S40 – Australian Car.Reviews https://www.australiancar.reviews Australia's #1 site for car reviews, problems and recalls Sun, 07 Mar 2021 22:59:18 +0000 en-US hourly 1 https://wordpress.org/?v=6.6.2 https://www.australiancar.reviews/wp-content/uploads/2024/10/icon-120x120.png S40 – Australian Car.Reviews https://www.australiancar.reviews 32 32 Review: Volvo Mk.2 S40 (2004-12) https://www.australiancar.reviews/review-volvo-mk-2-s40-2004-12/ Sun, 07 Mar 2021 22:59:18 +0000 http://prod.australiancar.reviews/review-volvo-mk-2-s40-2004-12/ 3 stars
  • Willing 2.4-litre five-cylinder petrol engines
  • Responsive 2.5-litre turbo engine
  • Accomplished dynamics
  • Accurate steering
  • Standard suspension lacks low-speed compliance
  • For S40 T5, firm ride at all speeds
  • Tyre roar on coarse chip surfaces
  • Cramped rear seats
  • Small boot

Review: Volvo Mk.2-I S40 (2004-07)

Overview

Released in June 2004, the Volvo Mk.2 Phase I (Mk.2-I) S40 was a compact sedan. Manufactured in Ghent, Belgium, the Volvo S40 range initially consisted of the front-wheel drive 2.4 and T5 variants. From 2006, however, the T5 was fitted with a Haldex all-wheel drive system and, in 2007, the D5 was introduced.

B5244S4, B5254T3 and D5244T engines

Of the engines,

  • For the 2.4 variants, the 2.4-litre B5244S4 five-cylinder petrol engine had an aluminium block and cylinder heads, fracture-split steel connecting rods, double overhead camshafts, four valves per cylinder, continuously variable valve timing for the intake camshaft and a compression ratio of 10.3:1;
  • The 2.5-litre B5254T3 turbocharged petrol engine for T5 variants had similar properties but added a K04 Borg Warner turbocharger which provided peak boost pressure of 0.65 bar, an intercooler, continuously variable valve timing for the exhaust camshaft and had a compression ratio of 9.0:1; and,
  • For the D5 variants, the 2.4-litre D5244T8 (automatic) and D5244T13 (manual) turbo-diesel engines both had an aluminium block, common-rail direct injection (operating at 1600 bar), variable geometry turbocharger, cooled exhaust gas recirculation, double overhead camshafts, four valves per cylinder and a compression ratio of 17.3:1.

Volvo Mk.2-I S40 specifications
Variant Year Engine Trans. Peak power Peak torque
2.4,
2.4 SE
2004-05 2435 cc B5244S4 petrol I5 5sp auto,
5sp man.
125 kW at 6000 rpm 230 Nm at 4400 rpm
2.4 S,
2.4 LE
2006-07
T5 (FWD) 2004-05 2522 cc B5254T3 turbo petrol I5 5sp auto,
6sp man.
162 kW at 5000 rpm 320 Nm at 1500-4800 rpm
T5 AWD 2006-07 2522 cc B5254T3 turbo petrol I5 5sp auto,
6sp man.
162 kW at 5000 rpm 320 Nm at 1500-4800 rpm
D5 2007 2400 cc D5244T8 turbo diesel I5 5sp auto 132 kW at 4000 rpm 350 Nm at 1750 rpm

AWD system

From 2006 to 2010, the Volvo S40 T5 was fitted with a Haldex-based all-wheel drive system. In normal conditions, the 95 per cent of the engine’s torque was directed to the front wheels. In the event that the front wheels lost traction, however, the multi-plate clutch would engage to direct up to 50 per cent of the engine’s torque to the rear wheels (i.e. a 50:50 front:rear torque split).

Dimensions and body

The Volvo Mk.2 S40 was underpinned by Volvo’s P1 platform which was shared with the Volvo V50 and, later, the Volvo C30 . Compared to the Mk.1 S40 , the Mk.2 S40 was 48 mm shorter (at 4468 mm), 54 mm wider (1770 mm), 44 mm taller (1452 mm) and had a 78 mm longer wheelbase (2640 mm). Furthermore, the Mk.2 S40 chassis achieved a 68 per cent increase in torsional rigidity.

Suspension and steering

The Volvo Mk.2 S40 had MacPherson strut front and independent, multi-link rear suspension. Furthermore, teh Volvo S40 had rack-and-pinion steering with hydraulic power assistance.

Safety equipment

Standard safety equipment for the Volvo S40 2.4 and D5 variants included dual front airbags, front side airbags, full-length curtain airbags (i.e. for front and rear occupants), ABS, electronic brake force distribution, traction control, Volvo’s Whiplash Protection System (‘WHIPS’), anti-submarining seats, seatbelt pretensioners for the front and outer rear seats and load limiting seatbelts for the front seats; the S40 T5 was further equipped with electronic stability control.

From 2006, brake assist was fitted as standard across the range.

Euro NCAP crash testing

In Euro NCAP crash testing , a 2004 Volvo S40 sedan fitted with a 2.4-litre engine received a five star adult occupant protection rating with a score of 34.15 out of 37. In the frontal offset crash test, there was a slight risk of serious chest and leg injury for the front occupants. In the side impact and pole tests, however, the S40 received maximum points.

Features: Volvo S40

Initially, standard features for the Volvo S40 2.4 included 16-inch ‘Castalia’ alloy wheels, an six speaker sound system with CD player, climate control air conditioning, cruise control, front fog lights, a multi-function steering wheel, a 1/3 to 2/3 split and folding rear seat, remote central locking, power windows and mirrors, a tilt and reach adjustable steering wheel and immobiliser.

The S40 2.4 SE was further equipped with 16-inch ‘Caligo’ alloy wheels, leather seats, a power adjustable driver’s seat, a leather-wrapped steering wheel, trip computer, floor mats and wood-effect interior inlays (the latter unique within the S40 range).

Beyond this, the Volvo S40 T5 added 17-inch ‘Stylla’ alloy wheels with Pirelli 205/50 89W tyres, an eight speaker sound system, bi-xenon headlights with washers and aluminium interior inlays.

2006: Volvo S40 update

With the introduction of the Volvo S40 2.4 S and 2.4 LE in 2006, standard features were revised. Compared to the original 2.4, the 2.4 S and 2.4 LE both had dual-zone climate control air conditioning and heated mirrors, while the 2.4 LE was distinguished by its eight speaker sound system, leather seats, power adjustable driver’s seat and leather-wrapped steering wheel. Released in 2007, the D5 was similarly equipped to the 2.4 S

The Volvo S40 T5 gained a six-disc CD player, dual-zone climate control air conditioning, heated front seats and rain-sensing wipers.

Related links

Review: Volvo Mk.2-II S40 (2007-12)

Overview

Released in October 2007, the Volvo Mk.2 Phase II (Mk.2-II) S40 introduced an updated interior and slight powertrain changes. For the S40 T5, the B5254T3 engine was replaced by the B5254T7 which had a slightly different turbocharger design and a reprogrammed ECU (resulting in a 7 kW peak power increase).

While a six-speed manual transmission was introduced for the D5, this engine was replaced in September 2009 by the 2.0D unit. Like its predecessor, the 2.0-litre D4204T turbo-diesel engine had common-rail injection (albeit operating at 1800 bar), a variable geometry turbocharger, double overhead camshafts and four valves per cylinder, but was also fitted with piezo-electric injectors and had a higher compression ratio of 18.5:1.

In August 2010, the range was revised: the 2.4, D5 and 2.0D variants were discontinued, while the T5 returned to being front-wheel drive and was offered as an ‘S’ or ‘R-Design’ edition.

Volvo Mk.2-II S40 specifications
Variant Years Engine Trans. Peak power Peak torque
2.4 S,
2.4 LE
2007-10 2435 cc B5244S4 petrol I5 5sp man., 5sp auto 125 kW at 6000 rpm 230 Nm at 4400 rpm
T5 AWD 2007-09 2521 cc B5254T7 turbo petrol I5 6sp man., 5sp auto 169 kW at 5000 rpm 320 Nm at 1500-4400 rpm
T5 S,
T5 R-Design
2010-12 2521 cc B5254T7 turbo petrol I5 5sp auto 169 kW at 5000 rpm 320 Nm at 1500-5000 rpm
T5 Lifestyle 2011-12
D5 2007-09 2400 cc D5244T8 turbo diesel I5 6sp man., 5sp auto 132 kW at 4000 rpm 350 Nm at 1750 rpm
2.0D 2009-10 1997 cc D4204T turbo-diesel I4 6sp DCT 100 kW at 4000 rpm 320 Nm at 2000 rpm

Safety equipment

Compared to its Mk.2-I predecessor, standard safety equipment for the Volvo Mk.2-II S40 was largely unchanged. However, the Mk.2-II S40 was fitted with Emergency Brake Lights which would flash rapidly in emergency braking situations when the vehicle’s initial speed was greater than 60 km/h.

Features

Standard features were largely unchanged, with the Volvo S40 2.0D similarly equipped to the 2.4 S.

Volvo S40 R-Design

From 2009, the Volvo S40 was available with an ‘R-Design’ pack which included unique 17-inch alloy wheels, R-Design embossed off-black ‘Vulcaflex’ upholstery and cream leather seats’, a sports steering wheel, gearshift and pedals, ‘R-Design’ floor mats, a satin-finished grille and side mirrors, sports bodykit, chrome exhaust tips and rear spoiler.

August 2010 update: T5 variants only

Compared to the pre-existing S40 T5, the S40 T5 R-Design gained Bluetooth connectivity, auxiliary sound system inputs and the R-Design features described above. The T5 S, however, was fitted with 16-inch alloy wheels, a six speaker sound system and omitted the T5 R-Design’s bi-xenon headlights, leather seats, leather-wrapped steering wheel and trip computer.

October 2011: Volvo S40 update

In October 2011, standard features for the Volvo S40 were extended to include an eight speaker sound system, rear parking sensors, retractable door mirrors and an auto-dimming internal mirror. Furthermore, the S40 T5 Lifestyle edition was released; compared to the T5 S, the Lifestyle edition was further equipped with leather seats and directional bi-xenon headlights with washers.

Specifications

Related links

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Review: Volvo Mk.1 S40 (1997-04) https://www.australiancar.reviews/review-volvo-mk-1-s40-1997-04/ Sun, 07 Mar 2021 22:59:17 +0000 http://prod.australiancar.reviews/review-volvo-mk-1-s40-1997-04/ 2 stars
  • Comfortable and supportive front seats
  • Phase II S40 has much-improved ride and handling
  • Underpowered 1.8-litre petrol engines
  • Original suspension settings lacked compliance
  • Poor rear leg room
  • Vague steering

Review: Volvo Mk.1-I S40 (1997-00)

Overview

Released in March 1997, the Volvo Mk.1 Phase I (Mk.1-I) S40 was a compact sedan. Manufactured in the Netherlands, the front-wheel drive Volvo S40 range initially consisted of the naturally aspirated 1.8, 2.0 and turbocharged T4 variants. The S40 range, however, was subsequently expanded with T variants in February 1998 and 1.8 variants in July 1999.Transmission options consisted of four-speed automatic and five-speed manual units.

Co-developed with the Volvo V40 wagon, the S40 was 4483 mm long, 1717 mm wide, 1411 mm tall and had a 2550 mm long wheelbase. Furthermore, the S40 had MacPherson strut front suspension and independent, multi-link rear suspension. As part of an updated introduced in July 1999, the suspension was revised for greater ride comfort.

Volvo Mk.1-I S40 specifications
Variant Edition Years Engine Trans. Peak power Peak torque
1.8 N/A 1997-99 1731 cc B4184S petrol I4 4sp auto,
5sp man.
85 kW at 5500 rpm 165 Nm at 4100 rpm
1.8 N/A 1999-00 1783 cc B4184S2 petrol I4 4sp auto,
5sp man.
90 kW at 5800 rpm 170 Nm at 4000 rpm
2.0 N/A,
SE
1997-99 1948 cc B4204S petrol I4 4sp auto,
5sp man.
103 kW at 6000 rpm 183 Nm at 4500 rpm
SE 1999-00 1948 cc B4204S2 petrol I4 4sp auto,
5sp man.
100 kW at 5800 rpm 190 Nm at 4000 rpm
T N/A,
SE
1998-99 1948 cc B4204T turbo petrol I4 4sp auto,
5sp man.
118 kW at 5100 rpm 230 Nm at 1800 rpm
SE 1999-00
T4 N/A,
SE
1997-99 1855 cc B4194T turbo petrol I4 5sp man. 147 kW at 5500 rpm 300 Nm at 2400-3600 rpm
1998-99 4sp auto
SE 1999-00 1855 cc B4194T turbo petrol I4 4sp auto,
5sp man.
147 kW at 5500 rpm 300 Nm at 2400-3600 rpm

Safety equipment

Standard safety equipment for the Volvo Mk.1-I S40 included dual front airbags, front side airbags, ABS and front seatbelt pretensioners. The S40 T4 was further equipped with traction control.

From July 1999, electronic brake force distribution was fitted as standard.

Euro NCAP crash testing

In Euro NCAP crash testing , a 1997 Volvo S40 – fitted with a driver’s airbag and front side airbags – received a four star adult occupant protection rating with a score of 26. In the frontal offset test, protection of the driver’s head and thighs was rated as good, though chest, lower leg and foot protection was rated as marginal, giving a score of 12. In the side impact test, protection of the driver’s chest, abdomen and pelvis were rated as adequate, giving a score of 14.

Features: Volvo S40

Standard features for the Volvo S40 1.8 and 2.0 included a four speaker sound system with a radio and cassette player, air conditioning, 60/40 split and folding rear seats, central locking, power windows and heated mirrors, a height adjustable driver’s seat, a tilt-adjustable steering wheel and immobiliser. In July 1999, a six speaker sound system was introduced.

The S40 SE was further equipped with alloy wheels, a CD player, climate control air conditioning, leather seat trim, cruise control, leather-wrapped steering wheel and ‘woodline’ dash and door trim.

Compared to the S40 1.8 and 2.0, the Volvo S40 T was fitted with 15-inch alloy wheels as standard. Beyond this, the S40 T4 added 16-inch alloy wheels, sports seats, leather-wrapped steering wheel, a trip computer and rear spoiler.

Review: Volvo Mk.1-II S40 (2000-04)

Overview

Released in August 2000, the Volvo Mk.1 Phase II (Mk.1-II) S40 introduced a range of cosmetic, mechanical and handling upgrades. For the drivetrains,

  • Five-speed automatic transmissions with adaptive shift behaviour were introduced across the range;
  • For T4 variants, the B4194T petrol engine was replaced by the B4204T5 unit; and,
  • Both the T and T4 variants (i.e. the B4204T3 and B4204T5 engines) were fitted with twin-scroll turbochargers which reduced turbo lag by approximately 50 per cent and continuously variable valve timing (CVVT).

The front suspension was fitted with new lower wishbones and revised springs and dampers which operated with less bind. Furthermore, there were new tyre specifications, track was increased by 18 mm, the wheelbase extended by 12 mm and a new steering housing which contributed to improved steering feel. Refinement was also improved with the introduction of hydro engine mounts and greater insulation between the engine bay and cabin.

Visually, the Volvo Mk.1-II S40 could be identified by its new bumpers, flared wheel arches, clear-glass headlights and tail-lights, larger side indicator lights and new alloy wheel designs.

Volvo Mk.1-II S40 specifications
Variant Edition Years Engine Trans. Peak power Peak torque
1.8 N/A 2000-01 1783 cc B4184S2 petrol I4 5sp auto,
5sp man.
90 kW at 5800 rpm 170 Nm at 4000 rpm
2.0 N/A 2001-04 1948 cc B4204S2 petrol I4 5sp auto,
5sp man.
100 kW at 5800 rpm 190 Nm at 4000 rpm
SE 2000-04
Sport 2002
AKTIV 2003
T N/A 2001-03 1948 cc B4204T3 turbo petrol I4 5sp auto,
5sp man.
121 kW at 5250 rpm 240 Nm at 1800-4500 rpm
SE 2000-01
Sport 2002
T4 N/A 2001-03 1948 cc B5204T5 turbo petrol I4 5sp auto,
5sp man.
147 kW at 5500 rpm 300 Nm at 2500-4000 rpm
SE 2000-01

Safety equipment

Standard safety equipment for the Volvo Mk.1-II S40 included dual front airbags (two-stage), front side airbags, full-length curtain airbags, ABS, electronic brake force distribution, active front seat head restraints and front seatbelt pretensioners. The T and T4 variants were also fitted with traction control.

Features

Standard features for the Volvo S40 1.8 and 2.0 included a six speaker sound system with a CD player, air conditioning, leather seat trim, rear fog lights, leather-wrapped steering wheel, 1/3 to 2/3 split and folding rear seats, remote central locking, power windows and heated mirrors, a height adjustable steering wheel, height adjustable driver’s seat, 12 volt power outlet and immobiliser.

The Volvo S40 2.0 SE and T variants were further equipped with 15-inch alloy wheels, climate control air conditioning, leather-faced seats and cruise control. Beyond this, the T4 added 16-inch alloy wheels with ‘Dynamic’ suspension settings, front fog lights, a trip computer and rear spoiler.

2002 S40 Sport and 2003 S40 AKTIV editions

In January 2002, a limited-run 2.0 Sport edition was released; it was distinguished by its 15-inch alloy wheels, front fog lights and a rear spoiler. In May 2002, the T Sport was released – it was fitted with 16-inch alloy wheels, but also gained front fog lights and a rear spoiler.

In June 2003, the S40 2.0 AKTIV was released; it was distinguished by its 15-inch ‘Vogon’ alloy wheels, leather upholstery, front fog lights, black-blend dual headlights, claret wood-effect inlays and rear spoiler.

Related links

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Recalls & faults: Volvo Mk.2 S40 (2004-12) https://www.australiancar.reviews/recalls-faults-volvo-mk-2-s40-2004-12/ Sun, 27 Dec 2020 23:27:40 +0000 http://prod.australiancar.reviews/recalls-faults-volvo-mk-2-s40-2004-12/

Recalls: Volvo Mk.2 S40

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: Volvo Mk.2 S40

  • In May 2006, a recall was issued for model year 2004 to 2006 Volvo S40 vehicles fitted with the T5 engine. For these vehicles, the fuel line connecting to the engine was sensitive to extreme temperatures that may occur in the area where the turbo/exhaust manifold is located. As a result, the fuel line may leak after parking the vehicle. The recall involved the replacement of the fuel line with a component which withstood these temperatures (PRA 2006/8474).
  • In April 2008, a recall was issued for front wheel drive model year 2008 Volvo S40 vehicles in the VIN range 391077 to 391907. In some of these vehicles, the incorrect wheel studs were fitted to the rear wheel hubs. In rear cases, the wheels may become loose during particular forms of low speed manoeuvring (PRA 2008/10001).
  • In July 2008, a recall was issued for model year 2008 and 2009 Volvo S40 R-Design vehicles in the VIN range 0363521 to 0442033. For these vehicles, the driver’s floor may was too long and could interfere with the R-Design accelerator pedal. In certain circumstances, this interference could lead to the accelerator pedal remaining fully open (PRA 2008/10172).
  • In June 2010, a recall was issued for model year 2010 Volvo S40 vehicles fitted with a 2.5-litre engine, manual transmission and in the VIN range 497461 to 514357. For these vehicles, the ball joint and cylinder pin on the gearshift lever may be mounted with an incorrect torque, which could lead to the ball joint coming loose. As a result, the driver may be unable to change gears which could create an unsafe driving condition. However, the driver would be able to stop the vehicle by depressing the clutch, brake and turning off the ignition (PRA 2010/11719).
  • In December 2010, a recall was issued for model year 2010 and 2011 Volvo S40 vehicles in the VIN range 461283 to 539442. For these vehicles, the front power seat stop lugs may not be assembled to specification. As a result, the maximum allowable seat travel may be exceeded and the positioning of the seat beyond the intended maximum can cause increased risk of injury to the front passengers in the event of a collision (PRA 2010/12228).
  • In March 2011, a recall was issued for 2011 model year Volvo S40 vehicles in the VIN range 541586 to 542670. For these vehicles, the right side support member in the engine bay may be cracked. In this situation, the front structure of the car may be adversely affected, reducing its safety performance (PRA 2011/12425).
  • In April 2011, a recall was issued for 2011 model year Volvo S40 vehicles fitted with a headlight cleaning system and in the VIN range 530029 to 544424. For these vehicles, the headlight cleaning pump may affect the washer fluid level sensor. As such, the driver may not receive information on the instrument panel when the washer fluid level is low, constituting non-compliance with the Motor Vehicle Standards Act 1989, ECE R45 (PRA 2011/12502).
  • In May 2015, a recall was issued for model ‘year 2008’ to ‘model year 2011’ Volvo S40 vehicles that had six-speed manual transmissions. In these vehicles, the clutch cylinder rod may break such that it may not be possible for the driver to disengage the clutch. The clutch cylinder rod could break without warning to the driver and pose an accident hazard to the driver and other road users. The recalled Volvo S40 vehicles had serial numbers (i.e. the last six digits of the VIN) in the range 379552 to 546435 (PRA 2015/14692).

Problems and faults: Volvo Mk.2 S40

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

Problems and faults: Volvo Mk.2 S40

  • The battery may drain overnight if the ‘infotainment’ system prevents the central control module from entering ‘sleep’ mode.
  • Noise from the power steering pump may be due to it coming into contact with the air conditioning accumulator.
  • The remote central locking system may only work intermittently because a screw in the unit becomes loose and electrical connections are affected.
  • The climate control air conditioning system may blow hot air when cold is selected or all the flaps may close off airflow – these problems are due to a fault in the climate control module software which needs to be recalibrated.
  • The anti-theft alarm may be activated while driving and an ‘alarm service required’ message may appear on the driver information centre; if so, the central communications module requires replacement.
  • For models with 16-inch wheels, noisy front brakes may be fixed by installing a bigger caliper.
  • Rear brake noise may be fixed by fitting revised brake pads.
  • For some vehicles, the harness connector inside the A-pillar could get wet and corrode – this could be prevented by pre-emptively replacing the connector or packing it with grease.
  • Unwanted noises may come from the speakers if an auxiliary music player is used. A revised cable for the wiring harness was subsequently released to fix this problem, though the audio module may also require replacement.
  • If the audio system stops playing music and the display freezes, yet the problems stop when the car is restarted, flashing the control module may resolve the problem.

Problems and faults: Volvo S40 T5

Volvo S40 T5: PCV diaphragm rupture (B5254T3)

For the 2.5-litre B5254T3 turbocharged petrol engine, the positive crankcase ventilation (PCV) diaphragm – located in the oil filter housing – may rupture. Symptoms of a ruptured PCV diaphragm include:

Volvo S40 T5: oil filter housing
  • A high-pitched, whining/whistling noise that increases with engine speed. This noise is caused by excessive crankcase pressure escaping via the oil seals. For reference, this noise stops when the dipstick is removed (since removing the dipstick releases back pressure, see video below);
  • A lack of boost pressure in low gears;
  • Excessive oil consumption;
  • High oil pressure at idle;
  • Blue smoke from the exhaust; and,
  • Illumination of the engine warning light.

To fix, the air filter housing assembly needs to be removed so that the oil filter housing can be replaced. Sometimes, the breather hose from the assembly to the block may be damaged and also require replacement.

Volvo S40 T5: camshaft oil seal leak

If the PCV diaphragm has ruptured, the vehicle should not be run until the oil filter housing is replaced since doing so could damage the camshaft or crankshaft oil seals and cause oil leaks. If an oil leak occurs at the timing belt end, the timing belt and seals must be replaced. If, however, an oil leak occurs at the crankshaft’s main oil seal, then the gearbox must be removed, the seal replaced and, in extreme cases, the clutch replaced.

It is understood that Volvo and Ford (for the XR5 Turbo) subsequently introduced an uprated diaphragm which had an additional vent on the diaphragm cover, though failures of the updated diaphragm do still occur. Failures are more common in low mileage vehicles that:

  • Have been used to drive short distances since the engine does not reach its operating temperatures; and,
  • Reside in high humidity environments.


Volvo S40 T5: cracked cylinder liners (B5254T3)

The 2.5-litre B5254T3 engine had an open deck block and steel cylinder liners that were press-fitted into the block. For standard B5254T3 engines, however, there have been rare cases of cracked cylinder liners (also known as sleeves). Symptoms of cracked cylinder liners include:

  • Misfire when cold;
  • Loss of coolant;
  • Excessive white smoke; and,
  • Rough running on start-up.

Volvo S40 T5: cracked cylinder liner

Engines that have been modified for greater power are considered more vulnerable to cracked cylinder liners (particularly beyond 240 kW) due to the following factors –

  • Excessive boost pressure;
  • Aggressive ignition timing from poorly developed aftermarket tunes; and,
  • Coolant leaks that have not been rectified (see also ‘coolant leaks’, below).

It has also been suggested that cracked cylinder liners were most common for pre-April 2008 engines, though cracked liners have been observed in all years of B5254T3 engines.

For B5254T3 engines to produce more than 300 bhp (224 kW), OEM Denied recommends a ‘block mod’ in which the cylinder head is removed and stainless steel shims are fitted in the expansion gaps between the cylinder liners. Although this does not guarantee that cracked cylinder liners will not happen, OEM Denied has not seen this occur in the vehicles they have worked upon.

B5254T3 engine: solenoid boost valve

For the 2.5-litre B5254T3 turbocharged petrol engine, the solenoid boost valve is susceptible to failure. If there is a lack of performance and the boost gauge boost doesn’t go beyond a quarter of the dial, this is indicative of a failed solenoid boost valve. If the valve is operating properly, the dial on the boost pressure gauge should go beyond halfway before settling down in the middle.

Volvo S40 T5: coolant leaks

Volvo S40 T5: thermostat housing leak

Volvo S40 T5 vehicles are susceptible to coolant leaks from –

  • The thermostat housing at the cylinder head side gasket. Specifically, the leak occurs at the bottom corner and a mirror is required to see it;
  • The turbo coolant feed and return; and,
  • The radiator top hose joint at the back of the engine on the gearbox side.

The coolant hoses may also experience internal delamination as the vehicle ages. Where internal delamination has occurred, the hoses will appear swollen in size.

Volvo S40 T5: suspension

For the Volvo S40 T5, the following suspension components may wear prematurely:

  • The front anti-roll bar drop links;
  • The rear bushes on the front wishbones bushes (oil-filled).

It is recommended that the oil-filled bushes be replaced with more durable polyurethane bushes.

Volvo S40 T5: clutch does not return

For the Volvo S40 T5, the clutch pedal may not fully return to the ‘up’ position. This may be due to:

  • The seal from the original slave cylinder tearing and becoming stuck in the clutch line – this usually occurs after the clutch has been replaced. To fix, the clutch line has to be removed, blown out with compressed air and then have clean brake fluid poured through it. The brake fluid should flow easily and consistently in both directions; or,
  • In the case of hard driving (during or after), hydraulic fluid may boil and cause air bubbles to form. To fix, the clutch should be bled and high boiling-point DOT 5.1 fluid used.

Volvo S40 T5: air conditioning

  • During full throttle acceleration, the air conditioning compressor clutch is designed to shut down to reduce accessory losses;
  • The air conditioning may stop working due to failure of the air conditioning compressor clutch – this is caused by the spacing shims expanding and preventing the clutch from fully engaging. A common symptom of this fault is the air conditioning blowing cold for 10-15 minutes and then blowing hot; and,
  • The air conditioning may stop working due to a refrigerant leaking from the compressor shaft seal.

Volvo S40 T5: drive shafts

Volvo S40 T5: drive shaft

For the Volvo S40 T5, the OEM drive shafts have a ball-type CV joint for the outer and a tripod style joint for the inner – this design enables the shafts to have some ‘in and out’ movement with suspension articulation. However, hard acceleration from rest will quickly destroy the original drive shafts.

In contrast, aftermarket drive shafts tend to have inner and outer ball type CV joints which restrict the ‘in and out’ movement. As a result, however, most aftermarket shafts cause vibrations during driving as they lock up on themselves.

As Volvo S40 T5 vehicles age, the CV boots can split – these need to be replaced promptly or grease will be flung out of the driveshaft as it rotates and the shaft will require replacement.

Volvo S40 T5: front wheel bearings

For the Volvo S40 T5, the front wheel bearings are:

  • A complete hub and bearing setup;
  • An interference press fit into the knuckle with no retaining clips; and,
  • Not serviceable.

Over time, the hub assembly can start to ‘walk out’ of the hub. When this occurs, the gap between the ABS trigger wheel and the sensor is too great for the sensor to get a reading so it causes the ABS and TC warning light to illuminate; vehicle performance is also greatly reduced.

Volvo S40 T5: other problems and faults

  • Difficulty starting the vehicle and poor engine performance – including entering ‘limp home’ mode – may be due to the Power Control Module (PCM) cluster gateway not closing properly and draining the battery; reprogramming the PCM should fix the problem.
  • Engine vibration, ‘engine malfunction’ warnings and entering ‘limp home’ mode may be due to a fault in the throttle body switch which requires replacement. In the interim, stopping the vehicle, turning the engine off and waiting five minutes should re-set the switch and enable the journey to be completed.

AustralianCar.Reviews thanks OEM Denied for their contributions to this page.


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Recalls & faults: Volvo Mk.1 S40 (1997-04) https://www.australiancar.reviews/recalls-faults-volvo-mk-1-s40-1997-04/ Sun, 27 Dec 2020 23:27:39 +0000 http://prod.australiancar.reviews/recalls-faults-volvo-mk-1-s40-1997-04/

Recalls: Volvo Mk.1 S40

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: Volvo Mk.1 S40

  • In June 2001, a recall was issued for 2001 model year Volvo S40 vehicles due to a diode in the climate control unit which could fail. As a result, the climate control unit and windscreen demister would stop working (PRA 2001/4800).
  • In November 2003, a recall was issued for 2003 and 2004 model year Volvo S40 vehicles because the end cover on the service nipple side of the engine fuel rail could leak fuel – this presented a potential fire hazard and could also cause drivability disturbances (PRA 2003/6593).

Problems and faults: Volvo Mk.1 S40

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

Problems and faults: Volvo Mk.1 S40

  • For early models, the bottom front suspension ball joints may wear prematurely and the anti-roll bar mountings can become loose.
  • The exhaust-manifold nuts are susceptible to coming loose. If so, the nuts should be replaced with new ones which have captive washers.
  • The seat adjustment mechanism may squeak if it is not regularly lubricated.
  • The fuel gauge sensor is susceptible to failure.



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Images: Volvo Mk.2 S40 (2004-12) https://www.australiancar.reviews/images-volvo-mk-2-s40-2004-12/ Wed, 04 Nov 2020 10:48:32 +0000 http://prod.australiancar.reviews/images-volvo-mk-2-s40-2004-12/ Images: Volvo Mk.2-I S40 (2004-07)

Released in June 2004, the Volvo Mk.2 Phase I (Mk.2-I) S40 was a compact sedan. Manufactured in Ghent, Belgium, the S40 range initially consisted of the front-wheel drive 2.4 and T5 variants. From 2006, however, the T5 was fitted with a Haldex all-wheel drive system and, in 2007, the D5 was introduced… Read full Volvo Mk.2 S40 review

Images: Volvo Mk.2-II S40 (2007-12)

Released in October 2007, the Volvo Mk.2 Phase II (Mk.2-II) S40 introduced an updated interior and slight powertrain changes. For the S40 T5, the B5254T3 engine was replaced by the B5254T7 which had a slightly different turbocharger design and a reprogrammed ECU that resulted in a 7 kW peak power increase. In August 2010, the S40 range was revised: the 2.4, D5 and 2.0D variants were discontinued, while the T5 returned to being front-wheel drive and was offered in ‘S’ or ‘R-Design’ editions.


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Videos: Volvo Mk.2 S40 (2004-12) https://www.australiancar.reviews/videos-volvo-mk-2-s40-2004-12/ Thu, 08 Oct 2020 02:22:54 +0000 http://prod.australiancar.reviews/videos-volvo-mk-2-s40-2004-on/

Euro NCAP: 2004 Volvo S40 2.4 crash testing

In Euro NCAP crash testing, a 2004 S40 sedan fitted with a 2.4-litre engine received a five star adult occupant protection rating with a score of 34.15 out of 37. For more information about this testing, please see the Euro NCAP website. Videos are provided with the permission of Euro NCAP.

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