Volvo made a critical error in marketing this Mitsubishi built car as a Volvo. It has really hurt their overall rep in the USA. While the car is decent and can last a good while if HEAVILY cared for (now at 135K and still running strong), it just does not have the build quality of a Swedish built sedan. Volvo if you learn anything from this experience, do NOT sell out again just to get market share...it hurts you in the long run. Volvo buyers are NOT simple minded and we know good products and bad products. The 2000-04 S40 is just a bad product (relative to what we expect)
I was able to rebuild the front end and work on the vehicle without much difficulty.