Volvo · S40 · 2005
3
Recalls
81
Complaints
-
Not Rated
The 2005 Volvo S40 has 3 recalls and 81 owner-reported complaints on file with NHTSA. Most reported issue: electrical system (11 reports).
Source: NHTSA Public Records · Updated Apr 22, 2026
This page combines three types of NHTSA data: recall campaigns (official manufacturer or government actions), owner complaints (unverified consumer reports), and crash test ratings (where available). A vehicle with many complaints is not necessarily less reliable — complaint volume correlates with sales volume and vehicle age. Recalls indicate identified defects, not overall quality. To compare this model year with others, use the year navigation in the sidebar or return to the model overview page.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Remedy Status
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.
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.
Remedy Status
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 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.
Remedy Status
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.
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.
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.
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 DRIVEN IN THE STATE OF MICHIGAN THE PAST 6 YEARS. THE FAILURE MILEAGE WAS 147,000.
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
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
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
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 THERE WAS A RECALL ON THAT PART ALL OVER THE INTERNET BUT VOLVO SAID THERE WASN'T WHICH I DON'T BELIEVE WHY WOULD THE INTERNET SAY THERE WAS ON LIKE 5OR NOTRE WEBSITES
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
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 BE DIAGNOSED. A DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 43,000.
CAR IS ALL OF A SUDDEN ACCELERATING ON ITS OWN. IT HAS HAPPENED A HANDFUL OF TIMES WITHIN THE LAST MONTH. I WILL MAKE A TURN, LET OFF THE GAS PEDDLE AND THEN THE CAR WILL JUST JERK FORWARD REVVING UP THE RPMS AND ACCELERATING ON ITS OWN.
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
FUEL PUMP CONTROL MODULE (PEM) FAILS DURING WET CONDITIONS. CAR WILL CRANK LIKE NORMAL BUT WILL NOT START. LET CAR DRY OUT FOR A FEW DAYS AND THEN THE CAR WILL RUN NORMAL AGAIN.
TAKATA RECALL. I HAD ENGINE STUTTERING AT HIGH SPEED. MY FUEL PRESSURE SENSOR FAILED AND WAS REPLACED. I QUESTION WHY IT IS NOT COVERED UNDER THE NHTSA CAMPAIGN I.D. # 07V226000 WHICH IS FOR THE SAME PART IN THE SAME ENGINE BUT IN 2004 S60 MODELS.
TL* THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT THE KEY WAS UNABLE TO TURN AND PREVENTED THE VEHICLE FROM STARTING. THE BATTERY WAS TESTED BY AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DETERMINE THE CAUSE OF THE FAILURE. THE VEHICLE WAS TO BE TAKEN TO A DEALER FOR DIAGNOSTIC TESTING. THE VEHICLE WAS UNABLE TO BE DRIVEN. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN AND FAILURE MILEAGE WERE NOT AVAILABLE.
TL* THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT WHILE DRIVING AT 55 MPH, THE STEERING WHEEL AND ENTIRE VEHICLE BEGAN TO SHAKE AS THERE WAS AN ABNORMAL NOISE. IN ADDITION, THE AIR CONDITIONER, RADIO, HORN AND SUN ROOF FAILED TO FUNCTION WHEN ACTIVATED. THE SRS WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE ECM, FRONT AXLES AND STRUTS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 194,000.
TL* THE CONTACT OWNS A 2005 VOLVO S40. WHILE DRIVING APPROXIMATELY 40 MPH, THE BRAKE PEDAL TRAVELED TO THE FLOORBOARD AND FAILED TO STOP THE VEHICLE WHEN IT WAS DEPRESSED. THE VEHICLE SHOOK VIOLENTLY WITHOUT WARNING. THE CONTACT LET THE VEHICLE DECELERATE AND THEN SLOWLY DROVE THE VEHICLE TO THE DEALER. THE DEALER DIAGNOSED THAT THE BRAKE VACUUM PUMP FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V474000 (SERVICE BRAKES, HYDRAULIC). THE APPROXIMATE FAILURE MILEAGE WAS 70,000.
INSERTED KEY IN IGNITION AND NOTHING HAPPENED. COMPUTER READS KEY ERROR TRY AGAIN. KEPT TRYING AND FINALLY STARTED. NEXT DAY SAME THING HAPPENED.
2005 VOLVO S40 FAULTY WIRE IN IGNITION SWITCH. CAR FAILS TO START. NO MESSAGES INITIALLY, THEN IMMOBILIZER LIGHT INDICATED. UNSURE OF EQUIPMENT MODEL. ORIGINAL TO FACTORY INSTALLED. *TR
TL* THE CONTACT OWNS A 2005 VOLVO S40. WHILE DRIVING VARIOUS SPEEDS ON SEVERAL OCCASIONS, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP ELECTRONIC MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 08V033000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.
(S40 2.4I) INITIAL CAR MESSAGE: "BRAKE FAILURE, PULL OVER SAFELY." I CONTINUED TO DRIVE HOME SINCE I WAS A FEW BLOCKS AWAY. MESSAGE CHANGED TO "ANTI SKID SERVICE REQUIRED" THEN BACK TO BRAKE FAILURE AGAIN. DIFFICULTY ACCELERATING AFTER STOPPING, FELT LIKE THE PARKING BRAKE WAS ON BUT DROVE OK ONCE ACCELERATED. ATTEMPTED TO TURN OFF CAR BUT MESSAGE CHANGED TO "IMMOBILIZER, CHECK MANUAL" AND COULD NOT TURN KEY TO OFF POSITION. FROM WHAT I READ IN THE MANUAL, IT APPEARED THAT THE CARD DIDN'T RECOGNIZE IT WAS IN PARK. TURNED PARKING BRAKE ON AND OFF A FEW TIMES AND WAS ABLE TO TURN OFF CAR. BROUGHT TO LOCAL MECHANIC WHO REPLACED BRAKE PAD SENSOR AND ANTI-STOP SWITCH. --IN AND OUT OF AUTO REPAIR SHOP 4X OVER THE PAST MONTH W/THE SAME ISSUES AND NEW SYMPTOMS: WIPERS TURNED ON AUTOMATICALLY AND DON'T SHUT OFF AND NEW MESSAGE: ENGINE SYSTEM SERVICE URGENT. --MECHANIC REPLACED SOME RUSTED WIRES, BROUGHT TO A VOLVO DEALER WHO RESET COMPUTER AND DID NOT FIND ANY PROBLEMS. --STILL HAVING SAME ISSUES. CANNOT PUT CAR INTO DRIVE OR TURN OFF CAR WHEN BRAKE FAILURE OR ANTI-SKID MESSAGE APPEAR BUT IF I WAIT A FEW MINUTES, I CAN TURN THE CAR OFF AND ON A COUPLE OF TIMES TO GET TO THE ENGINE SYSTEM SERVICE URGENT MESSAGE AND I CAN THEN PUT IT INTO DRIVE. SOMETIMES ALL MESSAGES GO AWAY AND IT IS FINE FOR A FEW DAYS BUT THEN THE CAR JERKS FORWARD AS IF SOMEONE BUMPED THE CAR AND ALL MESSAGES APPEAR AGAIN. NEW MESSAGE: POWER STEERING MESSAGE FLASHED BRIEFLY .. ALTHOUGH THERE WAS NO PROBLEM W/THE STEERING. BRINGING TO ANOTHER VOLVO DEALER.. THE SAGA CONTINUES. --I READ PRIOR CONSUMER COMPLAINTS ON THIS SITE AND I ALSO HAD THE SUNROOF LEAKAGE PROBLEM IN 2013. ENTIRE FLOOR OF CAR WAS SOAKED, ESPECIALLY PASSENGER SIDE. TOOK 3 VISITS, WEEKS AND $900 TO GET IT FIXED. VOLVO FIRST CLEANED OUT THE CLOGGED LINE BUT CARPETS WERE WET AGAIN SO THEY THEN REPLACED THE ENTIRE LINE. *JS
Showing 1–20 of 25 complaints
The 2005 Volvo S40 has 3 recalls recorded by NHTSA.
NHTSA has received 81 owner-reported complaints for the 2005 Volvo S40.
NHTSA has not published a safety rating for the 2005 Volvo S40.
The most commonly reported complaint categories for the 2005 Volvo S40 are electrical system (11 reports), engine and engine cooling (10 reports), fuel system, gasoline (7 reports).
Yes. NHTSA has 3 recalls on record for the 2005 Volvo S40. Scroll up to review the published recall summaries, consequences, and remedies. To check for unrepaired recalls on your specific vehicle, use your VIN at nhtsa.gov/recalls.
Look up recalls and complaints for any year, make, and model.
This page summarizes publicly available data from the National Highway Traffic Safety Administration (NHTSA). Complaint counts reflect reports submitted to NHTSA by vehicle owners and do not by themselves prove defect severity or vehicle safety. Safety ratings may not be available for all vehicle-years. This site is not affiliated with NHTSA or any vehicle manufacturer. For official information, visit the official NHTSA page for this vehicle.