NHTSA lists 6 recalls for the 2004 Volvo S40 FWD; the most frequently affected component is fuel system, gasoline. Owners filed 50 complaints, most often about service brakes. Among the 12 model years of this model in the database, 2004 ranks #1 for number of recalls.
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.
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.
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.
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.
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.
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 — Hoses, lines/piping, and fittingsCampaign 04V493000 · 14 Oct 2004
Problem: On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
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, gasolineCampaign 03V424000 · 24 Oct 2003
Problem: On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
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 — LabelsCampaign 03V284000 · 01 Aug 2003
Problem: 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: 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.
What owners complain about
Share of the 38 most recent complaints stored for this model year, by component. Owners can list more than one component.
Service brakes9 · 24%
Air bags7 · 18%
Hydraulic6 · 16%
Electrical system6 · 16%
Fuel system5 · 13%
Gasoline5 · 13%
Vehicle speed control4 · 11%
Engine and engine cooling3 · 8%
When complaints were filed
20072
20084
20094
20106
20113
20125
20143
20153
20163
20171
20182
20191
20201
From owner complaints
Tl*the contact owns a 2004 volvo s40. While driving 30 mph, the vehicle rapidly accelerated automatically. The vehicle would not slow down when the brake pedal was depressed. The contact had a difficult time pulling the vehicle over to the side of the road. The vehicle behind her notified her that the vehicle was on…
My 2004 volvo s40 occasionally does not seem to have any hydraulic brake assistance when it is first started in the morning. This was very occasional starting a couple of years ago, but is becoming more frequent. On monday, i had to restart the car 5 times before the brakes felt "normal". *tr
Tl* the contact owns a 2004 volvo s40. While driving 50 mph the check engine light illuminated on the instrument control panel, and then the vehicle stalled. After a period of waiting she was able to restart the vehicle. The volvo manufacturer was notified, but no assistance was provided. The failure mileage was…
Tl*the contact owns a 2004 volvo s40. While attempting to park the vehicle with the brake pedal depressed, the vehicle accelerated on its own and crashed into a telephone pole. The contact was uninjured. The vehicle was taken to the dealer and they repaired the damages at the cost of $8,000. The cause of the failure…
Recall and complaint records from the US National Highway Traffic Safety Administration (NHTSA). A recall listed here may not apply to every vehicle of this model year — always check your VIN with NHTSA or a dealer.