2004-2008 Volvo S40 FWD 2.5L

Overview

The second-generation Volvo S40, introduced for the 2004 model year, represented a significant departure from its predecessor. Developed on the Ford P1 platform, which it shared with the Mazda3 and the European Ford Focus, the S40 was engineered to provide a more agile and compact alternative to the larger S60. Volvo shifted production for this model to the Ghent plant in Belgium, emphasizing a global approach to manufacturing that prioritized structural rigidity and advanced safety systems.

The S40 2.5L variant utilized a turbocharged inline-five-cylinder engine, a hallmark of Volvo’s engineering philosophy during this era. This powertrain was designed to offer a balance between efficiency and performance, catering to a demographic that valued Scandinavian design, high-quality interior materials, and industry-leading safety features. The exterior styling adopted the “boxy but safe” heritage of the brand while incorporating modern, rounded aesthetics that defined the mid-2000s design language of the company.

Throughout its production cycle, the S40 remained a staple in the premium compact segment. It was marketed as a sophisticated, entry-level luxury vehicle, often cross-shopped with the BMW 3 Series and the Audi A4. While the model was eventually succeeded by the V40 and later the S60, the 2004-2008 S40 is remembered for its distinct “floating” center console design and its commitment to occupant protection, which helped maintain Volvo’s reputation for building some of the safest vehicles on the road.

Vehicle Overview
Brand	Volvo
Model	S40 FWD
Model Year	2004-2008
Generation	2nd Generation (P1)
Trim	2.4i / T5
Body Style	4-Door Sedan
Vehicle Segment	Compact Executive
Vehicle Class	Compact Cars
Market	USA
Platform	Ford P1
Assembly Plant	Ghent, Belgium
Country of Origin	Belgium
Production Start	2004
Production End	2008
VIN Identifier	–
Base MSRP	$24,000 – $28,000
Destination Charge	$700
Total MSRP	–
Powertrain
Powertrain Type	Internal Combustion Engine
Engine Family	Volvo Modular Engine
Engine Name	B5254T3
Engine Code	–
Engine Configuration	Inline-5
Displacement	2.5 Liters
Bore x Stroke	83 mm x 93 mm
Compression Ratio	9.0:1
Aspiration	Turbocharged
Fuel Delivery	Multi-point fuel injection
Valve Train	DOHC, 4 valves per cylinder
Engine Block Material	Aluminum Alloy
Cylinder Head Material	Aluminum Alloy
Oil Capacity	6.1 qts
Oil Specification / Viscosity	5W-30
Horsepower	218 hp @ 5000 rpm
Torque	236 lb-ft @ 1500 rpm
Redline	6500 rpm
Drivetrain	Front-Wheel Drive
Transmission	Automatic (S5)
Final Drive Ratio	–
Axle Ratio	–
Fuel Economy
Fuel Type	Premium Gasoline
Recommended Octane	91
EPA City MPG	19
EPA Highway MPG	28
EPA Combined MPG	22
Fuel Economy (L/100 km)	–
Fuel Tank Capacity (gal)	15.9
Estimated Driving Range	–
Annual Fuel Cost	–
CO₂ Emissions	–
Greenhouse Gas Score	–
Smog Rating	–
Performance
0-30 mph	–
0-60 mph	6.7 seconds
0-100 mph	–
Quarter Mile	15.2 seconds
Top Speed	149 mph
Braking Distance (60-0 mph)	128 ft
Lateral Acceleration	0.82g
Power-to-Weight Ratio	–
Dimensions & Capacities
Length (in)	175.8
Width (Without Mirrors) (in)	69.7
Width (With Mirrors) (in)	–
Height (in)	57.2
Wheelbase (in)	103.9
Front Track (in)	60.5
Rear Track (in)	60.5
Ground Clearance (in)	5.3
Curb Weight (lbs)	3200
GVWR (lbs)	–
Towing Capacity (lbs)	–
Payload Capacity (lbs)	–
Passenger Volume (cu ft)	91.0
Cargo Volume (Behind Rear Seats) (cu ft)	12.6
Cargo Volume (Max) (cu ft)	–
Turning Circle	34.8 ft
Approach Angle	–
Departure Angle	–
Breakover Angle	–
Safety Ratings
NHTSA Overall Rating	–
NHTSA Frontal Crash	–
NHTSA Side Crash	–
NHTSA Rollover	–
IIHS Award	Top Safety Pick
Small Overlap Front	–
Moderate Overlap Front	Good
Side Impact	Good
Headlights Rating	–
Front Crash Prevention	–
Technology & Connectivity
Infotainment Display	–
Instrument Cluster	Analog
Apple CarPlay	No
Android Auto	No
Navigation System	Optional
Audio System	Premium Sound System
Speaker Count	8
Wireless Charging	No
Wi-Fi Hotspot	No
OTA Updates	No
Digital Key	No
Warranty & Ownership
Basic Warranty	4 years / 50,000 miles
Powertrain Warranty	4 years / 50,000 miles
Corrosion Warranty	12 years / unlimited miles
Roadside Assistance	4 years / 50,000 miles
Complimentary Maintenance	3 years / 36,000 miles
Specs.Autos Exclusive Data
Engine Assembly Plant	Skövde, Sweden
Transmission Supplier	Aisin Warner
Gear Ratios	–
Differential Type	Open
Cooling System Capacity	–
Roof Load Capacity (lbs)	165
Safety Recall Count	–
Production Volume	–
Units Sold in USA	–

Consumer Insights & Market Appeal

The 2004-2008 Volvo S40 is widely regarded as a solid, comfortable, and safe entry-level luxury sedan, though prospective buyers should be aware of specific maintenance requirements. The 2.5L turbocharged engine is generally robust, but it requires strict adherence to oil change intervals to prevent sludge buildup, which can affect the variable valve timing solenoids. Common issues include failure of the PCV system, worn suspension bushings, and occasional electrical gremlins related to the climate control module. In the used market, these vehicles offer significant value for those seeking a stylish, well-built car with excellent seat comfort and crash-test performance. While not as sharp as some German competitors, the S40 provides a composed ride and a unique interior aesthetic that remains appealing to enthusiasts of the brand.