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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

Fuel System, Gasoline complaints

5 reports
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118,600 miles · Jun 11, 2014
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S40. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE ENGINE STALLED. THE CHECK ENGINE AND BATTERY INDICATORS ILLUMINATED WHEN THE FAILURE OCCURRED, AND THE VEHICLE VEERED TO THE RIGHT. THE CONTACT PULLED THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE WOULD NOT RESTART AND WAS TOWED TO …

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TL* THE CONTACT OWNS A 2004 VOLVO S40. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE ENGINE STALLED. THE CHECK ENGINE AND BATTERY INDICATORS ILLUMINATED WHEN THE FAILURE OCCURRED, AND THE VEHICLE VEERED TO THE RIGHT. THE CONTACT PULLED THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE WOULD NOT RESTART AND WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAILURE OCCURRED TWICE. THE MANUFACTURER WAS NOT NOTIFIED AND ADVISED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 08V033000 (FUEL SYSTEM, GASOLINE). A DIAGNOSTIC TEST INDICATED THAT THE FUEL PUMP MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED AND THE FAILURE DID NOT RECUR. THE FAILURE MILEAGE WAS 118,600. ..UPDATED 08/11/14 *BF THE VEHICLE WAS REPAIRED AT THE OWNER'S EXPENSE. UPDATED 08/21/2014 *JS

NHTSA ODI #10597709

95,000 miles · Mar 15, 2011
Fuel System, Gasoline

TL*THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING APPROXIMATELY 30 MPH, THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED WHEN THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE FAILURE WAS SIMILAR TO NHTSA CAMPAIGN ID NUMBER: 08V033000 (FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP). THE DEALER REFUSED TO REPAIR …

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TL*THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING APPROXIMATELY 30 MPH, THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED WHEN THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE FAILURE WAS SIMILAR TO NHTSA CAMPAIGN ID NUMBER: 08V033000 (FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP). THE DEALER REFUSED TO REPAIR THE DEFECTIVE COMPONENT. THE MANUFACTURER INFORMED THE CONTACT THAT THEY WILL ONLY REPLACE THE COMPONENT AFTER IT FAILED ALTHOUGH THE VEHICLE MAY STALL WHILE DRIVING. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO NOTIFIED THE CONTACT THAT THEY NEEDED TO REPLACE THE FUEL PUMP AND PERFORMED THE REPAIRS; HOWEVER, THE REPAIR DID NOT CORRECT THE FAILURE. THE LOCAL MECHANIC STATED THAT THEY NEEDED TO REPLACE THE PUMP ELECTRIC MODULE AND THE VEHICLE WAS AWAITING REPAIRS. THE CURRENT MILEAGE WAS 105,000 AND THE FAILURE MILEAGE WAS 95,000.

NHTSA ODI #10390269

Mileage unknown · Sep 14, 2010
Fuel System, GasolinePower Train

VOLVO S40 T5 2004 IS NOT ACCELERATING PROPERLY. RPMS INCREASE DRASTICALLY AND SPEED DOES NOT INCREASE. THE VEHICLE HAS STALLED TWICE WHILE DRIVING ALONG WITH TRAFFIC. REPAIRS RELATED TO SIMILAR SYMPTOMS: REPLACED AND RELOCATED PEM IN 2008, ENGINE CONTROL MODULE SOFTWARE WAS UPDATED DUE TO FAULTY SOFTWARE IN 2008 SAME PROBLEMS O…

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VOLVO S40 T5 2004 IS NOT ACCELERATING PROPERLY. RPMS INCREASE DRASTICALLY AND SPEED DOES NOT INCREASE. THE VEHICLE HAS STALLED TWICE WHILE DRIVING ALONG WITH TRAFFIC. REPAIRS RELATED TO SIMILAR SYMPTOMS: REPLACED AND RELOCATED PEM IN 2008, ENGINE CONTROL MODULE SOFTWARE WAS UPDATED DUE TO FAULTY SOFTWARE IN 2008 SAME PROBLEMS OCCURRED A MONTH AGO AND RECURRING AT A MORE EXTREME LEVEL NOW. THIS FAULTY MANUFACTURING DOES NOT INCLUDE OTHER PROBLEMS THAT WERE FIXED A FEW MONTHS AGO WHILE UNDER WARRANTY AND NOW REAPPEARING AGAIN. *TR

NHTSA ODI #10355630

64,000 miles · Aug 30, 2010
Fuel System, Gasoline

ON CERTAIN VOLVO VEHICLES, INSUFFICIENT SEALING OF THE FUEL PUMP ELECTRONIC MODULE MAY LEAD TO WATER INGRESS CORROSION, POSSIBLY CAUSING THE UNIT TO FAIL. THIS MAY RESULT IN INCREASED, DECREASED, OR LOSS OF FUEL PRESSURE. ENGINE STALLING WOULD RESULT IN LOST PROPULSION WHICH, IN CONJUNCTION WITH TRAFFIC AND ROAD CONDITIONS, AND …

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ON CERTAIN VOLVO VEHICLES, INSUFFICIENT SEALING OF THE FUEL PUMP ELECTRONIC MODULE MAY LEAD TO WATER INGRESS CORROSION, POSSIBLY CAUSING THE UNIT TO FAIL. THIS MAY RESULT IN INCREASED, DECREASED, OR LOSS OF FUEL PRESSURE. ENGINE STALLING WOULD RESULT IN LOST PROPULSION WHICH, IN CONJUNCTION WITH TRAFFIC AND ROAD CONDITIONS, AND THE DRIVER'S REACTIONS, COULD INCREASE THE RISK OF A COLLISION OR SERIOUS PHYSICAL INJURY. CORRECTION: DEALERS SHOULD REPLACE AND RELOCATE THE FUEL PUMP ELECTRONIC MODULE. RELOCATION OF PEM IS DUE TO A DESIGN FLAW AND SHOULD NOT BE LIMITED TO GEOGRAPHICAL AREAS OF VEHICLE USE. THIS DESIGN FLAW PRESENTS A MANUFACTURING DEFECT THAT MAY AFFECT THE SAFE OPERATION OF THE VEHICLE. VOLVO EXTENDED THE WARRANTY BUT HAS NOT VOLUNTARILY RECALLED THIS COMPONENT FOR THE 2004 THROUGH 2007 VOLVOS. BY EXTENDING THE WARRANTY THEY ARE AVOIDING THEIR RESPONSIBILITY TO REPLACE A DESIGN FLAW THAT MAY ENDANGER OCCUPANTS OF VOLVOS. PLEASE REFER TO TRANSPORT CANADA'S MANDATE REGARDING MOTOR VEHICLE SAFETY ACT. *TR

NHTSA ODI #10352679

Mileage unknown · Mar 10, 2010
Fuel System, Gasoline

I LIVE IN TEXAS. I OWN A VOLVO. 2004 S-40. APPARENTLY HAVE BEEN SEVERAL RECALLS ON VOLVO S-40'S PERTAINING TO THE GASOLINE FUEL PUMPS. THESE RECALLS ONLY APPLY TO CERTAIN STATES UP NORTH. I DID SPEAK TO A CUSTOMER SERVICE REPRESENTATIVE (BART) AT VOLVO. I FEEL LIKE I AM INVOLVED IN A CAT AN MOUSE GAME WHEN I TALK TO HIM. HE SAY…

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I LIVE IN TEXAS. I OWN A VOLVO. 2004 S-40. APPARENTLY HAVE BEEN SEVERAL RECALLS ON VOLVO S-40'S PERTAINING TO THE GASOLINE FUEL PUMPS. THESE RECALLS ONLY APPLY TO CERTAIN STATES UP NORTH. I DID SPEAK TO A CUSTOMER SERVICE REPRESENTATIVE (BART) AT VOLVO. I FEEL LIKE I AM INVOLVED IN A CAT AN MOUSE GAME WHEN I TALK TO HIM. HE SAYS MY VIN NUMBER IS NOT INVOLVED IN THE RECALL. I TOLD HIM IT PROBABLY WOULD NOT BE INVOLVED IN THE RECALL SINCE VOLVO HAS ONLY INVOLVED STATES UP NORTH. THAT WAS THE PURPOSE OF MY CALL. HOW IS IT THAT AUTO COMPANY'S ARE ALLOWED TO GET AWAY WITH THESE GLITCHES? THE RECALL INVOLVES FUEL PUMPS EXPOSURE (CORROSION)TO SALT (CHEMICAL) ON THE ROADS THAT ARE MOSTLY EXPOSED IN NORTHERN STATES. I THINK THIS IS IRRESPONSIBLE. WHAT IF THE OWNER MOVES FROM TEXAS UP NORTH TO LIVE? THE PERSON THAT MOVES FROM SOUTH TO NORTH STILL WILL NEVER BE AWARE OF THE RECALL NOTIFICATION BECAUSE THEY BOUGHT THE VEHICLE DOWN SOUTH. WHAT IF THE PERSON IS IN A AREA OF THE STATE (OTHER THAN UP NORTH) AND THE CAR IS EXPOSED TO SALTY ENVIRONMENT. I DID NOT GET ANYWHERE WITH THE REPRESENTATIVE BECAUSE HE WAS ?PLAYING WITH WORDS? LITERALLY TRYING TO CONFUSE ME. MY POINT IS THIS THE RECALLS SHOULD NOT BE PLACED ON WERE YOU LIVE WHEN IT COMES TO CLIMATE. PEOPLE MOVE ALL THE TIME. ALSO SOMETIMES THEY FIND THAT THE PROBLEM HAS NOTHING TO DO WITH WHERE PEOPLE LIVE IT COULD BE THE OVERALL PROBLEM WITH THE CAR DESPITE LOCATION. DO PEOPLE HAVE TO DIE BEFORE THIS IS FIGURED OUR. I FEEL VOLVO IS BEING VERY DECEPTIVE BY PRESENTING THIS RECALL THE WAY THAT IT DID. THERE ARE MORE THAN ONE RECALL PERTAINING TO THE FUEL PUMP. THERE ARE SEVERAL. ALSO I JUST RECENTLY SAW TODAY ON TV ABOUT TOYOTA RECALLING TUNDRA TRUCKS UNDER VERY SIMILAR CIRCUMSTANCES AS I DESCRIBED WITH VOLVO( CLIMATE EXPOSURE). THE TUNDRAS WERE RUSTING AND THE WHEELS AND GAS TANKS WERE FALLING OFF(APPARENTLY IT WAS ONLY IN 20 COLD STATES) NOW THEY EXPANDED TO 50 STATES. WHY? *TR

NHTSA ODI #10318428

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.