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2004 Volvo S40: Problems, Recalls and MPG

What this means

NHTSA lists 6 recall campaigns for the 2004 Volvo S40, most recently filed November 2010. Owners have filed 48 complaints with NHTSA, most often about the service brakes.

Data summary generated from official records. Methodology Data: NHTSA, DOT, EPA · Refreshed Oct 6, 2026
Caution Fewer than 50 complaints filed. With this few reports, patterns may not be meaningful.
Recalls 6campaigns 2 fuel system · 1 electrical · 1 fuel pump Source: NHTSA Complaints 48filed Owner reports, 2000–2009 shown Source: NHTSA ODI Fuel economy 23mpg combined $2,840/yr at this week's prices Source: EPA · EIA Specs 2.5 L 5-cyl· 5-speed automatic 3 engine and transmission configurations Source: NHTSA vPIC
Compare

Recalls (6)

NHTSA lists 6 recall campaigns for the 2004 Volvo S40. Check whether yours was repaired with NHTSA's free VIN lookup ↗

Only NHTSA and your automaker know whether your specific car was repaired. PlainVIN shows every recall campaign listed for a model year, with the official text and how many cars have been fixed so far.

Check on NHTSA ↗
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 10V566000 Filed Nov 8, 2010

760 PORTABLE AUTOMOTIVE GPS UNITS/GARMIN

Equipment · electrical · navigational system(global positioning system)
Official NHTSA text
Summary
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence
AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
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.
Repair progress not yet reported416 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 10V566000
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 08V033000 Filed Jan 28, 2008

PUMP ELECTRONIC MODULE (PEM) CORROSION

Fuel system, gasoline · delivery · fuel pump
Official NHTSA text
Summary
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.
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.
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.
Repair progress not yet reported23,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 08V033000
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 06V137000 Filed Apr 24, 2006

FUEL LINE

Fuel system, gasoline
Official NHTSA text
Summary
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.
Consequence
THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
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.
Repair progress not yet reported16,175 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 06V137000
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 04V493000 Filed Oct 14, 2004

VOLVO/VACUUM VALVE/HOSE ASSEMBLY

Service brakes, hydraulic · power assist · vacuum · hoses, lines/piping, and fittings
Official NHTSA text
Summary
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
Consequence
IF THIS OCCURS, MORE BRAKE PEDAL FORCE MAY BE REQUIRED TO STOP THE VEHICLE AND/OR MAY EXPERIENCE A ROUGH ENGINE IDLE, WHICH COULD RESULT IN A CRASH.
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.
Repair progress not yet reported1,719 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 04V493000
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 03V424000 Filed Oct 24, 2003

VOLVO/FUEL LEAK

Fuel system, gasoline
Official NHTSA text
Summary
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
Consequence
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
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.
Repair progress not yet reported15,067 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 03V424000
Listed for 2004 Volvo S40. Not checked against your VIN.
Recall 03V284000 Filed Aug 1, 2003

VOLVO/ISOFIX GUIDE

Equipment · other · labels
Official NHTSA text
Summary
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.
Consequence
THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
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 A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.
Repair progress not yet reported220,407 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA or ask a dealer to check campaign 03V284000

PlainVIN shows public government records for education. It isn't a vehicle inspection or legal advice. Check your own VIN with NHTSA or your dealer.

Which S40 years had the most recalls?Best & worst years →Every recall for the Volvo S40All model years →Where is the VIN on my car?VIN location guide →

Owner complaints (48)

48 complaints filed with NHTSA (owner reports, not verified findings). The service brakes is mentioned most often.

5involved a crash
1involved a fire
4injuries reported
0deaths reported

As reported by owners in their complaints. These are reports, not NHTSA findings.

Most-reported components

Complaints filed with NHTSA for the 2004 Volvo S40, by component (top 10). One complaint can list several components, so these add up to more than 48.Source: NHTSA ODI owner complaints · Retrieved Oct 6, 2026 · Report a data error

How 2004 compares with other S40 years

Best and worst S40 years →
122 84 27 18 48 69 58 25 16 10
2000200120022003200420052006200720082009
This year (2004)Other yearsStill collecting reports

Counts are owner reports, not failure rates. Higher sales years tend to draw more reports. Owners are still filing reports for recent model years, so these counts will grow. Source: NHTSA ODI, retrieved Oct 6, 2026.

Fuel economy: up to 23 mpg combined

23
mpg combined
19
city
28
highway
EPA annual fuel cost
$3,550
CO₂ tailpipe
386 g/mi
EPA class
Compact Cars

What it costs you to run

$2,840per year
$237per month
652gallons a year

Miles ÷ 23 mpg × $4.354 (EIA US average regular, week of Oct 5, 2026, all taxes included). Source: EPA · EIA.

EPA label estimates from lab tests; your mileage will vary.

Specs by configuration

2004 Volvo S40 configurations with EPA data
Engine · transmissionDriveCity / Hwy / CombEPA $/yrCO₂ g/mi
2.5 L 5-cyl · 5-speed automaticFront-Wheel Drive19 / 28 / 23$3,550386
1.9 L 4-cyl · 5-speed automaticFront-Wheel Drive19 / 27 / 22$3,750404
2.4 L 5-cyl · 5-speed automaticFront-Wheel Drive19 / 28 / 22$3,750404

Source: EPA fuel economy data, retrieved Oct 6, 2026. Configurations are listed when EPA and NHTSA records match.

Used blue SUV on a sunny dealer lot with its hood open and a clipboard on the fender

Looking at a 2004 S40 for sale?

Print a one-page buyer's checklist: each recall campaign with a box to tick when the seller shows proof of repair, the top complaint areas to inspect, crash stars, MPG, and a link back to this page.

All S40 years

Where to next

Which S40 years drew the fewest complaints?Best & worst years →2005 Volvo S40 report69 complaints · 3 campaigns →2003 Volvo S40 report18 complaints · 2 campaigns →Have a VIN? Decode itVIN decoder →

2004 Volvo S40 FAQ

How many recalls does the 2004 Volvo S40 have?

NHTSA lists 6 recall campaigns: 10V566000 (electrical), 08V033000 (fuel pump), 06V137000 (fuel system), 04V493000 (brake), 03V424000 (fuel system), 03V284000 (equipment). Use NHTSA's VIN lookup to see whether a specific car was repaired.

What are the most common 2004 Volvo S40 problems?

Owners filed 48 complaints with NHTSA. Service brakes (12), Air bags (11), Electrical system (11) are mentioned most. These are owner reports, not verified findings.

What mpg does the 2004 Volvo S40 get?

EPA rates the 2.5 L 5-cyl · 5-speed automatic version at 19 city, 28 highway and 23 combined mpg. Other configurations are listed in the fuel economy section.

How does the 2004 S40 compare with other years?

Among the 2000–2009 Volvo S40 model years at least five years old, the 2009 drew the fewest complaints (10) and the 2000 the most (122). The 2004 drew 48. Counts are owner reports, not failure rates.

How this page was madeSources, processing, limits, review and changes

Processing

  • Complaints are counted per component. One complaint can list several, so component totals add up to more than the total.
  • Fuel cost = miles per year ÷ EPA combined mpg × EIA weekly price for your region.

Limitations

  • Complaint counts are owner reports, not verified findings or failure rates. There is no sales denominator.
  • Recall campaigns are listed for the model year. Only NHTSA and the automaker know whether a specific car was repaired.
  • Recent model years are still collecting reports.

Review

Data compiled automatically from the official files listed here.

Changelog

  • 2026-10-06 Data refreshed from the official files.
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