CarRecallDB

2005 Volvo S40 recalls and problems

3 recalls and 69 owner complaints on file with NHTSA for the 2005 Volvo S40.

3
recalls
69
owner complaints
2
complaints mentioning a crash
0
mentioning a fire

Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.

2005 Volvo S40 recalls

Equipment: electrical, navigational system(global positioning system)

NHTSA campaign 10V566000 · reported November 8, 2010 · VOLVO CARS OF N.A. LLC. · 416 vehicles potentially affected

The problem
Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
The risk
An overheated battery could lead to a fire.
The fix
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

NHTSA campaign 08V033000 · reported January 28, 2008 · VOLVO CARS OF N.A. LLC. · 23,000 vehicles potentially affected

The 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.
The 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.
The fix
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

NHTSA campaign 06V137000 · reported April 24, 2006 · VOLVO CARS OF N.A. LLC. · 16,175 vehicles potentially affected

The 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.
The risk
This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
The fix
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.

Most reported problems

Areas named in owner complaints to NHTSA. One complaint can name several areas.

What owners report

Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.

Mar 20, 2024 · Power train · 170,000 miles

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…

Sep 24, 2023 · Seat belts

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…

Mar 18, 2021 · Fuel system, gasoline · 147,000 miles

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…

Jun 15, 2020 · Fuel/propulsion system · 84,000 miles

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.

Jun 6, 2020 · Unknown or other · 168,505 miles

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.

S40 model years compared

YearRecallsComplaintsCrashesFires
2002 12740
2003 21801
2004 64851
2005 36920
2006 35810
2007 22541
2008 21650

Across all years, the 2000 S40 has the most complaints (122). All Volvo S40 years →

Questions

Does the 2005 Volvo S40 have any recalls?
Yes. NHTSA lists 3 recalls for the 2005 Volvo S40, the most recent reported on November 8, 2010 (Equipment: electrical, navigational system(global positioning system)). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2005 Volvo S40?
Owners have filed 69 complaints with NHTSA. The most frequently reported area is electrical system (19 complaints), followed by engine and engine cooling (11).
How many 2005 Volvo S40 complaints mention a crash or fire?
2 of 69 complaints report a crash and 0 a fire; 1 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received March 20, 2024.