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2005 Volvo S40 Recalls & Complaints

3

open safety recalls on record

Critical

91 owner complaints filed · Severity Index 0.09 · updated 2026-08-07

The recalls

Critical10V566000

Equipment:Electrical:Navigational System(Global Positioning System)

OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy & full details

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.

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Critical06V137000

Fuel System, Gasoline

THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE.

Remedy & full details

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.

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.

Serious08V033000

Fuel System, Gasoline:Delivery:Fuel Pump

IF THIS OCCURS, THE CHECK ENGINE LIGHT MAY ILLUMINATE.

Remedy & full details

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.

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.

Complaint volume

91 this model-year 6 median, same year

Volume alone is not a fault rate — popular vehicles attract more reports. Read it next to the severity mix below.

What owners reported happened

2Crashes
0Fires
1Injuries
0Deaths

Across 91 complaints. Severity Index 0.09.

Severity Index weights each complaint's reported outcome (death ×10, injury ×4, fire ×3, crash ×2) and divides by total complaints. It measures how severe reports are, not how often faults occur.

What owners report most

Electrical System19 · 21%Engine And Engine Cooling8 · 9%Fuel System, Gasoline8 · 9%Fuel/Propulsion System8 · 9%Engine5 · 5%Fuel System, Gasoline · D…4 · 4%Air Bags4 · 4%Engine And Engine Cooling…3 · 3%
  1. Electrical System — 19 reports
  2. Engine And Engine Cooling — 8 reports
  3. Fuel System, Gasoline — 8 reports
  4. Fuel/Propulsion System — 8 reports
  5. Engine — 5 reports
  6. Fuel System, Gasoline:Delivery:Fuel Pump — 4 reports
  7. Air Bags — 4 reports
  8. Engine And Engine Cooling:Engine — 3 reports
  9. Unknown Or Other — 3 reports
  10. Seat Belts — 3 reports

What to do

  1. Find your 17-character VIN on the driver's door jamb or the base of the windscreen.
  2. Check it against NHTSA's official lookup at nhtsa.gov/recalls — the authoritative record for your exact car.
  3. Book the repair with any franchised dealer. Safety recall work is free, with no time limit and regardless of who owns the car now.

Other model years

2000 (1) · 2001 (2) · 2002 (1) · 2003 (2) · 2004 (6) · 2005 · 2006 (3) · 2007 (2) · 2008 (2) · 2009 (3) · 2010 (2) · 2011 (2)

Numbers in brackets are open recall campaigns for that year.

Questions

Does an open recall mean the car is unsafe to drive?

Not usually. NHTSA issues a "do not drive" or "park outside" advisory when a defect is dangerous enough to keep you out of the car — those are flagged Critical above. Everything else should be repaired promptly but is not an immediate stop-driving order.

Do I pay for recall repairs?

No. Federal law requires the manufacturer to fix a safety recall free of charge, including parts and labour, whether or not you are the original owner.

Why are there complaints but no recalls?

Complaints are unverified reports filed by owners. They can prompt an investigation, but many never become recalls — either the fault isn't safety-related or it isn't widespread.

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