Volvo 40 Series Exhaust Assembly for Sale | OEM Used Volvo S40 Sedan / V40 Wagon Complete System
$499.00
At a Glance
- Condition: OEM used, leak-tested before shipping
- Availability: In stock for Volvo S40 sedan and V40 wagon
- Shipping: Free shipping to all 50 states, freight heavy-item 5 to 10 day transit
- Stainless steel construction for modern Volvo era
- Leak-tested before shipping, donor disclosed
- Federal EPA OBD-II compliance verified
- 100% inspection before every order ships
- Backed by a 15 day replacement warranty
Description
About the Volvo 40 Series Exhaust Assembly
Direct fit Volvo S40 sedan US 2000 to 2011 (12 years) and Volvo V40 wagon US 2000 to 2004 (5 years; the wagon was discontinued in the US after 2004). “Volvo 40 Series” refers to the S40 sedan and V40 wagon: 40 indicates the compact sedan and wagon size tier in Volvo’s modern naming hierarchy (S is for sedan, V is for versatile / wagon; see the related Volvo 30 Series C30 listing for the 30 Series naming detail).
40 Series Production History
17-plus years across two generations: 1st generation 1995 to 2004 (US 2000 to 2004), and 2nd generation 2004 to 2012 (US 2004 to 2011). The modern V40 hatchback (2012 to 2019) was European-only and never US-sold.
1st generation 1995 to 2004 (US 2000 to 2004) was built on the Volvo P1 platform with the Mitsubishi Carisma as a sister vehicle at the NedCar Plant in the Netherlands. NedCar (Netherlands Car Company) was a joint venture between Volvo, Mitsubishi Motors, and the Dutch government. The two cars were identical mechanically underneath with different brand body styling. This was a notable era for Volvo-Mitsubishi cooperation.
2nd generation 2004 to 2012 (US 2004 to 2011) was built on the Ford C1 / Volvo P1 / EUCD platform shared with the C30 hatchback, V50 wagon, Ford Focus 2nd-gen, and Mazda3 1st-gen. This was the Ford-Volvo-Mazda alliance era platform sharing during Ford Premier Auto Group’s 1999 to 2010 ownership of Volvo.
40 Series Engines and Transmissions
40 Series engines varied by generation and market. US options included the 1.6L / 1.8L / 1.9L / 2.0L I4 (various smaller engines), the 2.4L I5 NA (approximately 168 hp from Volvo’s famous I5 engine family), and the 2.5L Turbo I5 T5 (approximately 227 hp performance variant). The 2.0L diesel was Europe-only. Transmissions: 5-speed manual or 5-speed automatic (1st gen), 6-speed manual M66 Aisin or 5-speed Geartronic automatic (2nd gen).
Drivetrain: FWD standard, with some 2nd-gen S40 T5 offering optional AWD in some markets. Trim levels varied: Base, T4 (1st-gen turbo), T5 (turbo performance), R-Design (2nd-gen sport with Polestar-inspired styling).
Exhaust Assembly Components
The complete exhaust system consists of: (1) front downpipe / flex section with catalytic converter mounting, (2) catalytic converter section with Pt/Pd/Rh 3-way catalyst over cordierite ceramic honeycomb, (3) mid-pipe with resonator for sound tuning, (4) muffler with internal baffling chambers for sound reduction, (5) tailpipe / exhaust tip, (6) all flanges with gaskets at junction points, and (7) rubber hangers / isolators suspending the exhaust from the chassis.
Construction: stainless steel for modern Volvo era (resistant to rust corrosion), with some sections aluminized steel where cost-optimized. Welded construction; manufacturer-pressed and spun mufflers. Modern Volvo exhausts are typically more durable than older Volvo 200, 700, and 900 series.
Common Failure Modes
- Rust-through corrosion (salt-belt areas, particularly after 10 to 15 years of road salt exposure)
- Broken hangers (rubber isolators deteriorate from UV, heat, and age, causing the exhaust to sag and hit the underbody)
- Dented from impacts (speed bumps, rocks, curb strikes)
- Catalyst failure (P0420 code)
- Cracked welds at stress points
- Flange leaks at gasket junctions
Symptoms: loud exhaust noise, hissing or roaring under load, exhaust fumes inside the cabin (safety concern), reduced fuel economy, check engine light P0420, visible smoke or external corrosion, or exhaust hanging low.
Replacement Difficulty
Moderate DIY 2 to 4 hours for full assembly. Requires vehicle lift or jack stands. May need penetrating oil for seized flange bolts on aging vehicles. Replacement of all gaskets and hangers is recommended during installation.
Vehicle Compatibility
| Detail | Description |
|---|---|
| Volvo S40 1st Gen US 2000-2004 | Different P1 platform exhaust |
| Volvo V40 Wagon 1st Gen US 2000-2004 | Different P1 platform exhaust |
| Volvo S40 2nd Gen US 2004-2011 | Ford C1/EUCD platform exhaust |
| Generation Note: 2004 transition year both platforms possible | |
| Engine Specific: | |
| 2.4L I5 NA Engine | Standard exhaust |
| 2.5L Turbo I5 T5 Engine | Different exhaust (higher flow, turbo specific) |
| 1.8L/1.9L/2.0L I4 (1st Gen) | I4-specific exhaust |
| Body Style: | |
| S40 Sedan | Sedan-specific routing |
| V40 Wagon (1st gen US 2000-2004) | Wagon-specific routing |
| Sister Vehicles (2nd Gen Same Platform): | |
| Volvo C30 Hatchback 2007-2013 | Same engines – cat section may share |
| Volvo V50 Wagon 2004-2011 | Same engines – some parts share |
| Ford Focus 2nd Gen / Mazda3 1st Gen | Different engines – NOT interchangeable |
| California Emissions (CARB) | Different cat section than 49-state federal |
| NOT Compatible: Modern V40 Hatch (2012-2019) | European-only different platform |
Fitment Assistance
Call (855) 634-4447. Critical questions: (1) year (2000 to 2011), (2) generation (1st-gen P1 2000 to 2004 vs 2nd-gen Ford C1 2004 to 2011), (3) body style (S40 sedan or V40 wagon), (4) engine (I4 vs I5, different exhaust sizing), (5) federal vs California emissions, (6) specific section(s) needed (full assembly vs partial sections).
Inspection Workflow
- Stainless steel sections, no rust-through (surface rust acceptable)
- Mufflers and resonators intact, no internal baffle damage (rattle test)
- Catalyst section verified (substrate intact if cat included)
- Welds inspected, no cracked or detached welds
- Flanges intact, no warping, gasket surface clean
- Hangers present, all rubber isolators inspected
- No major dents that would restrict exhaust flow
- O2 sensor bungs intact (pre-cat and post-cat)
- Leak-tested with compressed air or smoke test
- Donor vehicle disclosed
Why Buy From Part Nests
- Volvo 40 Series exhaust for S40 sedan and V40 wagon
- 12-year S40 plus 5-year V40 US production coverage
- Volvo modern naming hierarchy expertise
- 1st generation P1 platform knowledge
- Mitsubishi Carisma sister vehicle context (NedCar Netherlands)
- NedCar joint venture heritage (Volvo-Mitsubishi-Dutch government)
- 2nd generation Ford C1 / EUCD platform expertise
- Sister C30 hatch and V50 wagon cross-compatibility
- Ford-Volvo-Mazda alliance era (Ford PAG 1999 to 2010)
- Volvo I5 engine family knowledge
- 2.4L NA vs 2.5L Turbo T5 distinction
- Multiple I4 engine variant knowledge
- Stainless steel modern Volvo construction knowledge
- Cat section P0420 diagnostic context
- Leak-tested before shipping
- Donor disclosed, free shipping, no core charge
- 15 day replacement warranty
- Call (855) 634-4447 with your year, generation, body style, and engine for compatibility verification before ordering
15 Day Replacement Warranty
Every used Volvo 40 Series exhaust assembly purchased through Part Nests carries a 15 day replacement warranty starting on the delivery date.
What Is Covered
- Operational defects in exhaust integrity (leaks beyond what was disclosed)
- Catalyst section failures within 15 days (P0420 codes)
- Welds, flanges, or hangers failing beyond what was disclosed
- Incorrect generation or engine variant shipped due to an error on our end
What Is Not Covered
- Damage caused during installation
- Damage from operating with an engine misfire or oil burning issue
- Rust development after installation
- State emissions inspection rejection in CARB states for federal-only catalyst sections
- Labor expenses of any kind
To start a warranty claim, reach us within 15 days of delivery at (855) 634-4447.
- Leak-Tested Before Shipping: Compressed air or smoke test performed
- Welds Inspected: No cracked or detached welds
- Flanges Intact: Gasket surface clean, no warping
- O2 Bungs Functional: Pre-cat and post-cat threads clean
- Donor Vehicle Disclosed: Year, generation, body, engine documented
- 15 Day Replacement Cover: Operational defects protected from delivery onward
Additional information
| Brand | Volvo |
|---|---|
| Part Type | Complete exhaust system assembly |
| Vehicle | Volvo S40 sedan US 2000-2011, V40 wagon US 2000-2004 |
| Naming | Volvo 40 Series = S40/V40 compact tier |
| Generations | 1st 1995-2004 (P1), 2nd 2004-2012 (Ford C1) |
| 1st Gen Sister | Mitsubishi Carisma (NedCar Netherlands) |
| 2nd Gen Sister | C30/V50/Focus/Mazda3 (Ford C1) |
| Modern V40 Hatch | 2012-2019 European-only |
| Engines | 1.6-2.0L I4, 2.4L I5 NA, 2.5L Turbo T5 |
| Transmissions | 5-spd manual/auto (1st), 6-spd M66/Geartronic (2nd) |
| Drivetrain | FWD standard, AWD optional some 2nd gen T5 |
| Components | Downpipe, cat, resonator, muffler, tailpipe, flanges, hangers |
| Construction | Stainless steel (modern Volvo) |
| Common Failure | Rust-through, broken hangers, dents, P0420 |
| Installation | Moderate DIY, 2-4 hours |
| Donor Disclosed | Year, generation, engine, body style |
| SKU | vaz542 |
| Price | $249.00 |
The 40 in Volvo's modern naming hierarchy indicates the compact sedan and wagon size tier. The S40 (S for sedan) and V40 (V for versatile / wagon) share the 40 designation. The C30 hatchback (this product's sister listing) is the 30 Series. Larger Volvos use 60, 80, and 90 designations. The 40 Series covers both 1st-gen P1 platform (2000 to 2004 US) and 2nd-gen Ford C1 / EUCD platform (2004 to 2011 US) cars.
Year is the primary indicator. US-market 2000 to 2004 = 1st-gen P1 platform. US-market 2004 to 2011 = 2nd-gen Ford C1 / EUCD platform. The 2004 model year is a transition year; both platforms exist. Call us with your VIN if you have a 2004 model year and we will identify the generation. Exhaust geometry differs between the two generations, so generation identification is critical for fitment.
The 1st-gen Volvo S40 / V40 (P1 platform) was built at the NedCar plant in the Netherlands as part of a joint venture between Volvo, Mitsubishi Motors, and the Dutch government. The Mitsubishi Carisma (a European-market sedan) was the sister vehicle built on the same platform with different brand body styling. This was a notable era for Volvo-Mitsubishi cooperation; mechanically the two cars are very similar underneath.
Body style determines fitment. S40 sedan exhaust and V40 wagon exhaust have different rear-section routing because the body style differs at the rear (sedan trunk vs wagon liftgate). Within the same generation and engine, the front sections (downpipe, cat) may share. We confirm body style on every order to ensure correct fitment.
Sizing and configuration. The I4 engines (1.6L, 1.8L, 1.9L, 2.0L) use a 4-cylinder exhaust with appropriate flow sizing. The I5 engines (2.4L NA, 2.5L Turbo T5) use a 5-cylinder exhaust with different runner geometry on the manifold side and higher flow capacity throughout. The two are NOT interchangeable. Always confirm engine when ordering.
Some sections, yes; the full assembly, no. The C30 hatchback (2007 to 2013) and V50 wagon (2004 to 2011) share the 2nd-gen Ford C1 / EUCD platform with the 2nd-gen S40 / V40. The catalyst section may share between the three platform sisters within the same engine. Mid-pipe, resonator, muffler, and tailpipe sections differ because of different body style routing. Call us with your specific configuration for cross-reference.
A 5-door hatchback sold in European markets from 2012 to 2019. The modern V40 is NOT the same vehicle as the 1st-gen V40 wagon (2000 to 2004) sold in the US. The modern V40 was never officially sold in the US. This listing applies to the original V40 wagon and S40 sedan; it does not fit the modern V40 hatchback.
No. There is no core return required.
Margareta L. –
Got the part for my Volvo 40 Series Exhaust Assembly. Simple process end to end.
Hans G. –
Bolted up to the Volvo 40 Series Exhaust Assembly clean. Nothing to complain about.