NHTSA lists 48 complaints for the 2004 Volvo S40, 5 of them mention a crash and 1 mention a fire. 4 complaints mention an injury, with 4 injuries and 0 deaths reported.
Data build 2026-10-08.
NHTSA lists this vehicle as VOLVO S40.
Model-generated complaint tags: This model year has not been tagged.
Recalls
See new recalls and investigations this week.
6 recalls.
Date: 2010-11-08. Systems: EQUIPMENT.
Defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT. (excerpt)
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE. (excerpt)
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 GARMI (excerpt)
Do not drive: No. Park outside: No.
Date: 2008-01-28. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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-WE (excerpt)
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. (excerpt)
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. (excerpt)
Do not drive: No. Park outside: No.
Date: 2006-04-24. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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: 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.
Do not drive: No. Park outside: No.
Date: 2004-10-14. Systems: SERVICE BRAKES, HYDRAULIC.
Defect: ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
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.
Do not drive: No. Park outside: No.
Date: 2003-10-24. Systems: FUEL SYSTEM, GASOLINE.
Defect: ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
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.
Do not drive: No. Park outside: No.
Date: 2003-08-01. Systems: EQUIPMENT.
Defect: 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. (excerpt)
Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD. (excerpt)
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 1-80 (excerpt)
Do not drive: No. Park outside: No.
Manufacturer communications
239 manufacturer communications.
Communications by system| System | Count |
|---|
| EQUIPMENT | 105 |
|---|
| ELECTRICAL SYSTEM | 65 |
|---|
| EQUIPMENT ADAPTIVE/MOBILITY | 22 |
|---|
| WHEELS | 17 |
|---|
| ENGINE AND ENGINE COOLING | 14 |
|---|
| UNKNOWN OR OTHER | 14 |
|---|
| SERVICE BRAKES, HYDRAULIC | 9 |
|---|
| POWER TRAIN | 8 |
|---|
11032678
Date: 2026-04-23. Type: Service Bulletin/Repair Instructions. Systems: ENGINE.
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.
11032671
Date: 2026-04-07. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
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
11027173
Date: 2025-12-06. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
This is a Technical Journal. Vehicle type and platform identification.
11020437
Date: 2025-04-10. Type: Service Bulletin/Repair Instructions. Systems: EXTERIOR LIGHTING.
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: a ?Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. a ?Connect to the vehicle over a wired connection using a
11016002
Date: 2025-02-21. Type: Service Campaign. Systems: UNKNOWN OR OTHER.
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
11015994
Date: 2025-02-13. Type: Service Campaign. Systems: UNKNOWN OR OTHER.
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
11014112
Date: 2025-01-16. Type: Service Bulletin/Repair Instructions. Systems: EXTERIOR LIGHTING.
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: a ?Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. a ?Connect to the vehicle over a wired connection using a
11014113
Date: 2025-01-16. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory
11007925
Date: 2024-08-14. Type: Other. Systems: ELECTRICAL SYSTEM.
Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service
10249191
Date: 2024-01-12. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM.
This is a Technical Journal: 12V Battery Testing Method