Total Complaints
91 filings
VOLVO S40 · model year
91 NHTSA complaints, 2 crash reports, and 3 active recalls for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2005VOLVOS40 carries 91 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 2 crashes, 0 fires, 1 injury, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2005 S40 is electrical system with 19 filings, followed by engine and engine cooling (8) and fuel system, gasoline (8). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 3 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.
NHTSA currently has 28 investigation files overlapping the 2005 S40. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
91 filings
Crashes Reported
2 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| ELECTRICAL SYSTEM | 19 |
| ENGINE AND ENGINE COOLING | 8 |
| FUEL SYSTEM, GASOLINE | 8 |
| FUEL/PROPULSION SYSTEM | 8 |
| ENGINE | 5 |
| FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP | 4 |
| AIR BAGS | 4 |
| ENGINE AND ENGINE COOLING:ENGINE | 3 |
| UNKNOWN OR OTHER | 3 |
| SEAT BELTS | 3 |
| VISIBILITY:SUN/MOON ROOF ASSEMBLY | 3 |
| SERVICE BRAKES | 3 |
| POWER TRAIN | 2 |
| PARKING BRAKE | 1 |
| EQUIPMENT:MECHANICAL:ACCESSORY SCISSOR/SCREW/BOTTLE JACK/LIFT | 1 |
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 DISTRI
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.
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.
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.
Mileage: 170,000
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.
Mileage: 170,000
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.
Mileage: 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.
Mileage: 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
Mileage: 84,000
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
Mileage: 168,505
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
Mileage: 168,505
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
Mileage: 86,000
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
Mileage: 45,506
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
Mileage: 205,000
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
Mileage: 200,011
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.
Mileage: 43,000
CAR LOOSING POWER AND ENGINE MISSING AT HIGHWAY SPEEDS. ENGINE LIGHT WENT ON. FAILURE OF FUEL PRESSURE MONITOR.
Mileage: 62,000
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.
Mileage: 122,115
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.
Mileage: 156,000
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.
Mileage: 156,000
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.
Mileage: 95,000
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.
[THIS IS A PREVENTATIVE COMPLAINT. NO INJURY SUSTAINED.] THIS CAR HAS A FAILED PASSENGER SEAT SENSOR THAT WHEN DEPRESSED ACTIVATES THE PASSENGER SIDE AIR BAG. THIS VEHICLE ALSO HAS A DRIVER SIDE SEAT BELT THAT CLICKS AND THEN CAN BE PULLED OUT OF THE LOCKING HARNESS. THESE ITEMS ARE NOT RECALLED BY THE MANUFACTURE BUT, IN MY OPINION, SHOULD BE FOR CUSTOMER SAFETY.
Mileage: 80,000
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.