VOLVO S40 · model year

2005 VOLVO S40

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.

91
Complaints
2
Crashes
0
Fires
1
Injuries
0
Deaths

Total Complaints

91 filings

Crashes Reported

2 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
ELECTRICAL SYSTEM19
ENGINE AND ENGINE COOLING8
FUEL SYSTEM, GASOLINE8
FUEL/PROPULSION SYSTEM8
ENGINE5
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP4
AIR BAGS4
ENGINE AND ENGINE COOLING:ENGINE3
UNKNOWN OR OTHER3
SEAT BELTS3
VISIBILITY:SUN/MOON ROOF ASSEMBLY3
SERVICE BRAKES3
POWER TRAIN2
PARKING BRAKE1
EQUIPMENT:MECHANICAL:ACCESSORY SCISSOR/SCREW/BOTTLE JACK/LIFT1

Recalls (3)

08V03300028/01/2008

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

06V13700024/04/2006

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.

10V56600008/11/2010

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.

Recent Complaints

20240320POWER TRAIN

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

20240320ELECTRICAL SYSTEM

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

20240320FUEL/PROPULSION SYSTEM

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

20230924SEAT 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 becsuse it locks the seat belt so I'm not able to just buckle back in.

20210318FUEL SYSTEM, GASOLINE

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

20200615FUEL/PROPULSION SYSTEM

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

20200606UNKNOWN OR OTHER

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

20200606FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

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

20190823ENGINE

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

20190408STRUCTURE:BODY

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

20180716FUEL/PROPULSION SYSTEM

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

20180715FUEL/PROPULSION SYSTEM

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

20180102ENGINE

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

20171211ENGINE

CAR LOOSING POWER AND ENGINE MISSING AT HIGHWAY SPEEDS. ENGINE LIGHT WENT ON. FAILURE OF FUEL PRESSURE MONITOR.

Mileage: 62,000

20171101ENGINE

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

20170512ELECTRICAL SYSTEM

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

20170512FUEL/PROPULSION SYSTEM

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

20170216FUEL/PROPULSION SYSTEM

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

20170214ELECTRICAL SYSTEM

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.

20170110AIR BAGS

[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

Compare 2005VOLVOS40 to Similar Vehicles

NHTSA Investigations

View all investigations

Frequently Asked Questions

How many complaints does the 2005 VOLVO S40 have?
The 2005 VOLVO S40 has 91 NHTSA complaints, 2 crashes, 0 fires, 1 injuries, and 0 deaths reported.
Are there any recalls for the 2005 VOLVO S40?
Yes, the 2005 VOLVO S40 has 3 recall(s). The most common affected component is FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2005 VOLVO S40?
The most-complained component for the 2005 VOLVO S40 is ELECTRICAL SYSTEM with 19 complaints. Other frequently reported areas include ENGINE AND ENGINE COOLING and FUEL SYSTEM, GASOLINE.
Is the 2005 VOLVO S40 safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

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.