2005 Volvo S40 problems, complaints & recalls
Most-reported problem areas: Electrical System (11) · Fuel System, Gasoline (7) · Fuel/Propulsion System (6)
🧭 Reliability snapshot
Compared against other Volvo S40 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
56 NHTSA complaints that reported an odometer reading.
Safety recalls (1)
Equipment:electrical:navigational System(Global Positioning System) 2010-11-08 · campaign 10V566000 · 416 vehicles
Defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Fix: 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.
Service bulletins (169)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Engine 2026-04-23 · 35526.1.8 · Service Bulletin/Repair Instructions
this is a technical journal: text plus 2 pdfs and 1 .png oil consumption test. perform the test. follow service procedure description and service sections updated to clarify that vehicle reports are not required.
Unknown Or Other 2026-04-07 · 37809.1.1 · Service Bulletin/Repair Instructions
this is a tj text only - the purpose of this tj is to be a master reference list to easily identify any components that are on prior approval. this tj will be regularily updated as items are added or removed from prior approval. current items under prior approval are listed in the "service" sec
Unknown Or Other 2025-12-06 · 19245 · Service Bulletin/Repair Instructions
this is a technical journal. vehicle type and platform identification.
Exterior Lighting 2025-04-10 · 8501 · Service Bulletin/Repair Instructions
this is a technical journal: remote connection, bomgar application. before joining a remote session: •connect a suitable battery maintainer/charger and verify that the battery voltage indicated in vida is between 12.5v and 14.9v. •connect to the vehicle over a wired connection using a voe
Unknown Or Other 2025-02-21 · S10303 · Service Campaign
volvo cars usa llc and volvo car canada ltd on behalf of the volvo car corporation has decided to launch service action s10303 on certain model year 2025 ex90 vehicles. volvo car investigations have identified that there is a pairing issue with the key fob. as a result, there is a possibil
Unknown Or Other 2025-02-13 · S10303 · Service Campaign
volvo cars usa llc and volvo car canada ltd on behalf of the volvo car corporation has decided to launch service action s10303 on certain model year 2025 ex90 vehicles. volvo car investigations have identified that there is a pairing issue with the key fob. as a result, there is a possibil
Showing the 6 most recent of 169 bulletins. Search all of them free at nhtsa.gov.
What owners report
2024-03-20 · Power Train · 170,000 mi“the contact's wife owns a 2005 volvo s40. the contact stated the vehicle was difficult to start for several days. eventually, the failure progressed and the vehicle was not able to start. the check engine warning light was illuminated. the vehicle was repaired by the contact, a previous volvo technician. the contact stated the failure was due to…”
2023-09-24 · Seat Belts“the drivers seat belt does not lock/latch in properly. everytime i enter the vehicle i reach for my seat belt and buckle myself, well so i thought i did. when i insert the belt it seems as though its buckles however once i start to drive the belt comes un done and it i always have to pull over to put it back on becsuse it locks the seat belt so i'm…”
2021-03-18 · Fuel System, Gasoline · 147,000 mi“tl* the contact owns a 2005 volvo s40. the contact stated that while driving at an undisclosed speed, the vehicle stalled without warning. the vehicle was towed to an independent mechanic who diagnosed that the fuel pump electronic module had failed due to rusting and corrosion. the fuel pump electronic module was replaced and the failure was remed…”
2020-06-15 · Fuel/Propulsion System · 84,000 mi“i was told by shop that work on my car that were a recall on the pvc vaul on the 2005 volv s40 2.4. *tr…”
2020-06-06 · Unknown Or Other · 168,505 mi“my vehicle shuts off while im driving it. i took it to a mechanic 3 times and was advised its an issue with the fuel pump. i was also advised this is an known issue with this particular vehicle and was provided a nhtsa campaign id # 08v033000. *tr…”
2019-08-23 · Engine · 86,000 mi“2005 volvo s40 engine air conditioning malfunctioned. when the problem first begun the car would be cool at start then get warm until one day the air conditioning just quit working. i read on this forum authorized volvo dealership admits this is a common problem in this year/make/model. the compressor clutch or compressor or both required replacin…”
2019-04-08 · Structure:body · 45,506 mi“tl* the contact owns a 2005 volvo s40. the contact stated that the rear passenger side carpet was saturated with water after a rain storm. the cause of the failure was not determined. the manufacturer was notified of the failure. the local dealer was not notified. the failure mileage was 45,506. *bf consumer stated the foam in roof of car is cr…”
2018-07-16 · Fuel/Propulsion System · 205,000 mi“the car starts missing then stalls out after about 30miles of driving it stalled in the middle of crossing a 4 lane and was about hit.it is the pem they had recalls on them but not my car for some reason…”
2018-07-15 · Fuel/Propulsion System · 200,011 mi“every time i drive the car it misses a little then it just shuts down like it's not getting any fuel the car don't die just won't pull out i tried to cross a 4 lane and it stalled in the first lane and i about got hit in the side it also did it on the interstate.it is very dangerous i was told it's the electronic fuel module,or pen and was told the…”
2018-01-02 · Engine · 43,000 mi“tl* the contact owns a 2005 volvo s40. when the vehicle was started, there was an abnormal vibration coming from the vehicle. upon opening the hood and checking the engine, the contact noticed that the passenger side of the engine was fractured. the contact stated that the fracture was along the top side of the engine. the vehicle was not taken to …”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.