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2005 Volvo S40

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2005 S40.

Body PASSENGER CARTransmission Automatic (S5)

The 2005 Volvo S40 is a passenger car equipped with an automatic (S5) transmission and EPA ratings of 18 city, 25 highway, and 20 combined mpg, with an engine requiring 6.1 quarts of 10W-30, 5W-30, or 5W-40 API oil. Across the model's complaint history spanning 2000 through 2011, this model year's 81 owner complaints—led by electrical system issues and accompanied by three recalls—place it firmly in the upper-middle tier, well below the 134-complaint peak of 2000 but far above the 5-complaint low of 2011. That positioning places the 2005 S40 in a period of declining but still-elevated problem frequency, meaning researchers should weigh its electrical-system concerns against clear evidence that the platform was on a gradual reliability upswing toward the end of its run.

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
EPA fuel economy18/25/20 mpgEPA · verified

Fitment & sizes

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

From the factory this vehicle uses a BCI 91 · 590 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 91 · 590 CCAOEM · verified
Tire size205-50R17OEM · verified
Wheel / rim7 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter8692305
Engine air filter30757155
Fuel filter31271607 alt 31273741
Battery30772221 alt 30772226
Front wiper blades31457759
Thermostat31319608
Cabin air filter30780377 alt 30780376

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic (S5)

Dimensions & weight NHTSA vPIC

Overall length176.4 in
Overall width69.7 in
Overall height57.1 in
Wheelbase103.9 in
Curb weight2965 lb
Track (front / rear)59.8 / 59.1 in
Weight distribution (front / rear)61/39

Ratings & economy EPA / vPIC

EPA city / highway / combined18 / 25 / 20 mpg
Drivetrain4-Wheel or All-Wheel Drive
Passenger volume92 cu ft
Cargo volume14 cu ft
Recommended fuelPremium Gasoline

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.

6.7–7.1 sec0–60 mph (tested)quickest 6.70 sec — 2005 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. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

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
Manual Transmission FluidVolvo part number 1161745
Manual Transmission Fluid Capacity4.2

Engine torques

Crankshaft Pulley and/or Damper Bolts133 ft-lbs
Intake Manifold to Engine Bolts15 ft-lbs
Exhaust Manifold to Cylinder Head Bolts19 ft-lbs
Intake Manifold to Engine BoltsLower: 14 ft-lbs; Upper: 7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts27 ft-lbs
Engine Oil Pan Drain Plug28.0 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs4 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs48 ft-lbs

Chassis torques

Lug Nuts81 ft-lbs
Transfer Case Fill Plug27.0 ft-lbs
Front Wheel Hub26 ft-lbs

Ignition

Cylinder Firing Order1-2-4-5-3
Curb Idle Speed (No Load)720 rpm
Curb Idle Speed (No Load)670 rpm
Spark Plug Gap0.027 in
Spark Plug Torque22.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.20-1.30 lbs
Oil TypeVolvo part number 87085817 or equivalent
Oil Capacity6.00-6.10 oz
Standard BCI Group Number91
Standard BCI Cranking Performance590 cca
Standard BCI Group Number91
Standard BCI Cranking Performance590 cca

Service checks

Pressure Test22 psi
Radiator Cap Pressure Relief22 psi
Thermostat Opening Temperature194 °F
Pressure Test22 psi
Radiator Cap Pressure Relief22 psi
Thermostat Opening Temperature194 °F
RPMLine pressure 55 @ idle rpm
Injector Primary Resistance12 ohms

Brakes

Torque Caliper to Bracket22 ft-lbs
Torque to Knuckle88 ft-lbs / 51 ft-lbs
Minimum Pad ThicknessFront: 0.079; Rear: 0.079 in
Rotor Runout Limit0.0029 in / 0.0019 in
Rotor Minimum Machining0.937 in / 0.386 in
Rotor Discard at or Under0.906 in / 0.354 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs, Step 2: 18 ft. lbs, Step 3: 10011 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs, Step 2: 18 ft. lbs., Step 3: 10011 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs., Step 2: 18 ft. lbs., Step 3: 10011 ft. lbs
Cylinder Head — tightening sequence 3 stages
115 ft. lbs.15 ft. lbs
244 ft. lbs.44 ft. lbs
3130 degrees.130 degrees
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 60,000 mi.

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 Shift Interlock Solenoid (inspect) · Cabin Air Filter (replace) · Door Hinge (lubricate) · Engine Coolant System (inspect fluid level) · Final Drive (inspect fluid level)
Every 30,000 miBrake Line (inspect) · Fuel Line (inspect)
Every 37,500 miBrake Hydraulic System (drain, refill & bleed) · Engine Air Filter Element (replace)
At 60,000 miCV Joint Boot (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Exhaust System (Complete) (inspect) · Steering System (inspect) · Suspension System (inspect)
Every 60,000 miSpark Plugs (replace)
At 105,000 miDrive Belt (replace) · PCV Hose (inspect)
At 150,000 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.

Across this generation, federal records show an early peak in complaints in 2000 (134), a sharp decline to a low of 21 complaints in 2003, a sudden spike in 2004, and a steady tapering off from 2006 onward. The 2005 model year sits at the apex of this secondary spike, registering 81 complaints and 3 recalls, which is significantly higher than the preceding 2003 (21 complaints) and the subsequent 2006 (59 complaints). For the 2005 S40 specifically, the primary trouble areas are the Electrical System (11 complaints) and Engine & Engine Cooling (10 complaints), alongside Fuel System issues, though the data does not specify the root causes for these failures. Safety-related concerns remain limited, with only 2 crash complaints and 0 fire complaints recorded for this target year. Because the 2005 model exhibits a disproportionately high number of complaints and recalls compared to the more stable later years in this generation's arc, buyers should skip this year in favor of a 2007 or newer model.

3
Open recalls
NHTSA campaigns
177
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
81
Owner complaints
2 involved a crash · 0 a fire
Owner complaints by model year NHTSA · this generation & adjacent
’00’01’02’03’04’05’06’07’08’09’10’11

Owner complaints filed with NHTSA, by component

All 81 complaints on record, top 8 components.

Electrical System11
Engine & Engine Cooling10
Fuel System, Gasoline7
Fuel/Propulsion System5
Visibility5
Engine4
Service Brakes, Hydraulic4
Air Bags3

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 3 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 177 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.

Group 91 batteryVehicles taking 6.1 qtEngine oil filter 8692305Engine air filter 30757155Fuel filter 31271607Battery 30772221

Reference guides

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

Vehicle recalls & TSBsOBD-II trouble codesTorque specificationsMaintenance schedulesFluid capacities & specs

Frequently asked

How much oil does the 2005 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 2005 S40 have open recalls?

NHTSA lists 3 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the S40 get?

EPA figures are 18 city / 25 highway / 20 combined mpg.