VolvoS402004Overview/volvo/s40/2004/base/

2004 Volvo S40

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 S40.

Body PASSENGER CAR

As a passenger car, the 2004 Volvo S40 requires 6.1 quarts of engine oil—accepting 10W-30, 5W-30, or 5W-40 API viscosities—to maintain its internal operation. In terms of reliability, this model year carries 6 recalls and 50 total owner complaints, with air bag issues dominating the fault reports. When contextualized within the model's 2000-2011 history, the 2004 S40 sits well below the problematic 2000 peak of 134 complaints but far above the 2011 low of just 5, marking it as a transitional year where early-generation flaws were fading but notable safety concerns remained unresolved.

Model year201220112010200920082007200620052004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity6.1 qtOEM · verified
Engine oil type10W-30 / 5W-30 / 5W-40 APIOEM · verified
Lug nut torque81 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 48 · 600 CCA battery, OE oil filter 8692305. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 48 · 600 CCAOEM · verified

OE service part numbers OEM · verified

Engine oil filter8692305 alt 1275810
Engine air filter30757155 alt 30850831
Fuel filter31271607 alt 30620512
Battery30772221 alt 30772226
Front wiper blades30638442 alt 31457759
Thermostat271664 alt 6842214
Cabin air filter30780376 alt 30780377

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length178.7 in
Overall width67.7 in
Overall height55.9 in
Wheelbase100.8 in
Curb weight2767 lb
Track (front / rear)57.9 / 57.9 in
Weight distribution (front / rear)61/39

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the S40 of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

6.5–7.1 sec0–60 mph (tested)quickest 6.50 sec — 2006 T5 Sedan
YearTrim / engine0–60¼ mileHPDrivetrain
2005T5 Sedan 2.5L Turbo I-56.70 sec15.00 sec218 hpFWD
2005T5 Sedan 2.5L Turbo I-56.80 sec15.10 sec218 hpAWD
2005T5 Sedan 2.5L Turbo I-56.90 sec15.20 sec218 hpFWD
2005T5 Sedan 2.5L Turbo I-57.10 sec15.30 sec218 hpAWD
2006T5 Sedan 2.5L Turbo I-56.50 sec14.90 sec218 hpAWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 6.1 qt of 10W-30 / 5W-30 / 5W-40 API engine oil, DOT 4 brake fluid. Torque lug nuts to 81 ft-lbs, the oil drain plug to 28.0 ft-lbs. The firing order is 1-2-4-5-3.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity8
Brake FluidDOT 4
Engine Oil10W-30 · API · 5W-30 · 5W-40
Engine Oil Capacity6.1 qt
Engine Oil Capacity6.1 qt
Engine Oil15W-40 · API · 10W-30 · 5W-30
Engine Oil Capacity5.7 qt

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs13 ft-lbs
Crankshaft Pulley and/or Damper Bolts133 ft-lbs
Intake Manifold to Engine Bolts15 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Intake Manifold to Engine Bolts15 ft-lbs
Exhaust Manifold to Cylinder Head Bolts19 ft-lbs
Engine Oil Pan Drain Plug24.0 ft-lbs
Engine Oil Pan Drain Plug28.0 ft-lbs

Chassis torques

Lug Nuts81 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Cylinder Firing Order1-2-4-5-3
Curb Idle Speed (No Load)775 rpm
Ignition Coil Primary Resistance.05-1.5 ohms
Ignition Coil Secondary Resistance8000-9000 ohms
Spark Plug Gap0.027-0.031 in
Spark Plug Torque18.0 ft-lbs
Spark Plug Gap0.027 in

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.88 lbs
Oil TypeVolvo part No. 1161 627-3
Oil Capacity6.09 oz
Standard BCI Group Number48
Standard BCI Cranking Performance600 cca
Standard BCI Group NumberEarly Build: 48, Late Build: 91
Standard BCI Cranking PerformanceEarly Build: 600, Late Build: 590 cca

Service checks

Regulated Fuel System Pressure (Without Vacuum)44.0-46.0 Relative to manifold psi
Regulated Fuel System Pressure (With Vacuum)42.0-45.0 At injectors psi
Residual Pressure58.0-73.0 psi
Injector Primary Resistance11.6-12.4 ohms
Injector Primary Resistance12 ohms
Engine Compression159-188 psi

Brakes

Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle74 ft-lbs
Minimum Pad ThicknessFront: 0.079; Rear: 0.079 in
Rotor Runout Limit0.0016 in
Rotor Minimum Machining0.87 in
Rotor Discard at or Under0.846 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 9015 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 9015 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs, Step 2: 18 ft. lbs, Step 3: 10011 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
118 ft. lbs., step 2: 3018 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs. Step 2: 6533 ft. lbs
Main Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 33 ft. lbs.; M8 Bolts: 18 ft. lbs.; M7 Bolts: 13 ft. lbs.; M10 Bolts: 90 degrees15 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 45,000 mi; coolant every 15,000 mi. The big-interval services (every 15,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 miBrake Linings (inspect) · Brake Rotor (inspect) · CV Joint Boot (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Engine Oil (drain & refill)
Every 15,000 miBattery (inspect) · Brake Hydraulic System (drain, refill & bleed) · Brake Shift Interlock Solenoid (inspect) · Cabin Air Filter (replace) · Door Hinge (lubricate) · Engine Coolant System (leak inspection)
Every 30,000 miBrake Line (inspect) · Fuel Line (inspect)
Every 37,500 miEngine Air Filter Element (replace)
Every 45,000 miPCV Hose (inspect) · Spark Plugs (replace)
At 60,000 miCV Joint Boot (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Exhaust System (Complete) (inspect) · Steering System (inspect) · Suspension System (inspect)
At 105,000 miDrive Belt (replace) · Fuel Filter (replace) · PCV Hose (inspect)
At 120,000 miTiming Belt (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Volvo S40 stands out as a peak problem year within the 2000–2011 generation. After complaints had fallen from 134 in 2000 to just 21 in 2003, they jumped to 50 in 2004, and recalls hit a generation-high of six—triple the count of most surrounding years. Technical service bulletins also peaked at 239, far above the 161–197 range of other years, suggesting the model required frequent dealer intervention. The top complaint areas—air bags, brakes, fuel system, and engine cooling—along with five crash and one fire complaint, point to multiple safety-related concerns. While later years (2007–2011) show steadily declining complaints and fewer recalls, the 2004 model appears to be an outlier with elevated risk. Based solely on this federal record, the 2004 S40 is a poor choice to buy compared to the more reliable 2002–2003 or 2007–2011 model years.

6
Open recalls
NHTSA campaigns
239
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
50
Owner complaints
5 involved a crash · 1 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 50 complaints on record, top 8 components.

Air Bags7
Service Brakes, Hydraulic5
Fuel System, Gasoline4
Engine & Engine Cooling4
Electrical System3
Steering3
Service Brakes2
Engine2

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 6 campaigns on record for this vehicle.

10V566000Equipment:Electrical:Navigational System(Global Positioning System)Reported 08/11/2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT. Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL…

06V137000Fuel System, GasolineReported 24/04/2006

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH T5 TURBO ENGINES, THE POLYAMIDE TUBE IN THE FUEL LINE IS SENSITIVE TO THE EXTREME TEMPERATURES THAT MAY OCCUR IN THE AREA WHERE THE TURBO/EXHAUST MANIFOLD IS LOCATED. Remedy: DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

Technical service bulletins NHTSA · verified

Showing 5 of 239 bulletins on record with NHTSA.

BulletinDateComponentSummary
35526.1.82026-04-23EngineThis is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform…
37809.1.12026-04-07Unknown Or OtherThis is a TJ text only - The purpose of this TJ is to be a master reference list to…
192452025-12-06Unknown Or OtherThis is a Technical Journal. Vehicle type and platform identification.
85012025-04-10Exterior LightingThis is a Technical Journal: Remote connection, BOMGAR application. Before joining a…
S103032025-02-21Unknown Or OtherVolvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific S40. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 S40 take?

6.1 qt of 4 degrees F TO 104 degrees F: 10W-30 API, BELOW 86 degrees F: 5W-30 API, BELOW 104 degrees F: 5W-40 API, per the factory manual.

Does the 2004 S40 have open recalls?

NHTSA lists 6 recall campaign(s) for this model year. Check your specific vehicle by VIN.