Problems owners report
Complaints filed with NHTSA about the 2002 Volvo S40, by the system named in each complaint. One complaint can name several.
- Service brakes, hydraulic6
- Electrical system5
- Suspension3
- Engine and engine cooling3
- Exterior lighting3
- Power train2
- Air bags2
- Visibility2
- Seat belts1
- Vehicle speed control1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 2 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
New York safety inspections
At its first New York inspection the 2002 Volvo S40 failed the safety check 2.71% of the time — 35% more often than the average 2002 passenger car (2.00%). Median odometer at inspection: 99,795 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Engines
The most common engines in 2002 Volvo S40 cars on Dutch roads are the 1.8 petrol (90 kW, 121 hp), 1.9 petrol (100 kW, 134 hp) and 1.6 petrol (80 kW, 107 hp).
| Engine | Power | Cars |
|---|---|---|
| 1.8 petrol | 90 kW 121 hp | 233 |
| 1.9 petrol | 100 kW 134 hp | 58 |
| 1.6 petrol | 80 kW 107 hp | 26 |
RDW Open Data (CC0): registered passenger cars and their fuel data · engine size rounded to 0.1 litre, net maximum power · versions with at least 20 cars
In the Netherlands
346 first registered in 2002 are on Dutch roads; 4% arrived later as imports.
Most common APK defects
- Bandenspanning niet op juiste waarde257
- Stofhoes stuurinrichting beschadigd, dicht niet af137
- Kentekenplaatverlichting werkt niet (goed) / ontbreekt119
- Achterlicht werkt niet (goed)110
- Band onvoldoende profiel99
- Stofhoes aandrijfas beschadigd en dicht niet af84
- Band(en) aanwezig met een profieldiepte van 1,6 t/m 2,5 mm81
- Stadslicht werkt niet (goed)75
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In the United Kingdom
286 cars built in 2002 were licensed for the road at the end of 2025, and 411 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
MOT test results in Great Britain
In 2023, 562 of these cars first registered in 2002 took their annual MOT test. 54% passed first time; among all cars first registered in 2002 the figure was 58%.
| Failed on | These cars | All cars from 2002 |
|---|---|---|
| Lamps, reflectors and electrical equipment | 23.7% | 20.8% |
| Suspension | 18.0% | 15.8% |
| Brakes | 15.3% | 13.6% |
| Body, chassis, structure | 9.3% | 9.7% |
| Visibility | 6.8% | 7.7% |
| Steering | 6.0% | 4.0% |
DVSA anonymised MOT tests and results, 2023 (Department for Transport) · Open Government Licence v3.0 · first tests only; a fix made at the test station within the hour still counts as a fail
In Finland
635 of these cars first registered in 2002 were in use in Finland on 30 Jun 2026, with an average of 256,000 km on the odometer at their last inspection.
Traficom (Finnish Transport and Communications Agency), open data on vehicles in use · CC BY 4.0
In New Zealand
14 2002 cars are on the New Zealand register; 21% arrived as used imports, 71% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 1 variant: combined 10.7 L/100 km (about 22 mpg US), CO₂ 246 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| S40 Turbo · Compact · Premium gasoline | 12.3 | 8.7 | 10.7 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
1 Transport Canada recall for the 2002 Volvo S40.
| 2006066 27 Mar 2006 | Seats And Restraints Certain Volvo 850, S40, V40, V50, V70, XC70 and XC90 equipped with integrated child booster cushions were incorrectly labelled during vehicle assembly. The lab… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Volvo told its dealers about the 2002 Volvo S40: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 630879 | EXPERIENCING A KNOCKING NOISE FROM THE FRONT SUSPENSION. *TT |
| 11007925 | Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service |
| 10249191 | This is a Technical Journal: 12V Battery Testing Method |
| 10241661 | COMPLIMENTARY UPGRADE C00009 DESCRIPTION. |
| 10241651 | Rubber cushion |
| 10219421 | Engine Control Module (EMS) Software (MSW) Information August 2022; Improvement List (Change Log) - US21+OBD22 (13L VGT, TC) And US17+OBD22 (11L) Emissions |
| 10213885 | The Deutronic DBL-1200 is an advanced battery maintainer/charger with the flexibility to be updated as products and repair methods evolve. |
| 10213883 | ICUP/Google Built-In Diagnostic Operations |
| 10213882 | Battery Charger/maintainer requirement |
| 10212892 | Shipping and Handling of Volvo Lithium-ion 48V Mild Hybrid Battery to Global Battery Solutions (GBS) |
| 10212891 | VIDA QR Scanner Mobile App |
| 10188881 | Volvo?s Warranty Department tracks Retailer warranty spending by utilizing the Warranty Retailer Counseling Process (WRCP). The WRCP is used to gauge individual retailer performance on objective measures over time. By setting clear performance expectations and parameters and assisting retailers in focusing on individual processes and procedures, all retailers are provided with adequate tools to help achieve the ultimate goal of qualifying for self-authorization status. |
| 10181041 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
| 10179681 | This is a Service Manager Bulletin: Service 2.0 Software & Total Upgrade Reminder |
| 10178520 | This is a Service Manager Bulletin: Volvo Lithium-ion Hybrid Battery Packs shipping and handling to Volvo Reman |
| 10178516 | This is a Service Manager Bulletin: Volvo Lithium-ion Hybrid Battery Packs shipping and handling to Volvo Reman |
| 10178503 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
| 10177386 | Service Manager Bulletin: Vehicle Type and Platform Information |
| 10173760 | This is a Service Manager Bulletin: Service 2.0 Software & Total Upgrade Reminder |
| 10171676 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
| 10170147 | Service Manager Bulletin TITLE : Service Action Notification Re - Mails GROUP : NO : ISSUING DEPARTMENT : CAR MARKET : Product Safety & Compliance United States and Canada 00 325 REFERENCE BULLETINS : DATE : SMB00 - 323 and SMB00 - 323A YEAR MONTH DAY SERVICE SERVICE WARRANTY 2013 02 15 MANAGER WRITER ADMINISTRATOR Service Personnel : Read and initial Page 1 of 1 Volvo monitors completion rates for all service actions and will complete notification re - mails to vehicle owners when necessary . Listed below are the latest notification re - mails . Please refer to SMB 00 - 323 and SMB 00 - 323A |
| 10169394 | This is a Technical Journal: Swapping control modules from vehicle to vehicle for diagnostics should be avoided. Swapping control modules may result in consequential damage to the swapped control module and in certain cases several other control modules in the vehicle. Swapping the Driver Information Module (DIM) is strictly forbidden as the DIM it is the main carrier of the odometer function, and will, in case of swapping, result in manipulated odometer value. Service: Please do NOT swap any control modules from vehicle to vehicle for testing, unless instructed to do so in a Vehicle Report by |
| 10169393 | This is a Technical Journal: Swapping control modules from vehicle to vehicle for diagnostics should be avoided. Swapping control modules may result in consequential damage to the swapped control module and in certain cases several other control modules in the vehicle. Swapping the Driver Information Module (DIM) is strictly forbidden as the DIM it is the main carrier of the odometer function, and will, in case of swapping, result in manipulated odometer value. Service: Please do NOT swap any control modules from vehicle to vehicle for testing, unless instructed to do so in a Vehicle Report by |
| 10169391 | Software Installation Policy changes. |
| 10169389 | This is a Service Manager Bulletin: Technician Skillset Requirments |
NHTSA manufacturer communications (public domain)