Faults:

I haven't had any issues with this car, honestly. It warms the deep holes in my heart knowing that this vehicle is extremely well built and is able to handle pot holes and rough roads like a champ.

I had to replace a valve or gasket (something dealing with the fuel tank) at 108000 miles and it cost about $300. But besides that, I haven't had ANYTHING go wrong. It still looks beautiful and contemporary.

In addition to that, people still comment that they thought my car was brand new (or they did after I had just purchased it).

General Comments:

I have a 2004.5. Weird, I know. What that means is I have the 2005-2007 version of the Volvo S40, but they were eager to throw this car into the market, so Volvo discontinued its old 2004 S40 halfway through the year and began selling the 2005 S40 halfway through 2004.

So technically, my car is registered as a 2004 S40, but for all of the mechanic's preferences I've talked to, I'm supposed to refer to it as a 2005 (or 2004.5, they know what that means, too).

I just really love this car. This is my little Swedish tank. It feels like a hefty car, but I can always fit in the tiniest parking spots.

It also, albeit it doesn't look like it, can turn on a dime. I literally ZIP AND ZOOM around in this vehicle. This is my beautiful precious Volvo.

General Comments:

I was broadsided on the driver door side by an Infiniti SUV going about 35 mph - all airbags deployed - not hurt at all - plenty shook up though - but the car was total loss.

The dealer was right - they are very safe!!

Faults:

The electric seat adjuster on the driver side wore out resulting in the seat rocking back and forth. The dealer replaced it under (extended) warranty.

A vibration in the front of the car (tire balance?) was fixed by the dealer putting on two new tires. They were replaced for free as this was a previously known condition.

A few of the warning lights on the dash would come on periodically when starting up. The dealer replaced the associated wiring loom and all is now well.

The vehicle surges slightly under hard acceleration but I have yet to take it to the dealer for diagnosis.

General Comments:

I am completely happy with the car. My wife bought a 2002 S40 a few years back, and her's has had even fewer problems. We are a Volvo family at the moment and are quite happy about that.

Performance wise, the car accelerates like a high power V6 but returns mileage better than my 1998 VW Jetta. Usually around 9.0 l/100km in the city and I have seen 6.1 l/100km on the highway. Very comfortable interior. My only complaint would be that the FM receiver is a little weak. Otherwise, I'm prepared to keep this car for at least 10 years.

Addendum 22nd September 2010: The dealer put me off until the warranty expired. The steering vibration was never found, but the transmission had burned out clutch packs. The dealer just figured that out. No problem though as I just traded it in on a 2011 Mercedes Benz GLK 350 4-matic.

Faults:

Leak detection pump failed at 72,180 miles. No cost to me; dealer fixed before I purchased.

Power antenna mast broke off. Dealer fixed for free; it was broken during a service visit, their fault.

Light bulbs behind climate controls burned out, Dealer also fixed for free.

General Comments:

First I must say I disagree with the negative reviews others posted about this car. My car is the 2004 1.9T model not the newer 2004.5, 2.4i model.

My Volvo dealer took great care of me and quickly addressed the little issues I had when I purchased it. I think any car is only as good as the dealer you have standing behind it, and they did a lot to help me BEFORE AND AFTER the sale.

ENGINE:

This car runs and drives great. The turbo operation is very smooth and quiet; you wouldn't even know it was a turbocharged motor by driving it, you would think it was a V6, not a 4 cylinder. I average 27 MPG, but I drive hard. When I drive more reserved I can get 30 MPG no problem.

TRANSMISSION:

The automatic transmission takes a bit of getting used to. I read reviews about the transmission "jerking" when down-shifting at low speeds, but I actually like the way it operates. When you are going slow and need to take off quickly, such as coming onto an interstate ramp, it's nice to have the transmission already in a low gear and ready to take off. It also has a tendency to down-shift when creeping down a hill in traffic etc., also a good thing in my opinion because it holds the car back. Another nice option is the "Weather Mode" that you can activate to increase winter traction. It puts the car in 3rd gear from the start to decrease the chance of wheels slip in unfavorable road conditions.

CLIMATE CONTROL:

The climate control knobs are easy to adjust and the system does a great job at keeping a comfortable temperature without having to keep adjusting the settings. Set it to "Auto" mode, turn to the desired temp and forget it, easy! The cabin air filter is under the passenger side dash and filters the A/C and Heater air in both fresh air mode and recirculate mode. Most cars only filter the cabin air coming in from the outside not the air inside the car. The heated seats are sweet on those cold days, and even turn on automatically in freezing weather so if you start your car to warm it up, it warms the seats too. Headlight washers and wipers are also a great feature for those foul winter days.

STEERING AND SUSPENSION:

The car handles very well. Steering is very responsive, and stiff enough for a sporty feel and great control. Ride is a bit stiff, and bumpy roads cause a few minor rattles, but it's worth it for good handling. DSA (Dynamic Stability Assistance) helps.

BRAKE SYSTEM:

Brakes work great! I replaced factory pads with Akebono Euro Ceramic brakes pads only because the Volvo pads cause way too much brake dust on my wheels. My wheels were turning black every 3-4 days. The Akebono pads work just as well with no brake dust at all. The 4 wheel ABS reacts very well in emergency situations.

COMFORT:

It is said Volvo makes some of the worlds most comfortable seats, and I have to totally agree. The seats do a great job of supporting your whole body.

The controls are laid out very well. Turn signals, cruise control, and wipers are accessible without having to take your hands off the wheel.

The power sunroof opens with just a tap of a button on the roof, and does a great job and bringing in fresh air.

The back seat is not very roomy, but the shape of the front seat-backs, provides some extra hidden space to give more leg room. I have had adults fit comfortable in the back without having to move up the front seats more than a little bit. The integrated child seats are also a nice feature, though I don't have children to try them out.

SAFETY:

Dual front air bags, side air bags, inflatable side curtain air bags, whiplash protection seats, seat belt pre-tensioners (remove excess belt slack during accident impact), 4 wheel ABS, dynamic stability assistance, would anyone expect less from Volvo?

SUMMARY:

I am very glad I purchased this car, it has not been any more expensive to maintain than the American made cars I owned. I feel very safe driving this car despite its small size.

I would definitely purchase another Volvo, and recommend the S40 1.9T (not the 2004.5 2.4i, I had one as a loaner and didn't like it as much) to anyone looking for a smaller European model.