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	2435 cc B5244S4 petrol I5	5sp auto, 5sp man.	125 kW at 6000 rpm	230 Nm at 4400 rpm
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.

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