2 0 0 5
VOLVO
S40

pg. 155 Bulbs




Bulbs used in the car
1. Low beam headlight 55W H11
2. Bi-Xenon headlight (option) 35W D2S
3. High beam headlight 55W HB3
4. Brake light, Rear fog light P21/W5
5. Turn signal, front/rear (amber bulb) PY21W
6. Tail lights, Parking light, Side marker light P21/W5
7. Footwell lighting, cargo compartment light W5W
8. Vanity mirror 1,2W
9. License plate
lighting, Parking light
in headlight housing
Side turn signal
(amber bulb)
W5W
10. Front fog light (option) 55W H11

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 not listed here should only be replaced by an authorized Volvo service technician.

    pg. 156 Replacing front bulbs



    Removing the headlight housing
    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.
    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 an authorized Volvo service technician.



    Cover with retaining clamps

    Low beam bulb
    1. Open the hood.
    2. Remove the headlight housing.
    3. Press the retaining clamps to the sides.
    4. Release the bulb's retaining spring by pressing it to the right, and then moving it outward and downward.
    5. Pull out the bulb.
    6. Disconnect the wiring connector from the bulb.

    Installing a new bulb.
    1. Insert the new bulb. It can only be installed in one position.

    pg. 157 Replacing front bulbs



    Low beam bulb

    2. Press the retaining spring upward and slightly to the left until it snaps into place.
    3. Press the wiring connector onto the bulb.
    4. Put the plastic cover in place.
    5. Press the retaining clamps back into place.
    6. Reinstall the headlight housing.

    High beam bulb

    High beam bulb
    1. Open the hood.
    2. Remove the headlight housing.
    3. Turn the bulb holder counterclockwise and pull it out. Replace the bulb. Note how the bulb holder is positioned.
    4. Reinstall the bulb holder. It can only be installed in one position.
    5. Reinstall the headlight housing.



    Parking light bulb
    1. Pull out the bulb holder with a pair of pliers. The bulb holder should not be pulled out by the wire.
    2. Replace the bulb.
    3. Press the bulb holder back into place. It can only be installed in one position.

    pg. 158 Replacing front bulbs




    Turn signal
    1. Turn the bulb holder counterclockwise and remove it.
    2. Remove the bulb from the holder by pressing it in and twisting it counterclockwise.
    3. Insert a new bulb and reinstall the bulb holder in the headlight housing.



    Side marker light
    1. Turn the bulb holder counterclockwise, pull it out, and replace the bulb.
    2. Reinstall the bulb holder. It can only be installed in one position.



    Front fog light (option)
    1. Switch off all lights and turn the key to position 0.
    2. Remove the panel around the fog light housing.
    3. Unscrew both torx screws in the fog light housing and remove it.
    4. Disconnect the connector from the bulb.
    5. Turn the bulb counterclockwise and pull it out.
    6. Install the new bulb in its seat and turn it clockwise.
    7. Reconnect the connector to the bulb.
    8. Secure the fog light housing with the screws and press the panel back into place.

    pg. 159 Replacing tail light bulbs



    Removing the tail light bulb holder
    All bulbs in the tail light cluster can be replaced from the trunk. To access the bulb holder:
    1. Switch off all lights and turn the key to position 0.
    2. Remove the covers in the left/right panels to access the bulbs.
    3. Disconnect the wiring connector from the 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.



    Location of tail light bulbs
    1. Brake light
    2. Parking light
    3. Turn signal
    4. Fog light (driver's side only)
    5. Back-up light

    High-level brake light
    These bulbs are of a special type. It is recommended that they be replaced by an authorized Volvo service technician.



    License plate lighting
    Replacing the bulb
    1. Switch off all lights and turn the key to position 0.
    2. Remove the screw with a screw driver.
    3. Detach the entire bulb housing and carefully pull it out. Turn the connector counterclockwise and pull out the bulb.
    4. Replace the bulb.
    5. Reinstall the connector and turn it clockwise.
    6. Reinstall the entire bulb housing and screw it into place.

    pg. 160 Replacing interior bulbs

    Footwell lighting
    The footwell lighting is located under the dashboard on the driver's and passenger's sides. To replace a bulb:
    1. Insert a screwdriver under the edge of the lens. Turn the screwdriver gently to detach the lens.
    2. Remove the defective bulb.
    3. Install a new bulb.
    4. Press the lens back into place.

    Trunk lighting
    1. Insert a screwdriver and turn it gently to detach the bulb housing.
    2. Remove the defective bulb.
    3. Install a new bulb.
    4. Press the bulb housing back into place.

    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.

    pg. 161 Fuses

    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 an authorized Volvo retailer.

    WARNING!
    Never use fuses with higher amperage than those stated in the following tables. Doing so could overload the vehicle's electrical system.




    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.

    pg. 162 Fuses




    Fuses in the engine compartment
    1. Coolant fan (radiator), 50A
    2. Power steering, 80A
    3. Feed to passenger compartment fuse box, 60A
    4. Feed to passenger compartment fuse box, 60A
    5. Element, climate unit, 80A
    6. Not in use
    7. ABS pump, 30A
    8. ABS valves, 20A
    9. Engine control module (ECM), 30A
    10. Climate system blower, 40A
    11. Headlight washers, 20A
    12. Feed to heated rear window, 30A
    13. Starter motor relay, 30A
    14. Trailer connector, 40A
    15. Not in use
    16. Feed to audio system, 30A
    17. Windshield wipers, 30A
    18. Feed to passenger compartment fuse box, 40A
    19. Not in use
    20. Horn, 15A
    21. Not in use
    22. Subwoofer, 15A
    23. Engine control module (ECM)/transmission control module (TCM), 10A
    24. Not in use
    25. Not in use
    26. Ignition switch, 15A
    27. A/C compressor, water shut-off valve, 10A
    28. Climate system control module (CCM), Multimedia control module (MMM) 10A
    29. Front fog lights (option), 15A
    30. Engine control module (ECM), 3A
    31.Generator voltage regulator, 10A
    32. Fuel injectors, 10A
    33. Heating element - heated oxygen sensor, vacuum pump, 20A
    34. Ignition coils, engine control module, 10A
    35. Engine sensor valves, A/C relay, relay coil water shut-off valve, 15A
    36. Engine control module (ECM), 10A

    pg. 163 Fuses




    Fuse box in the passenger compartment
    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 (1 cm) 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.

    pg. 164 Fuses




    Fuses in the passenger compartment
    37. Not in use
    38. Not in use
    39. Not in use
    40. Not in use
    41. Not in use
    42. Not in use
    43. Audio system, 15A
    44. Supplemental Restrain System (SRS), 10A
    45. 12-volt socket in rear seat, 15A
    46. Lighting - glove compartment, instrument panel, and footwells, 5A
    47. Moon roof (option), door mirrors, 5A
    48. Headlight washers, 15A
    49. Supplemental Restrain System (SRS), Occupant Weight Sensor (OWS), 10A
    50. Not in use
    51. Bi-Xenon headlights (option), 10A
    52. ABS, 5A
    53. Power steering, 10A
    54. Transmission control module (TCM), differential electronic module (DEM), 10A
    55. Not in use
    56. Battery charge control module, 10A
    57. On-board computers,, brake light switch, 15A
    58. Right high beam, auxiliary lights, 7.5A
    59. Left high beam, 7.5A
    60. Heated driver's seat (option), 15A
    61. Heated passenger's seat (option), 15A
    62. Moonroof (option), 20A
    63. Power window and door lock - rear passenger's side door, 20A
    64. Radio receiver, Global Positioning System - GPS (option), 5A
    65. Volvo Navigation system (option), Audio system, 5A
    66. Audio system control module (ICM), audio system relay coil, 10A
    67. Not in use
    68. Cruise control, 5A
    69. Climate system, rain sensor (option), 5A
    70. Not in use
    71. Not in use
    72. Not in use
    73. Moonroof, front ceiling lighting, auto-dim mirror, (option) seat belt reminder, 5A
    74. Fuel pump relay, 15A

    pg. 165 Fuses

    75. Not in use
    76. Not in use
    77. 12-volt socket in trunk, auxiliary equipment control module (AEM), 15A
    78. Not in use
    79. Back-up lights, 5A
    80. Not in use
    81. Power window and door lock - rear driver's side door, 20A
    82. Power window and door lock - front passenger's side door, 25A
    83. Power window and door lock - front driver's side door, 25A
    84. Power passenger's seat, 25A
    85. Power driver's seat, 25A
    86. Interior lighting relay, power seats, 5A

    pg. 166 This page intentionally left blank



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