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Recalls are issued for a make, model and model year. Whether the repair has already been done on one specific car is known only to its manufacturer and dealers. Check your vehicle's official status at nhtsa.gov/recalls or with a dealer.
US recalls (6)
Equipment: electrical, navigational system(global positioning system)
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Risk and remedy
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
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 GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
Fuel system, gasoline: delivery, fuel pump
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 and remedy
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.
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.
Fuel system, gasoline
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 and remedy
Risk: 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.
Service brakes, hydraulic: power assist, vacuum
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
Risk and remedy
Risk: 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.
Fuel system, gasoline
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
Risk and remedy
Risk: 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.
Equipment: other, labels
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.
Risk and remedy
Risk: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
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 1-800-458-1552.
Canadian recalls (6)
Show 6 Canadian recalls
Accessories
2010-11-08 · campaign 2010-396 · 87 vehicles
On certain vehicles, there is a possibility of overheating issues of batteries in the Garmin nüvi® 760 when certain batteries manufactured within a limited date code range are used in certain Garmin nüvi® 760 models with a specific printed circuit board (PCB) design. The interaction of these factors can, in some circumstances, increase the possibility of overheating, which may lead to a fire. Correction: Dealers will direct customers who have an affected unit to the Garmin Web site, which explains how to verify if their units are involved and includes procedures to follow for product exchange.
Fuel system
2008-01-28 · campaign 2008-023
On certain vehicles, insufficient sealing of the Fuel Pump Electronic Module may lead to water ingress corrosion, possibly causing the unit to fail. This may result in increased, decreased, or loss of fuel pressure. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. Correction: Dealers will replace and relocate the Fuel Pump Electronic Module.
Seats and restraints
2006-03-27 · campaign 2006-066
Certain Volvo 850, S40, V40, V50, V70, XC70 and XC90 equipped with integrated child booster cushions were incorrectly labelled during vehicle assembly. The label indicates that the booster cushion can be used for children weighing between 15 and 36 kg (33 and 80 lb). CMVSS 213 states that the minimum weight for use must be 18 kg (40 lb). Should an underweight child be placed in the booster cushion and the vehicle is involved in a crash, the child may have a greater risk of injury. Correction: Volvo Canada will send a letter to owners explaining this problem and will supply updated weight limit decal to be applied to each side window.
Brakes
2004-10-12 · campaign 2004-370 · 87 vehicles
On certain vehicles, the vacuum valve and hose assembly at the brake booster could develop a vacuum leak due to an incorrect welding process during assembly. A vacuum leak at the brake booster would affect the performance of the power-assisted brakes. More brake pedal force may be required to stop the vehicle. Correction: Dealers will inspect and, if necessary, replace the vacuum hose assembly.
Fuel system
2003-10-27 · campaign 2003-261
On certain vehicles, improper welding of the end cover that secures the service nipple to the fuel rail may eventually cause a fuel leak. A fuel leak in the presence of an ignition source could create the risk of a vehicle fire and possible injury or death. Correction: Dealer will install a V-clamp securing device to the fuel rail.
Other
2003-09-12 · campaign 2003-226
Certain vehicles do not comply with CMVSS 210.2. The symbol indicating the presence of a lower universal anchorage system, and a reproduction of this symbol were omitted from the owner's manual. Correction: The corrected owner's manual page will be mailed to owners.
Owner complaints (48)
Owners filed 48 complaints with NHTSA about the 2004 Volvo S40 (5 crashes, 1 fires, 4 injuries reported). Among 12 model years of this model, it ranks #5 for the most complaints (median 27).
| Most-reported problem | Complaints | |
|---|
| Air bags | 11 | |
| Electrical system | 11 | |
| Service brakes, hydraulic | 8 | |
| Engine and engine cooling | 5 | |
| Fuel system, gasoline | 5 | |
| Steering | 4 | |
| Vehicle speed control | 4 | |
| Service brakes | 3 | |
Crash test ratings
NHTSA 5-Star Safety Ratings for the 2004 Volvo S40.
| Version | Overall | Frontal | Side | Rollover |
|---|
| 2004 Volvo S40 4-DR. w/SAB (2004.5) | – | – | – | – |
Fuel economy
EPA ratings for each 2004 Volvo S40 version.
| Version | City MPG | Highway MPG | Combined | Yearly fuel cost |
|---|
| S40 FWD 1.9 L Automatic 5-spd | 19 | 27 | 22 | $3,750 |
| S40 FWD 2.4 L Automatic (S5) | 19 | 28 | 22 | $3,750 |
| S40 FWD 2.5 L Automatic (S5) | 19 | 28 | 23 | $3,550 |
Need this data in your app?
Recalls, complaints, crash ratings and fuel economy as a JSON API. Decode up to 50 VINs per call and get a daily feed of new recalls.
Explore the API →Sources: NHTSA recalls, complaints and 5-Star Safety Ratings, US EPA fuel economy and Transport
Canada's Vehicle Recalls Database (contains information licensed under the Open Government Licence – Canada).
Recalls updated 2026-10-30.