Model year record

2005 Volvo S40 recalls & problems

The 2005 Volvo S40 has 3 safety recalls and 69 owner complaints on file with NHTSA. The most-reported problem area is electrical system (19 complaints).

Recalls3safety recalls

Complaints69filed by owners

Crashes · fires2 · 0reported in complaints

Injuries · deaths1 · 0reported in complaints

2005 Volvo S40 in an NHTSA crash test — NHTSA crash test

Safety recalls

EquipmentNov 8, 2010

Electrical › Navigational system(global positioning system)

Recall 10V566000416 vehicles

Problem: 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.

Fuel system, gasolineJan 28, 2008

Delivery › Fuel pump

Recall 08V03300023,000 vehicles

Problem: 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.
Risk: 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.
Fix: 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.

Fuel system, gasolineApr 24, 2006

Fuel system, gasoline

Recall 06V13700016,175 vehicles

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

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2005 Volvo S40 4-DR. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2005 Volvo S40 NHTSA side crash test — NHTSA side barrier crash test

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

S40 FWD

22mpg combined

City / highway	19 / 27 mpg
Fuel	Premium Gasoline

2.4 L · 5 cyl · Manual 5-spd · Front-Wheel Drive · about $3,750/year to fuel

S40 FWD

22mpg combined

City / highway	19 / 27 mpg
Fuel	Premium Gasoline

2.4 L · 5 cyl · Automatic (S5) · Front-Wheel Drive · about $3,750/year to fuel

S40 FWD

22mpg combined

City / highway	19 / 29 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Manual 6-spd · Front-Wheel Drive · about $3,750/year to fuel

S40 FWD

22mpg combined

City / highway	19 / 27 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · Front-Wheel Drive · about $3,750/year to fuel

S40 AWD

20mpg combined

City / highway	17 / 25 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Manual 6-spd · 4-Wheel or All-Wheel Drive · about $4,100/year to fuel

S40 AWD

20mpg combined

City / highway	18 / 25 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,100/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Injuries	Typical mileage*
Electrical system	19	0	0	83,500 mi
Fuel system, gasolineDelivery › Fuel pump	12	0	0	75,000 mi
Engine and engine coolingEngine	11	0	0	71,500 mi
Fuel/propulsion system	8	0	0	125,500 mi
VisibilitySun/moon roof assembly; Windshield wiper/washer	6	0	0	60,000 mi
Air bagsFrontal	5	1	1	80,000 mi
Engine	5	0	0	62,000 mi
Unknown or other	3	0	0	65,000 mi
Seat belts	3	0	0	—
Service brakes	3	0	0	62,700 mi
EquipmentMechanical › Accessory scissor/screw/bottle jack/lift	2	0	0	—
Power train	2	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Power train
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 the pump electrical module being located out of the vehicle. The contact spoke with the dealer. The contact referenced The manufacturer was made aware of the failure. The approximate failure mileage was 170,000.
Feb 21, 2024 · 170,000 miles
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 not able to just buckle back in.
Apr 3, 2023
Fuel system, gasoline
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 REMEDIED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER 08V033000 (FUEL SYSTEM, GASOLINE). THE CONTACT STATED THAT THE VEHICLE HAD EXPERIENCED THE FAILURE LISTED IN THE RECALL. ADDITIONALLY, THE VEHICLE WAS ORIGINALLY SOLD IN THE STATE OF CALIFORNIA AND HAD BEEN…
Mar 15, 2021 · 147,000 miles
Fuel/propulsion system
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
Jun 14, 2020 · 84,000 miles
Unknown or other
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
Jun 4, 2020 · 168,505 miles
Engine
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 REPLACING. IN A CLASS ACTION LAWSUIT [FILED 2018] HTTP://WWW.AUTOPARTSCLASS.COM/INDEX.PHP INCLUDES THE 2005 VOLVO S40 AIR CONDITIONING UNIT: [SEE BELOW] CONGRATULATIONS! YOUR 2005 VOLVO S40 IS INCLUDED IN THE FOLLOWING AUTO PARTS CASES: IN RE: INSTRUMENT PANEL CLUSTERS IN RE: AIR CONDITIONING SYSTEMS IN RE: ALTERNATORS IN RE: WINDSHIELD WIPER SYSTEMS
Jun 1, 2017 · 86,000 miles
Structure › Body
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 CRUMBLING AND ROOF SEAMS ARE NO LONGER INTACT.*JB
Mar 1, 2019 · 45,506 miles
Fuel/propulsion system
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
May 10, 2018 · 205,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.