperatures)
Operation in hot climates
When temperatures exceed 104° F (40° C) in your area, Volvo recommends, for the protection of your engine, that you
use a heavier weight oil, such as such as SAE 5W -40 or 0W -40. See the viscosity chart.
Operation in temperate climates
Incorrect viscosity oil can shorten engine life. Under normal use when temperatures do not exceed 104° F (40° C),
SAE 5W -30 will provide good fuel economy and engine protection. See the viscosity chart.
Extreme engine operation
Synthetic oils meeting SAE 0W -30 or 0W -40 and 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, and for
prolonged driving in mountainous areas.
254 11 Specifications
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Engine oil
American Petroleum Institute (API) symbol
The API Service Symbol "donut" is divided into three parts:
The upper section describes the oil's performance level.
The center identifies the oil's viscosity.
The lower section indicates whether the oil has demonstrated energy-conserving properties in a standard test in
comparison to a reference oil.
1See the information on page 254.
255 11 Specifications
Engine specifications
1The engine specifications for horsepower and torque listed in this table are based on the use of premium fuel.
Charge air cooler (Intercooler)
Turbocharged engines employ a turbo-compressor to force air into the engine inlet manifold and a charge air cooler to
cool the compressed inlet air. The resulting increase in air flow raises pressure in the intake manifold and increases
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