Buying a used Volvo S40/V40 (1997-2004)

In a joint venture with Mitsubishi and the Dutch government, Volvo delivered the Corolla-sized S40 with Volvo mechanicals and safety levels. Joe Kenwright finds that it is standing up better as a used car than some larger Volvo models.

Volvo's history with Dutch car company DAF, which goes back to 1975, has delivered several smaller Dutch-built Volvo models to the Australian market starting with the 360 GLT in 1984. This small rear-drive model which featured the 2.0-litre version of larger Volvo engines was replaced by the front-drive Renault-powered 440 series from 1993 to 1996.

As Volvo merged some of its business activities closer to Renault during this period, the 440 built on historical links between DAF and Renault. When this ceased, Volvo's Dutch facility evolved into a joint venture in 1991 between Mitsubishi, Volvo and the Dutch state called Nedcar. Production of certain Mitsubishi models and an all-new Volvo S40/V40 began in 1995 as 440 production was phased out.

The new S40 was closely related to the Mitsubish Carisma, a model since replaced by the Lancer in some markets. A stylish small car not sold in Australia, the Carisma shared a family look with the Australian 1996 Mitsubishi Magna. The Carisma platform was the perfect size to replace the 440 and had the right profile to introduce Volvo's softer lines and less boxy proportions. Volvo's safety structure and powertrains derived from its larger engines gave the S40 a very different character to the more downmarket Carisma. The S40 was not a re-badged Carisma but more of a re-engineered variation with shared economies of scale and build processes that kept the price affordable.

While the S40 and its pretty V40 wagon derivative were well-received, its suspension received ongoing attention when the ride compliance in the early cars was not plush enough for prestige buyers. Australian roads tended to highlight this shortcoming so if ride quality is a high priority then the later Phase II series needs to be the starting point for a used buy. In general, the S40 is proving reliable with few major faults and is capable of high distances with only routine maintenance.

After Ford took over Volvo, the Nedcar arrangement involving Volvo ceased as it became a Daimler-Chrysler and Mitsubishi facility building certain small Mitsubishi and smart models for Europe. In 2004, the Volvo S40 evolved into the current series as the first to use a new development of the original Ford Focus platform that has since underpinned the current Ford Focus and Mazda3.

Volvo S40/V40 Model History in Australia

Feb 1997: Dutch-built front-drive range replaces competent but unloved Renault-powered 440GLT in Nedcar joint venture with Mitsubishi. Launched in Australia as a 2-litre four with new Volvo engine derived from larger five and six-cylinder Volvo engines with 103kW/183Nm. Available as S40 sedan or V40 wagon in base and SE spec.
Oct 1997: Sports body kit released. New turbocharged T-4 and T-4 SE available as S40 and V40 with 147kW/300Nm and manual only
Jan 1998: Automatic T-4 launched.
Feb 1998: Low-pressure S40 T and V40 T released with twin-scroll light boost turbo and 118kW/230Nm.
Jan 1999: Minor running changes. Look for ambient temperature gauge.
Jul 1999: Major range reshuffle ready for GST. New entry level 1.8 with 90kW/170Nm was tame and plain but more affordable. 2.0-litre engine shares its new low friction internals, variable valve timing, revised head design. Suspension upgraded with extra compliance. Look for dark grey plastic exterior parts and highlights.
Aug 2000: Phase II launched with fresher styling including new headlights, tail lights and flared front guards. Turbo engines received 1999 low friction upgrades and variable valve timing. Low-pressure turbo output upped to 121kW/240Nm. Hotter T-4 engine boosted from 1.9 to 2.0-litres with unchanged 147kW/300Nm output but lower torque peak. Suspension further improved with wider track and longer wheelbase. Five-speed auto offered.
Apr 2001: 1.8-litre base model replaced by base 2.0-litre version. T-4 V40 is discontinued. Five-speed manual available only on base 2.0-litre, special order on other models.
Aug 2002: MY2003 upgrade with block pattern grille announced. Better airbags, improved fuel economy, smoother front suspension, revised instrument design to match larger models. Examples filter onto market at close of 2002. 
May 2004: Original S40 series ends to be replaced with second-generation Volvo S40 platform later shared with current Focus and Mazda3.

Volvo S40/V40 Checkpoints

Check all mechanical components underneath to make sure they are not gouged or cracked from grounding on kerbs or raised road sections.

Oil and filter must be changed in the Turbo versions no later than every 7500 km with quality synthetic-base oil to minimise carbon build-up which can chop out rear main seal, camshaft top seal, valve stem seals and O-ring in turbo oil return line. Leaking turbo oil return lines appear to be a routine repair and not to be confused with rear main seal leak which is far more expensive.

Both turbo and non-turbo engines serviced according to long intervals under city driving are coming in with oil burning problems. If sludge has built-up there is a risk of blocking the oil pick-up. Specialists are suspecting blocked engine oil lines including return lines in the pistons are adding to oil consumption. Before replacing valve stem seals or undertaking an engine rebuild, consider a controlled oil flush program by an expert.

Top right engine mount goes hard with underbonnet heat then sends vibration throughout the car. Check this before addressing other possible causes.

Oil filter is prone to leaking as its O-ring becomes heat hardened. Check all engine seals for leakage. Plastic radiator header tank also relies on rubber O-ring to seal which can fail with heat hardening. Check all coolant system hoses and fittings for tell tale leaks. The high aluminum content in the engine can go downhill quickly if coolant is diluted by frequent top-ups with water because of a leak in the system.

There is an exhaust pulse valve that can burn out after it rots. 

Early variable cam timing engines can have rattling actuators.

Some early gearboxes had bearing problems and manual gearboxes can leak around the gear shift. Clutch hydraulics must have routine flush and fluid replacement otherwise will display typical seal failure and leaks.

Brakes and Suspension
S40 is particularly sensitive to tyre tread patterns. Block pattern treads can feather at the rear and set up low speed rumble that sounds like bearing failure. Experts advise sticking to more open tread pattern.

Steering rack oil leaks from pinion seal and boots show up on high mileage cars. CV joints last providing boots are not split. Inner sway bar bushes are a routine replacement item.

Quality local brake pads can reduce copious brake dust and frequent rotor replacement over originals. Original rotors are prone to shudder and excessive wear with original pads.

Most suspension parts including dampers are long lasting but ball joints, certain bushes and dampers are wear and tear items on high mileage cars

Main failure item inside is stepper motor that operates recirculation flap in heater system and is fiddly and costly to access and replace.

Lower front spoiler is frequently gouged and broken. Check alloys for kerb damage. Make sure tyre replacements meet Volvo recommendations.

Check operation of all electric windows. Leather trim on earlier cars is old enough to require major rejuvenating if a quality leather conditioner has not been applied regularly.