VOLVO V4 2002 Repair Manual
Manufacturer: VOLVO, Model Year: 2002, Model line: V4, Model: VOLVO V4 2002Pages: 88, PDF Size: 2.34 MB
Page 61 of 88
Fuel filter
The fuel filter should be replaced at 105,000 miles (168,000 km). The filter is replaced as a complete unit. Replace
more frequently if contaminated fuel is introduced into the tank, or if there is reason to suspect that this has occurred.
Fuel system, including filler cap, tank and lines and connections
The ability of the fuel system to contain hydrocarbons depends upon a leak-free system. Inspect fuel lines every
30,000 miles (48,000 km).Check for proper sealing of the fuel filler cap which contains "O" ring 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
light ("Malfunction indicator") may indicate a fault. However, your vehicle's performance will not be affected. Use
only Volvo original or approved fuel filler caps.
Timing belt
For proper functioning of the vehicle and its emission control systems, the timing belt and belt tensioner must be
replaced every 105,000 miles (168,000 km). Engine damage will occur if the belt fails.
PCV system
(on turbocharged models)
The nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be inspected and
cleaned at 105,000 miles (168,000 km) and thereafter, again at 150,000 mile (240,000 km) intervals.
Spark plugs
The spark plugs should be replaced every 45,000 miles (72,000 km) under normal driving conditions. City driving or
fast highway driving may necessitate replacement sooner.
Under normal driving conditions, spark plugs require no maintenance between replacement intervals. When installing
new plugs, be sure to use the right type and to tighten them correctly. When changing the plugs, clean the terminals
and rubber seals. Also check that the suppressor connectors are in good condition. Cracked or damaged connectors
should be replaced.
pg. 111 Engine compartment
Engine compartment S40/V40
1 Power brakes
2 Brake fluid reservoir
3 Fusebox
4 Air cleaner
5 Battery
7 Radiator
8 Oil filter
10 Engine oil dipstick
11 Generator
12 Windshield/headlight washer fluid reservoir
13 Power steering pump
14 Power steering fluid reservoir
15 Engine oil filler cap
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16 Coolant expansion tank
17 Windshield wiper motor
18 Chassis number
A ABS
B Air conditioning compressor
C Air conditioning condenser
D Air conditioning accumulator
WARNING!
The coolant fan may start or continue to operate (for up to 6 minutes) after the engine has been switched off.
pg. 112 Fuel/emissions systems
Fuel system
The fuel system is all electronic and is microprocessor controlled. 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 air-fuel 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 three-way catalytic
converter.
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
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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
light may indicate a fault.
· 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.
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Page 64 of 88
2 0 0 2
VOLVO
S40 & V40
Chapter 9 - Specifications
pg. 121 Specifications
Specifications
This chapter contains facts and figures pertaining to the technical specifications of your car. Oil/fluids specifications
122
Engine specifications123
Cooling/fuel/distributor ignition systems124
Front/rear suspensions124
Transmission, Capacities, Vehicle loading125
Electrical system/bulbs126
Dimensions/weights127
Volvo ON CALL roadside assistance128
pg. 122 Oil/fluid specifications
Oil quality
Meeting minimum ILSAC specification GF-2, including ACEA A1, API SJ, SJ/CF and SJ/Energy Conserving.
Oil additives must not be used
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Engine oilQuality:
Meeting minimum ILSAC specification GF-2, including
ACEA A1, API SJ, SJ/CF and SJ/Energy Conserving.
Capacity (incl. filter) : 5.7
US qts (5.4 liters).
Capacity (excl. filter) : 5.3
US qts (5.0 liters)
Automatic
transmission
fluid Quality:
JWS-3309 P/N 1161540 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+ boiling point >536°F (280°C), P/N 9437433 Capacity:
0.42 US qts.
(0.4 liters)
All specifications are subject to change without notice.
pg. 123 Engine
Engine
Liquid-cooled, gasoline, inline, 4-cylinder, turbocharged engine. Aluminum alloy cylinder block with cast-iron
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. Full-flow 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 T3
Output 162 hp at 5100 rpm (121 kw at 5100 rpm)
Max torque 177 ft. lbs. at 1800-4800 rpm (240 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
Valve clearance mechanical
All specifications are subject to change without notice.
pg. 124 Specifications
Cooling system
Type: Positive pressure, closed system
Thermostat begins to open at 186° F (90° C)
Coolant: Volvo original coolant/antifreeze
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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.
Front suspension
Spring strut suspension with integrated shock absorbers and control arms linked to the support frame. Power assisted
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: 1.4 mm + - 0.2 mm
Toe-in measured on tire sides: 2.0 mm + - 0.4 mm
Rear suspension
Multilink individual rear wheel suspension with longitudinal support arms, double link arms and track rods.
Toe-in measured on the tire sides: 2.6 mm + - 0.8 mm
pg. 125 Specifications
Power transmission
Automatic transmission: AW 50-50
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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 2.70:1
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)
Engine oil (excl. filter) : 5.3 US qts. ( 5.0 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.
All specifications are subject to change without notice.
pg. 126 Specifications
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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 beam H755W - 2
Low beam H755W - 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. 127 Specifications
Dimensions Length S40/V40 178.0 in. (452 cm)
Width S40/V40 67.7 in. (172 cm)
Height S40/V40 55.9 in. (142 cm)
Wheel base S40/V40 100.4 in. (255 cm)
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Track, frontS40/V40 57.1 in. (145 cm)
Track, rearS40/V40 57.9 in. (147 cm)
Turning circle: S40/V40 34.8 ft. (10.6 m)
Cargo capacity:
S40 13.2 ft
3 (374 liters)
V40 33.5 ft
3 (948 liters)
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 3924 lbs (1780 kg)
V40 3968 lbs (1800 kg)
Capacity Weight:
S40 826 lbs (375 kg)
V40 826 lbs (375 kg)
Permissible axle weight, front:
S40 2090 lbs (950 kg)
V40 2090 lbs (950 kg)
Permissible axle weight, rear:
S40 1870 lbs (850 kg)
V40 1920 lbs (870 kg)
Permissible axle weight total:
S40 3920 lbs (1780 kg)
V40 3970 lbs (1800 kg)
Curb weight:
S40 3068 lbs (1392 kg)
V40 3118 lbs (1414 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) 1000 lbs (455 kg)
(with brakes) 2002 lbs (908 kg)
Max tongue weight ** 110 lbs (50 kg)
* For non-Volvo roof racks, check the manufacturer's weight specifications. the maximum permitted roof load weight
may not be exceeded
** Please refer to section "Trailer towing"
WARNING!
When adding accessories, equipment, luggage and other cargo to your vehicle, the total loaded weight capacity of
the vehicle must not be exceeded.
All specifications are subject to change without notice.
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pg. 128 Road Assistance
Your new Volvo comes with a four year road assistance program named ONCALL. Additional information, features,
and benefits are described in a separate information package in your glove compartment.
If you have misplaced your package, dial:
In the U.S.A.
1-800-63-VOLVO (1-800-638-6586)
In Canada:
1-800-263-0475
In addition to Volvo factory training, Volvo supports certification by the National Institute for Automotive Excellence
(A.S.E.) .Certified technicians have demonstrated a high degree of competence in specific areas. Besides passing
exams each technicians must also have worked in the field for two or more years before a certificate is issued. These
professional technicians are fully able to analyze vehicle problems and perform the necessary service procedures to
keep your Volvo at peak operating condition.
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