Volvo Volvo S40 2004-2012 Fuel System Specifications
Volvo Volvo S40 2004-2012

Volvo Volvo S40 2004-2012 Fuel System Specifications

Explore detailed fuel specifications for the 2004-2012 Volvo S40, including fuel type, tank capacity, economy, and emission standards. Ideal for maintenance, troubleshooting, and performance upgrades.

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Overview Specifications

This document provides detailed fuel specifications for the 2004-2012 Volvo S40. It includes information on fuel types, consumption, tank capacity, and related technical details. Use this guide to understand the vehicle's fuel requirements and optimize performance. The document is organized into sections for easy navigation, with a quick reference table for key specifications.

How to Use

Use the search function to find specific terms or phrases related to fuel specifications. Enter keywords like 'fuel type' or 'tank capacity' to quickly locate relevant information.

Navigate through the document using the section titles and subsections. Each section is labeled clearly, and subsections provide detailed points for easy reference.

Key Specifications

Fuel Type

Premium Unleaded (91+ octane)

Fuel Tank Capacity

15.9 gallons

City MPG

20-22 MPG

Highway MPG

28-30 MPG

Combined MPG

24-26 MPG

Available Specifications

Fuel Types and Requirements

This section covers the types of fuel recommended for the 2004-2012 Volvo S40, including octane ratings and any specific requirements for optimal performance.

Recommended Fuel Types
  • Premium unleaded gasoline (91 octane or higher)
  • Regular unleaded gasoline (87 octane) acceptable but may reduce performance
  • Ethanol blends up to E10 (10% ethanol) are compatible
  • Diesel engines not available for this model year range
Fuel Additives
  • Use of fuel system cleaners recommended every 10,000 miles
  • Avoid additives containing methanol or silicone
  • Volvo-approved additives available for enhanced performance
  • Check owner's manual for specific additive recommendations

Fuel Consumption and Efficiency

This section provides details on the fuel consumption rates for the Volvo S40, including city, highway, and combined MPG ratings.

City and Highway MPG
  • City MPG: 20-22 MPG depending on engine and transmission
  • Highway MPG: 28-30 MPG depending on engine and transmission
  • Combined MPG: 24-26 MPG
  • Fuel efficiency varies with driving conditions and maintenance
Factors Affecting Fuel Efficiency
  • Aggressive driving reduces fuel efficiency
  • Proper tire inflation improves MPG
  • Regular maintenance ensures optimal fuel consumption
  • Use of air conditioning can lower efficiency

Fuel Tank and Capacity

This section outlines the fuel tank specifications, including capacity, materials, and refueling tips for the Volvo S40.

Fuel Tank Capacity
  • Fuel tank capacity: 15.9 gallons (60 liters)
  • Reserve fuel capacity: 2.1 gallons (8 liters)
  • Material: High-density polyethylene for durability
  • Tank design minimizes fuel evaporation
Refueling Tips
  • Always use the correct fuel grade for optimal performance
  • Avoid overfilling the tank to prevent spillage
  • Check fuel cap seal for leaks or damage
  • Refuel when the tank is 1/4 full to avoid running on reserve

Component Specifications

Overview

Type
Gasoline/Diesel
Configuration
Front-mounted fuel tank
Capacity
14.5 gallons (55 liters)
Fuel System
Sequential multi-port fuel injection
Emission Standard
Euro 4 compliant
Location
Under rear seat

Dimensions

Tank Length
32.5 inches (82.5 cm)
Tank Width
22 inches (56 cm)
Tank Height
10.5 inches (26.7 cm)
Filler Neck Diameter
1.5 inches (3.8 cm)
Fuel Line Diameter
0.5 inches (1.27 cm)
Fuel Pump Output
45 psi (3.1 bar)
Fuel Filter Size
4.7 inches x 2.4 inches (12 cm x 6 cm)

Materials

Tank Material
High-density polyethylene
Fuel Lines
Reinforced synthetic rubber
Filler Neck
Galvanized steel
Fuel Pump
Thermoplastic housing with stainless steel components
Fuel Filter
Cellulose and resin composite

Features

Fuel Delivery
  • Electronic fuel pump
  • Pressure regulator
  • Returnless fuel system
  • Quick-connect fuel line fittings
Monitoring
  • Fuel level sensor
  • Low fuel warning light
  • Fuel consumption display
  • Diagnostic port for fuel system
Safety
  • Rollover valve
  • Vapor recovery system
  • Impact-resistant tank design
  • Leak detection system
Environmental
  • Evaporative emissions control
  • Sealed fuel system
  • Recyclable tank material
  • Low-permeation fuel lines
Maintenance
  • Replaceable fuel filter
  • Serviceable fuel pump
  • Accessible fuel lines
  • Drain plug for tank cleaning

Safety Features

Crash Protection
  • Automatic fuel shutoff
  • Reinforced tank structure
  • Breakaway fuel lines
Fire Prevention
  • Flame arrestor in filler neck
  • Thermal protection for fuel lines
  • Vent system pressure relief
Environmental Protection
  • Double-walled tank design
  • Vapor recovery system
  • Spill-proof filler neck

Comfort Features

Refueling
  • Easy-access fuel door
  • Lockable fuel cap
  • Fuel level indicator
  • Automatic nozzle shutoff
Driving
  • Smooth fuel delivery
  • Quiet fuel pump operation
  • Stable fuel pressure
Maintenance
  • Easy fuel filter replacement
  • Accessible fuel pump
  • Clear fuel line routing

Accessories

Performance
  • High-flow fuel pump
  • Upgraded fuel filter
  • Fuel pressure regulator
Protection
  • Fuel tank skid plate
  • Fuel line protectors
  • Anti-siphon device
Diagnostics
  • Fuel pressure gauge
  • Fuel system scanner
  • Leak detection kit

Maintenance

Service interval
Every 30,000 miles or 24 months
Service Items
  • Inspect fuel lines for leaks
  • Replace fuel filter
  • Check fuel pump pressure
  • Clean fuel injectors
  • Inspect tank for damage
  • Test fuel level sensor
Maintenance Notes
Use only recommended fuel types and additives. Regular system cleaning recommended for optimal performance.

Warranty

Basic
Miles: 50,000
Years: 4
Coverage: Fuel pump and tank defects
Emissions
Miles: 80,000
Years: 7
Coverage: Fuel system emissions components
Corrosion
Miles: 100,000
Years: 10
Coverage: Fuel tank corrosion
Extended
Miles: 120,000
Years: 8
Coverage: Complete fuel system

Production Details

Manufacturer
Volvo Cars
Manufacturing Process
  • Injection molding for tank
  • Robotic assembly for fuel pump
  • Automated quality testing
Quality Control
Pressure Test: 100 psi for 24 hours
Leak Test: Helium detection
Material Test: Impact and chemical resistance
Sustainability Practices
  • Recycled materials in tank production
  • Low-VOC fuel lines
  • Energy-efficient manufacturing
Production Metrics
Units Per Day: 500
Defect Rate: 0.01%
Energy Usage: 15 kWh per unit

Service Information for fuel Service

Maintenance and service requirements specific to the fuel system

30,000
24
  • Inspect fuel lines and connections
  • Replace fuel filter
  • Check fuel pump pressure
  • Test fuel level sensor
  • Inspect tank for damage or leaks

Use only manufacturer-approved replacement parts

60,000
48
  • Clean fuel injectors
  • Inspect and clean fuel tank
  • Check evaporative emissions system
  • Test fuel pressure regulator
  • Inspect fuel filler neck and cap

Special tools required for fuel system diagnostics

100,000
84
  • Replace fuel pump assembly
  • Inspect and replace fuel lines if necessary
  • Perform complete fuel system flush
  • Test all fuel system sensors
  • Inspect and clean fuel tank vent system

Major service requiring specialized equipment and training

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What type of fuel is compatible with the 2004-2012 Volvo S40?

The 2004-2012 Volvo S40 is compatible with unleaded gasoline with an octane rating of 91 or higher. Using lower-octane fuel may result in reduced performance and engine knocking. Diesel or alternative fuels are not supported. Always refer to the owner's manual for specific fuel requirements and avoid using fuel additives unless approved by Volvo.

Q2

What are the maintenance requirements for the fuel system in a Volvo S40?

The fuel system in the 2004-2012 Volvo S40 requires regular maintenance, including fuel filter replacement every 30,000 miles and periodic inspection of fuel lines and injectors. Use high-quality fuel to prevent deposits. Check for leaks or unusual odors, and ensure the fuel cap is tightly sealed to maintain proper pressure and avoid emissions issues.

Q3

How do I replace the fuel filter in a 2004-2012 Volvo S40?

To replace the fuel filter, first, relieve fuel system pressure by removing the fuel pump fuse and running the engine until it stalls. Locate the fuel filter under the car near the fuel tank. Disconnect the fuel lines and remove the old filter. Install the new filter, ensuring proper orientation, and reconnect the fuel lines. Restore power to the fuel pump and check for leaks.

Q4

What should I do if my Volvo S40 has poor fuel economy?

Poor fuel economy in the Volvo S40 may result from a clogged fuel filter, dirty fuel injectors, or improper tire pressure. Check and replace the fuel filter if necessary, clean the injectors, and ensure tires are inflated to the recommended pressure. Additionally, inspect the air filter and oxygen sensors, as these can also impact fuel efficiency.

Q5

How can I optimize the fuel performance of my Volvo S40?

To optimize fuel performance, use high-octane gasoline, maintain proper tire pressure, and avoid excessive idling. Regularly replace the air and fuel filters, and ensure the engine is tuned correctly. Driving at consistent speeds and avoiding rapid acceleration can also improve fuel efficiency. Consider using fuel system cleaners periodically to maintain injector 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 Owner's Manual (2004-2012)

Coming Soon

Comprehensive guide covering fuel specifications, maintenance schedules, and troubleshooting tips for the Volvo S40.

Volvo S40 Technical Service Bulletin (TSB)

Coming Soon

Latest updates and fixes for common fuel system issues in the 2004-2012 Volvo S40.

Volvo S40 Fuel System Parts Catalog

Coming Soon

Detailed catalog of fuel system components, including filters, pumps, and injectors for the 2004-2012 Volvo S40.

About the Author

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Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

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