Volvo S40 (2012 year). Instruction

09 Maintenance and service

Self-maintenance

215

Before starting work on the car

Battery

Check that the battery cables are correctly
connected and tightened.

Never disconnect the battery when the engine
is running (e.g. if replacing the battery).

Never use a quick charger to charge the bat-
tery. The battery cables must be disconnected
when charging the battery.

The battery contains acid that is both corrosive
and toxic. It is therefore important to handle the
battery in an environmentally correct manner.
Let your Volvo dealer assist you.

WARNING

The ignition system has very high voltage
and output. The voltage in the ignition sys-
tem is highly dangerous. The ignition must
therefore always be switched off for work in
the engine compartment.

Do not touch the spark plugs or ignition coils
when the ignition is on or the engine is hot.

Raising the car

NOTE

Volvo recommends only using the jack that
belongs to the car model in question. If a
jack is selected other than the one recom-
mended by Volvo, follow the instructions for
use supplied with the equipment.

If the car is raised with a workshop jack; posi-
tion the jack against the front edge on the sub-
frame.

Do not damage the splashguard under the
engine. Ensure that the jack is positioned so
that the car cannot slide off the jack. Always
use axle stands or similar.

If you raise the car using a two-pillar workshop
lift, ensure that the front and rear lift arms are
fixed under the lifting points. See preceding
illustration.

Check regularly

Check the following at regular intervals, for
example, when refuelling:

•

Coolant – The level must be between the
MIN and MAX marks on the expansion
tank.

•

Engine oil – The level must be between the
MIN and MAX marks.

•

Power steering fluid – The level must be
between the MIN and MAX marks.

•

Washer fluid – The reservoir should be well
filled. Fill washer fluid with antifreeze at
temperatures around freezing point.

•

Brake and clutch fluid – The level must be
between the MIN and MAX marks.

WARNING

Remember that the radiator fan (located at
the front of the engine compartment, behind
the radiator) may start automatically some
after the engine has been switched off.

Always have the engine cleaned by a work-
shop. There is a risk of fire if the engine is
hot.

09 Maintenance and service

Bonnet and engine compartment

216

Opening the bonnet

G020793

The illustration shows a left-hand drive car.

Pull the handle on the far left under the
instrument panel. (In right-hand drive cars
the handle is on the far right.) You will hear
when the catch releases.

Insert your hand under the centre of the
front edge of the bonnet and press the
safety catch to the right.

Open the bonnet.

WARNING

Check that the bonnet locks properly when
closed.

Engine compartment

Washer fluid reservoir (4-cyl.)

Coolant expansion tank

Reservoir for the power steering fluid (con-
cealed behind the headlamp)

Dipstick

for engine oil

Radiator

Radiator fan

Washer fluid reservoir (5-cyl.)

Brake and clutch fluid reservoir (right-hand
drive)

Filling the engine oil

Brake and clutch fluid reservoir (left-hand
drive)

Engines with electronic oil level sensor have no dipstick (5-cyl. diesel).

The location varies depending on engine alternative.

09 Maintenance and service

Oils and fluids

218

Checking the engine oil

Volvo recommends Castrol oil products.

IMPORTANT

Always use oil of the prescribed grade.
Check the oil level frequently and change
the oil regularly. The engine will be damaged
if lower grade oil is used or if the car is driven
with the oil level too low.

When driving under adverse conditions, see
page 286.

IMPORTANT

In order to fulfil the requirements for the
engine's service intervals all engines are
filled with a specially adapted synthetic
engine oil at the factory. The choice of oil
has been made very carefully with regard to
service life, starting characteristics, fuel
consumption and environmental impact.

An approved engine oil must be used in
order that the recommended service inter-
vals can be applied. Only use a prescribed
grade of oil for both filling and oil change,
otherwise you will risk affecting service life,
starting characteristics, fuel consumption
and environmental impact.

Volvo Car Corporation disclaims all war-
ranty liability if engine oil of the prescribed
grade and viscosity is not used.

Volvo recommends that oil changes are car-
ried out at an authorised Volvo workshop.

Volvo uses different systems for warning of
low/high oil level or low/high oil pressure. Cer-
tain variants have an oil pressure sensor, and
then the lamp for oil pressure is used. Other
variants have an oil level sensor, and then the
driver is informed via the warning symbol in the
centre of the instrument unit as well as by dis-
play texts. Certain models have both variants.
Contact a Volvo dealer for more information.

Change the engine oil and oil filter in accord-
ance with the intervals specified in the Service
and Warranty Booklet.

Using oil of a higher than specified grade is
permitted. If the car is driven in adverse con-
ditions, Volvo recommends using an oil of a
higher grade, see page 286.

For capacities, see page 287 and onwards.

Engine with oil dipstick

Petrol engine.

Dipstick, petrol engines.

Filler pipe, engine oil.

Only applies to petrol and 4-cyl. diesel.

09 Maintenance and service

Oils and fluids

219

Diesel engine.

Dipstick, 4-cyl diesel engines.

Filler pipe, engine oil.

Checking the oil level in a new car is especially
important before the first scheduled oil change.

Volvo recommends checking the oil level every
2 500 km. The most accurate measurements
are made on a cold engine before starting. The
measurement will be inaccurate if taken imme-
diately after the engine is switched off. The
dipstick will indicate that the level is too low
because the oil has not had time to flow down
into the oil sump.

G020336

The oil level must be within the area marked on the
dipstick.

Measurement and filling if required

Ensure that the car is level. After switching
off the engine it is important to wait
5 minutes to allow the oil time to run back
to the sump.

Pull up and wipe the dipstick.

Re-insert the dipstick.

Pull it out and check the level.

If the level is close to MIN then 0.5 litres
should be added. If the level is significantly

below, then an additional amount is
required.

If required, check the level again, do it after
driving a short distance. Then repeat steps
1 - 4.

WARNING

Never fill above the MAX mark. The level
should never be above MAX or below MIN
as this could lead to engine damage.

WARNING

Do not spill oil onto the hot exhaust manifold
due to the risk of fire.

09 Maintenance and service

Oils and fluids

220

For engines with electronic oil level
sensor

Filler pipe.

You do not need to take action with respect to
the engine oil level before a message is shown
in the display, see the illustration below.

Message and graph in the display.

Message

Engine oil level

The oil level is checked using the electronic oil
level gauge with the thumbwheel when the
engine is switched off, see page 65.

WARNING

If the message

Oil service required

shown, visit a workshop. The oil level may
be too high.

IMPORTANT

In the event of the message

Oil level low,

Fill oil

, only fill with 0.5 litres.

NOTE

The oil level is only detected by the system
during driving. The system cannot directly
detect changes when the oil is filled or
drained. The car must be driven
about 30 km before the oil level display is
correct.

WARNING

Do not fill more oil if filling level (3) or (4)
appears as shown in the illustration below.
The level must never be above MAX or
below MIN, as this could lead to engine
damage.

WARNING

Do not spill oil onto the hot exhaust manifold
due to the risk of fire.

Only applies to 5-cyl. diesel.

Engines with electronic oil level sensor have no dipstick (5-cyl. diesel).

09 Maintenance and service

Oils and fluids

221

Measuring the oil level

If the oil level needs to be checked then it
should be carried out in accordance with the
sequence below.

Activate key position II, see page 150.

Rotate the thumbwheel on the left-hand
stalk switch to position

Engine oil level

Please wait...

> You will then see information displayed

about the engine oil level.

The figures 1-4 represent filling level. Do not fill
more oil if filling level (3) or (4) is shown. Recom-
mended filling level is 4.

Washer fluid, topping up

G020335

Location of washer fluid reservoir

The windscreen and headlamp washers share
a common reservoir.

For capacities, see the table Fluids on page
289.

Filler cap on 4-cylinder engines and diesel.

Filler cap on 5-cylinder engines.

Add washer fluid with antifreeze in the winter
so that the fluid does not freeze in the pump,
reservoir and hoses.

NOTE

Mix concentrated washer fluid with water
before filling.

TIP! Clean the wiper blades when topping up
washer fluid.

Checking and topping up the coolant

G020334

When topping up the coolant, follow the
instructions on the packaging. It is important
that the mixture of coolant concentrate and
water is correct for the prevailing weather con-
ditions. Never top up with water only. The risk

Depending on engine alternative.

09 Maintenance and service

Oils and fluids

222

of freezing increases with both too little and too
much coolant concentrate.

IMPORTANT

•

A high content of chlorine, chlorides
and other salts may cause corrosion in
the cooling system.

•

Always use coolant with anti-corrosion
agent as recommended by Volvo.

•

Ensure that the coolant mixture is 50%
water and 50% coolant.

•

Mix the coolant with approved quality
tap water. In the event of any doubt
about water quality, used ready-mixed
coolant in accordance with Volvo rec-
ommendations.

•

When changing coolant/replacing cool-
ing system components, flush the cool-
ing system clean with approved quality
tap water or flush with ready-mixed
coolant.

•

The engine must only be run with a well-
filled cooling system. Otherwise, tem-
peratures that are too high may occur
resulting in the risk of damage (cracks)
in the cylinder head.

For capacities and for standards regarding
water quality, see page 289.

Check the coolant regularly

The level must lie between the MIN and MAX
marks on the expansion tank. If the system is
not filled sufficiently, high local temperatures
could occur, causing a risk of damage (cracks)
to the cylinder head. Top up the coolant when
the level falls to the MIN mark.

WARNING

Coolant can be very hot. If the coolant
requires topping up when the engine is at
operating temperature, unscrew the expan-
sion tank cap slowly to gently release the
overpressure.

NOTE

The engine must only be run with a well-
filled cooling system. Otherwise, tempera-
tures that are too high may occur resulting
in the risk of damage (cracks) in the cylinder
head.

Checking and topping up the brake and
clutch fluid

G020333

09 Maintenance and service

Oils and fluids

223

Brake and clutch fluid have a common reser-
voir

. The fluid level must be between the

MIN and MAX marks. Check the level regularly.
Change the brake fluid every other year or at
every other regular service.

For capacities and recommended fluid grade,
see the table Fluids on page 289.

The fluid should be changed annually on cars
driven in conditions requiring hard, frequent
braking, such as driving in mountains or tropi-
cal climates with high humidity.

WARNING

If the brake fluid is under the MIN level in the
brake fluid reservoir, do not drive further
before topping up the brake fluid.

The reason for the loss of brake fluid must
be investigated.

Checking and topping up the power
steering fluid

NOTE

Check the level frequently.

The fluid does not require changing. For
capacities and recommended fluid grade, see
page 289.

If a fault should arise in the power steering sys-
tem or if the car is without power and must be
towed, it can still be steered. However, the
steering will be much heavier than normal and
it will require more effort to turn the steering
wheel.

Location dependent on whether car is left or right-hand drive.

09 Maintenance and service

Wiper blades

224

Wiper blades

G020330

NOTE

The wiper blades are different lengths. The
blade on the driver's side is longer than on
the other side.

Cleaning

For cleaning wiper blades and windscreen, see
page 206.

IMPORTANT

Check the wiper blades regularly.
Neglected maintenance shortens the serv-
ice life of the wiper blades.

Replacing the wiper blades, windscreen

Lift up the wiper arm.

Press the button located on the wiper
blade mounting and pull straight out (1),
parallel with the wiper arm.

Slide in (2) the new wiper blade until a
"click" is heard.

> Check (3) that the blade is firmly instal-

led and fold down the wiper arm.

09 Maintenance and service

Battery

225

Operation

The service life and function of the battery is
influenced by factors such as the number of
starts, discharging, driving style, driving con-
ditions and climatic conditions.

•

Never disconnect the battery when the
engine is running.

•

Check that the cables to the battery are
correctly connected and properly tight-
ened.

WARNING

•

The battery can generate oxyhydrogen
gas, which is highly explosive. A spark
can be formed if a jump lead is con-
nected incorrectly, and this can be
enough for the battery to explode.

•

The battery contains sulphuric acid,
which can cause serious burns.

•

If sulphuric acid comes into contact
with eyes, skin or clothing, flush with
large quantities of water. If acid
splashes into the eyes - seek medical
attention immediately.

NOTE

The life of the battery is shortened if it
becomes discharged repeatedly.

The life of the battery is affected by several
factors, including driving conditions and cli-
mate. Battery starting capacity decreases
gradually with time and therefore needs to
be recharged if the car is not used for a
longer time or when it is only driven short
distances. Extreme cold further limits star-
ting capacity.

To maintain the battery in good condition, at
least 15 minutes of driving/week is recom-
mended or that the battery is connected to
a battery charger with automatic trickle
charging.

A battery that is kept fully charged has a
maximum service life.

Symbols on the battery

Use protective goggles.

Further information in the
owner's manual.

Store the battery out of
the reach of children.

The battery contains cor-
rosive acid.

09 Maintenance and service

Battery

226

Option/accessory, for more information, see Introduction.

Avoid sparks and naked
flames.

Risk of explosion.

Must be taken for recy-
cling.

NOTE

An expended battery must be recycled in an
environmentally correct manner as it con-
tains lead.

Changing the battery

Removal

Remove the remote control key from the
ignition switch.

Wait at least 5 minutes before touching any
electrical terminals.

> The car's electrical system needs to

store the necessary information to the
control modules.

Remove the cover.

Detach the black negative cable.

WARNING

Connect and remove the positive and neg-
ative cables in the correct order.

Detach the red positive cable.

Undo the front wall of the battery box using
a screwdriver.

Detach the ventilation hose from the bat-
tery.

Release the clamp securing the battery.

Remove the battery.

Fitting

Fit the battery into position.

Tighten the clamp that holds the battery.

Connect the ventilation hose.

> Check that it is correctly connected to

both battery and outlet in the body.

Reinstall the front wall of the battery box.

Connect the red positive cable.

Connect the black negative cable.

Attach the cover to the battery.

For more information on the car's battery - see
pages 177 and 295.

DRIVe Start/Stop*

Cars with the Start/Stop function are equipped
with two 12 V batteries - one extra powerful
battery for starting and one standby battery
that helps during the Start/Stop function's star-
ting sequence.

For more information on Start/Stop - see
page 161.

09 Maintenance and service

Battery

227

Battery

Start

Standby

Cold start
capacity

CCA (A)

760

120

Dimen-
sions

L×W×H
(mm)

278×175×19

150×90×106

Capacity
(Ah)

In accordance with the SAE standard.

Largest possible size.

NOTE

•

The higher the current take-off in the car
(extra cooling/heating, etc.) the more
the batteries must be charged =
increased fuel consumption.

•

When the capacity of the battery has
fallen below the lowest permissible level
then the Start/Stop function is disen-
gaged.

Temporarily reduced Start/Stop function due
to high current take-off means:

•

The engine auto-starts

without the driver

depressing the clutch pedal.

Location of the batteries

1. Battery

2. Standby battery.

The standby battery normally requires no more
service than the normal battery that is used for
starting. A workshop should be contacted in
the event of questions or problems - an author-
ised Volvo workshop is recommended.

IMPORTANT

If the following instruction is not observed
then the Start/Stop function may temporar-
ily cease to work after the connection of an
external battery or battery charger:

•

The negative battery terminal on the
car's main battery must never be used
for connecting an external battery or
battery charger - only the car chassis
may be used as the grounding point.

See the section "Start assistance" - for a
description of how the cable clamps must
be attached.

Auto-start can only take place if the gear lever is in neutral position.

The battery is described in detail on page 225.

09 Maintenance and service

Battery

228

NOTE

If the battery has become so discharged
that everything is "black" and in principle
the car does not have all the normal electri-
cal functions and the engine is subsequently
started using an external battery or battery
charger, then the Start/Stop function will be
activated. It will then be possible for the
engine to be auto-stopped but in the event
of an auto-stop the Start/Stop function may
fail to auto-start the engine due to inade-
quate capacity in the battery.

The battery must first be charged in order to
ensure a successful auto-start after an auto-
stop. At an outside temperature of +15 °C
the battery needs to be charged for at least
1 hour. At a lower outside temperature a
charging time of 3-4 hours is recom-
mended. The recommendation is that the
battery is charged using an external battery
charger.

If this is not possible then the recommen-
dation is to temporarily deactivate the
Start/Stop function until the battery has
been adequately recharged.

For more information about recharging the
battery, see the section "Battery" in the
chapter "Maintenance and service".

09 Maintenance and service

Replacing bulbs

229

General

All bulb specifications are given on page 295.

The following list contains locations of bulbs
and other light sources that are specialised or
unsuitable for changing except at a workshop:

•

Active Xenon headlamps - ABL (Xenon
lamps)

•

Xenon headlamps (Xenon lamps)

•

Daytime running lights (DRL) in the spoiler

•

Direction indicators, door mirror and
approach lighting

•

Reading lamps, courtesy lighting and glo-
vebox lighting

•

General interior lighting in the roof

•

Brake light

WARNING

On cars with Xenon headlamps, the
replacement of Xenon lamps must be car-
ried out at a workshop - an authorised Volvo
workshop is recommended. Working with
Xenon lamps demands extreme caution
because the headlamp is equipped with a
high voltage unit.

IMPORTANT

Never touch the glass part of the bulbs with
your fingers. Grease and oil from your fin-
gers are vaporised by the heat, coating the
reflector and then causing damage.

Changing front bulbs

G019599

All front bulbs (except for fog lamps) are
changed by first removing the lamp housing
from the engine compartment.

Removing the lamp housing

Remove the remote control key and turn
the light switch to position 0.

Withdraw the lamp housing's locking pin.

IMPORTANT

Do not pull the electrical cable, only the con-
nector.

Pull the lamp housing to the side and then
forward.

Unplug the connector by pressing down
the clip with a thumb while moving out the
connector with the other hand.

G019600

Lift out the lamp housing and place it on a
soft surface to avoid scratching the lens.

09 Maintenance and service

Replacing bulbs

230

Fitting the lamp housing

Plug in the connector and refit the lamp
housing and locking pin. Check that the pin
is correctly inserted.

Check the lighting.

The lamp housing must be plugged in and
secured in place before the lighting is switched
on or the remote control key inserted into the
ignition switch.

Dipped beam

G019131

Removing the cover and bulb

Undo the whole lamp housing, see
page 229.

Bend aside the catches and remove the
cover.

Unplug the connector from the bulb.

Release the spring clip securing the bulb.
Press it in/down.

Pull out the bulb.

G019133

Fitting a new bulb

Fit the new bulb. It can only fit in one posi-
tion.

Press the spring clip in/up and then slightly
to the right in order to snap it into position.

Press the connector back on.

Refit the plastic cover.

Refit the lamp housing, see page 229.

Main beam, Halogen

G019136

The illustration shows a halogen bulb.

Undo the whole lamp housing, see
page 229.

Undo the cover, located above the lamp
housing, by turning it anticlockwise.

Left-hand headlamp:

Turn the bulb holder anticlockwise.

Right-hand headlamp:

Turn the bulb holder clockwise.

Volvo S40 (2012 year). Instruction - part 12