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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.

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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

Fuel/propulsion System complaints

2 reports
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104,000 miles · Jun 22, 2016
Fuel/propulsion System

CAR IS STALLING OUT WHILE DRIVING DOWN THE ROAD ENGINE LIGHT CAME ON WHEN PUT ON MACHINE ERROR GIVEN IS FUEL PRESSURE. THE FUEL PRESSURE WAS CHECKED AND WAS AT CORRECT PRESSURE FOR THE CAR. I HAVE REPLACED FUEL CENSER AND CAR RAN FINE FOR 2 DAYS THEN SAME ISSUE WITH SAME ERROR THE FUEL CONTROLLER HAS A CORRODED PEN I TRIED TO…

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CAR IS STALLING OUT WHILE DRIVING DOWN THE ROAD ENGINE LIGHT CAME ON WHEN PUT ON MACHINE ERROR GIVEN IS FUEL PRESSURE. THE FUEL PRESSURE WAS CHECKED AND WAS AT CORRECT PRESSURE FOR THE CAR. I HAVE REPLACED FUEL CENSER AND CAR RAN FINE FOR 2 DAYS THEN SAME ISSUE WITH SAME ERROR THE FUEL CONTROLLER HAS A CORRODED PEN I TRIED TO CALL VOLVO THEY ARE TELLING ME THERE IS NOTHING THEY CAN DO WHEN I CAN CLEARLY SEE THE YEAR MAKE AND MODEL HAVE HAD A RECALL FOR THE EXACT ISSUE THAT I AM HAVING WITH THIS CAR. THE RECALL NUMBER IN YOUR SYSTEM IS 08V033000 I NORMALLY WOULD JUST GET THE CAR FIXED BUT THIS IS A MAJOR ISSUE IT SEEMS THE LOCATION OF THE CONTROLLER NEEDS TO BE MOVED TO PREVENT THIS FROM HAPPENING AGAIN. THIS IS A CAR MY 16 YEAR OLD DAUGHTER DRIVES SO YOU CAN UNDERSTAND MY CONCERN WITH VOVLO NOT WANTING TO CORRECT THIS

NHTSA ODI #10875785

Mileage unknown · Nov 17, 2015
Fuel/propulsion SystemService BrakesCrashInjury

I GOT NEW CAR IN NOV 2003 OF THE YEAR 2004 MODEL. IT FEELS LIKE ONE HAS TO PUT FOOT ON BRAKES ALL THE WAY TO APPLY. IT IS PROGRESSIVELY GETTING WORSE. IN DEC 2005, WHILE EXISTING FROM HIGHWAY WE MEET AN ACCIDENT AS IT DID NOT STOP WHERE IT WAS SUPPOSE TO STOP. VOLVO DEALER TOP THE BREAK FLUID DURING MAINTENANCE. BUT DID NOT SOLV…

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I GOT NEW CAR IN NOV 2003 OF THE YEAR 2004 MODEL. IT FEELS LIKE ONE HAS TO PUT FOOT ON BRAKES ALL THE WAY TO APPLY. IT IS PROGRESSIVELY GETTING WORSE. IN DEC 2005, WHILE EXISTING FROM HIGHWAY WE MEET AN ACCIDENT AS IT DID NOT STOP WHERE IT WAS SUPPOSE TO STOP. VOLVO DEALER TOP THE BREAK FLUID DURING MAINTENANCE. BUT DID NOT SOLVE THE PROBLEM. WE GOT NEW BRAKE PADS FROM VOLVO DEALER AND CHANGED ALONG WITH BRAKE DISCS IN 2009. BUT, IT DID NOT SOLVE THE PROBLEM. IN THE MORNING, IT WILL NOT BREAK UNLESS ONE HAS TO PUT FOOT ON PEDAL FEW TIMES. AGAIN IN 2015 WE GOT BRAKE PADS FROM OTHER AUTO PART SHOP OF HIGH QUALITY BUT IT DOES NOT SOLVE THE PROBLEM. IN ADDITION, I SMELL GAS BUT COULD NOT LOCATE ANY LEAK OF FUEL. ALSO, STEERING WHEEL IS VERY HARD AND WE TOOK TO VOLVO FEW TIMES BUT IT IS THE SAME.

NHTSA ODI #10794522

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.