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2004 Volvo S40

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Volvo S40 do not stand out strongly from the model-year median of 26.

About this comparison →

When problems were reported

Mileage at the reported incident

35 reports with mileage · 13 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Air Bags. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

5 crash reports1 fire reports4 injury reports

Engine And Engine Cooling complaints

5 reports
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81,356 miles · Apr 20, 2012
Engine And Engine Cooling

FIRST OCCURRENCE ABOUT 87000 MILES WAS TRAVELING ON FREEWAY WHEN CAR STALLED. STARTED IT BACK UP AND CHECK ENGINE LIGHT CAME ON. TOOK VEHICLE TO DEALER AND THEY INSTALLED NEW SPARK PLUG AND WIRES. STALLED AGAIN AT ABOUT 89000 MILES AND WAS TOLD TO BRING BACK WHEN CHECK ENGINE LIGHT CAME BACK ON. CHECK ENGINE LIGHT CAME ON AGAI…

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FIRST OCCURRENCE ABOUT 87000 MILES WAS TRAVELING ON FREEWAY WHEN CAR STALLED. STARTED IT BACK UP AND CHECK ENGINE LIGHT CAME ON. TOOK VEHICLE TO DEALER AND THEY INSTALLED NEW SPARK PLUG AND WIRES. STALLED AGAIN AT ABOUT 89000 MILES AND WAS TOLD TO BRING BACK WHEN CHECK ENGINE LIGHT CAME BACK ON. CHECK ENGINE LIGHT CAME ON AGAIN AND TOOK VEHICLE IN ON SATURDAY BUT STORE WAS REMODELING AND COULDN'T GET ME IN. TOOK CAR IN FOR 90000 MILE SERVICE AND CHECK ENGINE LIGHT WAS ON. WAS TOLD THAT SPARK PLUGS WERE INSTALLED. I INFORMED THEM I HAD SPARK PLUGS AND WIRES INSTALLED THE LAST SERVICE AND THAT THIS STALLING OF MY VEHICLE IS DANGEROUS. WAS TOLD THAT AFTER THE SPARK PLUGS WERE INSTALLED IT CLEARED THE CHECK ENGINE LIGHT AND THAT I WOULD HAVE TO BRING THE CAR IN AGAIN WHEN THE CHECK ENGINE LIGHT WAS ON. DEALERSHIP HAS BEEN OF NO HELP WITH THIS ISSUE. LOOKED ONLINE FOR PEOPLE WITH SIMILAR PROBLEMS AND IT POINTS TO RECALL #08V033000. *JS

NHTSA ODI #10455940

36,000 miles · May 3, 2010
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2004 VOLVO S40. THE CONTACT STATED THE BRAKE WARNING LIGHT WOULD ILLUMINATE WHILE DRIVING AT ANY SPEED, CAUSING THE VEHICLE TO SHUT DOWN. THE VEHICLE WAS TAKEN TO THE DEALER THREE TIMES FOR THE FAILURE AND THE DEALER REPROGRAMMED THE COMPUTER SOFTWARE EACH TIME. ON A SEPARATE OCCASION, THE FAILURE RECURRE…

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TL* THE CONTACT OWNS A 2004 VOLVO S40. THE CONTACT STATED THE BRAKE WARNING LIGHT WOULD ILLUMINATE WHILE DRIVING AT ANY SPEED, CAUSING THE VEHICLE TO SHUT DOWN. THE VEHICLE WAS TAKEN TO THE DEALER THREE TIMES FOR THE FAILURE AND THE DEALER REPROGRAMMED THE COMPUTER SOFTWARE EACH TIME. ON A SEPARATE OCCASION, THE FAILURE RECURRED AND THE VEHICLE WAS TOWED TO THE DEALER. THE DEALER ADVISED THE COMPUTER MODULE WOULD NEED TO BE REPLACED. THE MANUFACTURER ADVISED AN INSPECTOR WOULD ASSESS THE FAILURE FURTHER. THE CONTACT WAS AWAITING RESULTS. THE FAILURE MILEAGE WAS 36,000 AND THE CURRENT MILEAGE WAS 40,000.

NHTSA ODI #10328646

48,000 miles · Dec 14, 2009
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING 50 MPH THE CHECK ENGINE LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. AFTER A PERIOD OF WAITING SHE WAS ABLE TO RESTART THE VEHICLE. THE VOLVO MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 48,000.

NHTSA ODI #10295636

Mileage unknown · Aug 22, 2005
Engine And Engine Cooling

THE ENGINE DIES INTERMITTENTLY ONCE EVERY SIX MONTHS. THIS NORMALLY HAPPENS WHEN MAKING A RIGHT TURN OR SLOWING DOWN. ALL OF THE WARNING LIGHTS IN THE DASHBOARD LIGHT UP. THE GEAR MUST BE PUT BACK IN PARK, MUST TURN OFF THE IGNITION AND THEN RE-START AGAIN. THE FIRST TIME IT HAPPENED, I THOUGHT IT MIGHT HAVE BEEN A FLUKE, THE SE…

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THE ENGINE DIES INTERMITTENTLY ONCE EVERY SIX MONTHS. THIS NORMALLY HAPPENS WHEN MAKING A RIGHT TURN OR SLOWING DOWN. ALL OF THE WARNING LIGHTS IN THE DASHBOARD LIGHT UP. THE GEAR MUST BE PUT BACK IN PARK, MUST TURN OFF THE IGNITION AND THEN RE-START AGAIN. THE FIRST TIME IT HAPPENED, I THOUGHT IT MIGHT HAVE BEEN A FLUKE, THE SECOND TIME I TOOK IT IN THEY CHANGED A VALVE IN THE ENGINE, THE THIRD TIME THEY KEPT THE CAR FOR 2 WEEKS AND THEY CHANGED THE AIR COMPRESSOR AND POSITIVE/NEGATIVE BATTERY CABLES (THEY HAD A VOLVO OF NORTH AMERICA TECHNICIAN COME DOWN). THE LAST TIME IT HAPPENED WAS FRIDAY, AUGUST 19, 2005. I'VE CALLED THE DEALERSHIP AND THEY DON'T SEEM TO WANT TO TAKE MY CALL.

NHTSA ODI #10133818

Mileage unknown · Oct 19, 2004
Air BagsEngine And Engine CoolingEquipment

MULTIPLE FAILURES. AIR BAG SYSTEM, PROBLEM STARTING AND NOISE IN STEERING. *BF THE VEHICLE ALSO HAD AN AIR CONDITION PROBLEM. THE AIR BAG LIGHT ILLUMINATED ON 3 OCCASIONS. THE CONSUMER STATED THE PASSENGER SEAT WAS EQUIPPED WITH A DEVICE THAT WEIGHED PASSENGERS TO DETERMINE IF THE AIR BAG SHOULD BE ACTIVATED. *JB

NHTSA ODI #10097709

Official recalls

6

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence & remedy

Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

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 BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.

08V033000 · Fuel System, Gasoline:delivery:fuel Pump

Jan 28, 2008

ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, REOCCURRING, LONG-TERM EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS SUCH AS SALTY-WET CONDITIONS, IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.

Consequence & remedy

Consequence: IF THIS OCCURS, THE CHECK ENGINE LIGHT MAY ILLUMINATE. IN SOME CASES, THE VEHICLE MAY FAIL TO START OR MAY STALL, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

06V137000 · Fuel System, Gasoline

Apr 24, 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.

Consequence & remedy

Consequence: THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

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.

04V493000 · Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings

Oct 14, 2004

ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.

Consequence & remedy

Consequence: IF THIS OCCURS, MORE BRAKE PEDAL FORCE MAY BE REQUIRED TO STOP THE VEHICLE AND/OR MAY EXPERIENCE A ROUGH ENGINE IDLE, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT, AND IF NECESSARY, REPLACE THE VACUUM HOSE. THE RECALL BEGAN ON NOVEMBER 29, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

03V424000 · Fuel System, Gasoline

Oct 24, 2003

ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.

Consequence & remedy

Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSTALL A V-CLAMP TO THE FUEL RAIL. OWNER NOTIFICATION BEGAN ON JANUARY 28, 2004. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

03V284000 · Equipment:other:labels

Aug 1, 2003

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE VEHICLES AND, IN CERTAIN CASES, THE OWNER'S MANUAL ISOFIX INFORMATION IS INCORRECT.

Consequence & remedy

Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy: OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUCTIONS, AND IN CERTAIN CASES, THE CORRECTED OWNER'S MANUAL MAY BE PROVIDED. IF THE OWNER WANTS TO TAKE THEIR VEHICLE TO A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.