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NHTSA vehicle safety data

2005 Volvo S40 Recalls, Ratings & Complaints

The 2005 Volvo S40 has 3 NHTSA recall campaigns and 69 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Volvo dealer.

NHTSA recall and complaint data for the 2005 Volvo S40, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.

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2005 Volvo S40 owner complaints

Owners have filed 69 complaints with NHTSA about the 2005 Volvo S40, describing incidents dated July 5, 2005 to February 21, 2024.

Most-cited components

  • Fuel/Propulsion System 20 complaints
  • Electrical System 19 complaints
  • Engine 16 complaints
  • Air Bags 5 complaints
  • Visibility/Wiper 5 complaints
  • Service Brakes 4 complaints

Of the 69 complaints on file, 2 report a crash; across all 69 complaints, owners report 1 injury (owner-reported, not verified by NHTSA).

Newest complaints

  • ODI #11578530 · Filed

    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…

  • ODI #11546212 · Filed

    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…

  • ODI #11403711 · Filed

    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…

Read all 69 complaints

760 PORTABLE AUTOMOTIVE GPS UNITS/GARMIN

NHTSA #10V566000 · Equipment — Electrical — Navigational System(GLOBAL POSITIONING SYSTEM) · NHTSA notice

Reported November 8, 2010 · VOLVO CARS OF N.A. LLC.

Potentially affected: 416 vehicles

Volvo campaign R231 · Owners notified November 18, 2010

Defect description

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

Safety consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Manufacturer 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.

Notes

VOLVO SAFETY RECALL NO. R231.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

PUMP ELECTRONIC MODULE (PEM) CORROSION

NHTSA #08V033000 · Fuel System, Gasoline — Delivery — Fuel Pump · NHTSA notice

Reported January 28, 2008 · VOLVO CARS OF N.A. LLC.

Potentially affected: 23,000 vehicles

Volvo campaign 190 · Owners notified February 20, 2008 · Vehicles built November 18, 2002 – August 22, 2005 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer 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.

Notes

VOLVO RECALL NO. 190.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

FUEL LINE

NHTSA #06V137000 · Fuel System, Gasoline · NHTSA notice

Reported April 24, 2006 · VOLVO CARS OF N.A. LLC.

Potentially affected: 16,175 vehicles

Volvo campaign R158 · Owners notified June 5, 2006 · Vehicles built December 6, 2002 – June 15, 2005 (per NHTSA)

Defect description

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.

Safety consequence

THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Manufacturer 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.

Notes

VOLVO RECALL NO. R158. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Other Volvo S40 model years

Check your 2005 Volvo S40 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Volvo S40 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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