2004 Volvo S40 Recalls, Complaints & Specs
6 safety recalls list the 2004 Volvo S40, and owners have filed 48 complaints with NHTSA. Check your own VIN below.
6 safety recalls for the 2004 Volvo S40
Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.
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Navigational system(global positioning system) (equipment)
Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
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…
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Fuel pump (fuel system)
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…
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.
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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.
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.
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Hoses, lines/piping, and fittings (service brakes)
On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
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.
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Fuel system, gasoline
On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
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.
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Labels (equipment)
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.
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…
48 owner complaints filed with NHTSA
Owners of the 2004 Volvo S40 have filed 48 complaints with NHTSA; 5 describe a crash and 1 describe a fire. Reports cite 4 injuries and 0 deaths. The average mileage at failure in those reports is 68,653 miles. Complaints peaked in 2005 with 6 filed that year.
Most-reported components
What owners are reporting
“Having a coolant leakage, crash mode and safety alarm system check keeps coming on...when crash mode comes on...car just shuts off.”
Owner complaint to NHTSA, November 8, 2020 · Electrical system
“Tl* the contact owns a 2004 volvo s40 equipped with cooper zeon rs3-a tires, size: 205/55/16r (na). The contact heard a loud humming noise coming from the tires. The inside of the tread had a line and”
Owner complaint to NHTSA, October 1, 2019 · Tires
Fuel economy and specs
EPA ratings for the 2004 Volvo S40 (S40 FWD). Ranges cover every tested configuration.
| Combined | 22–23 mpg |
|---|---|
| City / Highway | 19 / 27–28 |
| Fuel | Premium |
| EPA class | Compact Cars |
| Engine | 4/5 cyl, 1.9/2.4/2.5 L |
| Transmission | Automatic (S5); Automatic 5-spd |
Compare Volvo S40 model years
Recall and complaint counts for every Volvo S40 model year in NHTSA's database.
| Model year | Recalls | Complaints |
|---|---|---|
| 2000 Volvo S40 | 1 | 122 |
| 2001 Volvo S40 | 2 | 84 |
| 2002 Volvo S40 | 1 | 27 |
| 2003 Volvo S40 | 2 | 18 |
| 2004 Volvo S40 | 6 | 48 |
| 2005 Volvo S40 | 3 | 69 |
| 2006 Volvo S40 | 3 | 58 |
| 2007 Volvo S40 | 2 | 25 |
| 2008 Volvo S40 | 2 | 16 |
| 2009 Volvo S40 | 3 | 10 |
| 2010 Volvo S40 | 2 | 9 |
| 2011 Volvo S40 | 2 | 5 |
Checking a specific 2004 Volvo S40
How do I know if my 2004 Volvo S40 has an open recall?
Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 6 campaigns currently list the 2004 Volvo S40; your car may already have been repaired under some of them.
Is the recall repair free?
Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised Volvo dealer with your VIN and the NHTSA campaign number (for example 03V284000).
What is the difference between a recall and a complaint?
A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.
Other Volvo models
- XC901,528 complaints
- S601,266 complaints
- S80954 complaints
- V70933 complaints
- XC60651 complaints
- S70593 complaints
- 850569 complaints
- XC70417 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.