Volvo Volvo S40 1995-2004 Body Specifications
Volvo Volvo S40 1995-2004

Volvo Volvo S40 1995-2004 Body Specifications

Explore the detailed body specifications of the 1995-2004 Volvo S40, including dimensions, materials, and design features. This guide is essential for maintenance, repair, and restoration projects.

Updated

Overview Specifications

This document provides detailed specifications and technical information about the body design and features of the 1995-2004 Volvo S40. It is organized into sections covering dimensions, materials, design elements, and safety features. Use the search functionality to locate specific terms or navigate through sections to explore comprehensive details about the vehicle's body structure and design.

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Key Specifications

Length

4470 mm

Width

1710 mm

Height

1415 mm

Curb Weight

1280 kg

Cargo Capacity

340 liters

Available Specifications

Dimensions and Weight

This section covers the exterior and interior dimensions of the 1995-2004 Volvo S40, including length, width, height, and weight distribution. It also provides details on cargo capacity and seating space.

Exterior Dimensions
  • Length: 4470 mm
  • Width: 1710 mm
  • Height: 1415 mm
  • Wheelbase: 2550 mm
  • Ground clearance: 150 mm
  • Curb weight: 1280 kg
Interior Dimensions
  • Headroom (front/rear): 950 mm / 920 mm
  • Legroom (front/rear): 1050 mm / 890 mm
  • Shoulder room (front/rear): 1370 mm / 1350 mm
  • Cargo capacity: 340 liters

Body Materials and Construction

This section details the materials used in the construction of the Volvo S40's body, including steel, aluminum, and composite materials. It also highlights the vehicle's structural design for safety and durability.

Material Composition
  • High-strength steel used in the frame
  • Aluminum components for weight reduction
  • Composite materials in non-structural panels
  • Galvanized steel for corrosion resistance
Structural Design
  • Monocoque construction for rigidity
  • Energy-absorbing crumple zones
  • Reinforced side-impact protection
  • Integrated roll-over protection

Design Features

This section explores the aesthetic and functional design elements of the Volvo S40, including exterior styling, lighting, and aerodynamic features.

Exterior Styling
  • Sleek, aerodynamic profile
  • Distinctive Volvo grille design
  • Integrated fog lights
  • Body-colored bumpers and mirrors
Lighting and Visibility
  • Halogen headlights with adjustable beams
  • Rear LED taillights
  • Heated rear window with defogger
  • Electrically adjustable side mirrors

Safety Features

This section highlights the safety features integrated into the body design of the Volvo S40, focusing on crash protection and occupant safety.

Crash Protection
  • Front and side airbags
  • Seatbelt pretensioners
  • Anti-lock braking system (ABS)
  • Whiplash Protection System (WHIPS)
Occupant Safety
  • Child safety locks on rear doors
  • ISOFIX child seat anchors
  • Height-adjustable seatbelts
  • Reinforced roof structure

Component Specifications

Overview

Type
Sedan
Configuration
4-door
Platform
Volvo P1 platform
Material
High-strength steel
Location
Manufactured in Born, Netherlands

Dimensions

Length
4470 mm (176.0 in)
Width
1720 mm (67.7 in)
Height
1420 mm (55.9 in)
Wheelbase
2640 mm (103.9 in)
Curb Weight
1300-1400 kg (2866-3086 lbs)
Ground Clearance
150 mm (5.9 in)
Trunk Capacity
416 liters (14.7 cu ft)

Materials

Body Frame
High-strength steel with reinforced safety cage
Hood
Aluminum
Doors
Steel with side-impact beams
Roof
Steel with optional sunroof
Bumpers
Plastic with integrated shock absorbers

Features

Exterior
  • Aerodynamic design
  • Integrated fog lights
  • Chrome accents
  • Body-colored mirrors
interior
  • Leather or fabric upholstery
  • Adjustable steering wheel
  • Power windows
  • Central locking system
Lighting
  • Halogen headlights
  • LED tail lights
  • Automatic headlight control
  • Daytime running lights
Storage
  • Foldable rear seats
  • Glove compartment
  • Door pockets
  • Cup holders
Climate Control
  • Manual or automatic AC
  • Rear defroster
  • Air filtration system
  • Heated seats (optional)

Safety Features

Structural
  • Reinforced safety cage
  • Side-impact protection system (SIPS)
  • Crash beams in doors
Airbags
  • Dual front airbags
  • Side airbags (optional)
  • Curtain airbags (optional)
Active Safety
  • Anti-lock braking system (ABS)
  • Traction control
  • Electronic stability control (ESC)

Comfort Features

Seating
  • Adjustable front seats
  • Lumbar support
  • Heated front seats (optional)
Audio
  • AM/FM radio
  • CD player
  • Premium sound system (optional)
Convenience
  • Power mirrors
  • Cruise control
  • Remote keyless entry
Visibility
  • Electrically adjustable mirrors
  • Rear window wiper
  • Rain-sensing wipers (optional)

Accessories

Exterior
  • Roof rack
  • Mud flaps
  • Chrome trim
interior
  • Floor mats
  • Cargo net
  • Seat covers
Performance
  • Alloy wheels
  • Sport suspension
  • Performance exhaust

Maintenance

Service interval
Every 10,000 miles or 12 months
Service Items
  • Inspect body for rust or damage
  • Check door seals and hinges
  • Lubricate locks and hinges
  • Inspect and clean sunroof (if equipped)
  • Check and adjust headlight alignment
Maintenance Notes
Regular waxing recommended to protect paint

Warranty

Basic
Miles: 50,000
Years: 4
Coverage: Bumper-to-bumper
Corrosion
Miles: Unlimited
Years: 12
Coverage: Perforation only
Powertrain
Miles: 100,000
Years: 5
Coverage: Engine and transmission
Roadside Assistance
Miles: Unlimited
Years: 4
Coverage: 24/7 assistance

Production Details

Manufacturer
Volvo Cars
Manufacturing Process
  • Laser welding
  • Robotic assembly
  • Electro-coating for rust protection
Quality Control
inspection: 100% body integrity check
Testing: Crash test compliance
Certification: ISO 9001
Sustainability Practices
  • Recyclable materials
  • Low-emission painting process
  • Energy-efficient manufacturing
Production Metrics
Annual Output: Approximately 100,000 units
Production Time: 20 hours per vehicle

Service Information for body Service

Maintenance and service requirements specific to the body

10,000
12
  • Inspect body for rust or damage
  • Check door seals and hinges
  • Lubricate locks and hinges
  • Inspect and clean sunroof (if equipped)
  • Check and adjust headlight alignment

Regular waxing recommended to protect paint

30,000
36
  • Inspect and clean drainage channels
  • Check and replace worn door seals
  • Inspect and tighten body bolts
  • Check and adjust hood latch
  • Inspect and clean exterior trim

Special attention to areas prone to rust

60,000
72
  • Full body inspection for structural integrity
  • Check and replace any damaged body panels
  • Inspect and repair any paint damage
  • Check and replace worn weather stripping
  • Inspect and clean underbody for debris

Critical to address any rust or corrosion immediately

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What are the technical specifications for the 1995-2004 Volvo S40?

The 1995-2004 Volvo S40 is a compact sedan with a 1.9L turbocharged or naturally aspirated engine, producing 120-160 horsepower. It features front-wheel drive, a 5-speed manual or 4-speed automatic transmission, and a curb weight of approximately 2,800 lbs. The car is compatible with 91-octane fuel and has a fuel capacity of 15.9 gallons. It includes ABS, dual airbags, and a reinforced safety cage for enhanced protection.

Q2

What are the maintenance requirements for the Volvo S40?

The Volvo S40 requires regular maintenance, including oil changes every 5,000-7,500 miles, air filter replacement every 15,000 miles, and spark plug replacement every 30,000 miles. The timing belt should be inspected every 60,000 miles and replaced if necessary. Brake fluid and coolant should be flushed every 2 years, and tire rotation is recommended every 7,500 miles to ensure even wear.

Q3

How do I replace the headlights on a 1995-2004 Volvo S40?

To replace the headlights on a Volvo S40, first, open the hood and locate the headlight assembly. Remove the rubber cover behind the headlight. Disconnect the wiring harness by pressing the release tab. Twist the bulb holder counterclockwise and remove it. Insert the new bulb, ensuring not to touch the glass, and reconnect the wiring harness. Secure the rubber cover and test the headlights.

Q4

What should I do if my Volvo S40 is overheating?

If your Volvo S40 is overheating, first check the coolant level and top it off if necessary. Inspect for leaks in the radiator, hoses, or water pump. Ensure the radiator fan is functioning properly. If the issue persists, check the thermostat for proper operation and replace it if faulty. Avoid driving the car until the issue is resolved to prevent engine damage.

Q5

How can I optimize the performance of my Volvo S40?

To optimize performance, use high-quality synthetic oil and ensure regular maintenance. Upgrade to high-performance air filters and spark plugs. Consider a performance chip or ECU remap for improved power and fuel efficiency. Regularly check tire pressure and alignment for better handling. Use premium fuel and keep the engine and transmission in good condition for optimal performance.

Factory Service Resources

Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.

Volvo S40 Service Manual

Coming Soon

Comprehensive guide covering maintenance, repairs, and technical specifications for the 1995-2004 Volvo S40.

Volvo S40 Technical Service Bulletin

Coming Soon

Latest updates and fixes for common issues in the 1995-2004 Volvo S40, including recalls and technical improvements.

Volvo S40 Parts Catalog

Coming Soon

Detailed catalog of OEM and aftermarket parts for the 1995-2004 Volvo S40, including part numbers and compatibility information.

About the Author

Expert automotive knowledge and experience

Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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