Problems owners report
Complaints filed with NHTSA about the 2004 Volvo S40, by the system named in each complaint. One complaint can name several.
- Air bags11
- Electrical system11
- Service brakes, hydraulic8
- Fuel system, gasoline5
- Engine and engine cooling5
- Steering4
- Vehicle speed control4
- Service brakes3
- Exterior lighting2
- Structure2
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 4 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 2004 Volvo S40 failed the safety check 3.44% of the time — 56% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 116,744 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Engines
The most common engines in 2004 Volvo S40 cars on Dutch roads are the 2.4 petrol (103 kW, 138 hp), 1.8 petrol (90 kW, 121 hp) and 1.8 petrol (92 kW, 123 hp), out of 7 versions with at least 20 cars.
| Engine | Power | Cars |
|---|---|---|
| 2.4 petrol | 103 kW 138 hp | 513 |
| 1.8 petrol | 90 kW 121 hp | 159 |
| 1.8 petrol | 92 kW 123 hp | 127 |
| 1.9 petrol | 100 kW 134 hp | 113 |
| 2.4 petrol | 125 kW 168 hp | 113 |
| 2.5 petrol | 162 kW 217 hp | 60 |
| 2.0 diesel | 100 kW 134 hp | 20 |
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
1,138 first registered in 2004 are on Dutch roads; 12% arrived later as imports. Median list price when new: €34,733.
Most common APK defects
- Bandenspanning niet op juiste waarde621
- Band onvoldoende profiel486
- Stofhoes aandrijfas beschadigd en dicht niet af311
- Veer gebroken of gescheurd287
- Dimlicht onjuist afgesteld282
- Kentekenplaatverlichting werkt niet (goed) / ontbreekt246
- Band(en) aanwezig met een profieldiepte van 1,6 t/m 2,5 mm223
- Achterlicht werkt niet (goed)188
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In the United Kingdom
774 cars built in 2004 were licensed for the road at the end of 2025, and 549 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, 1,440 of these cars first registered in 2004 took their annual MOT test. 52% passed first time; among all cars first registered in 2004 the figure was 56%.
| Failed on | These cars | All cars from 2004 |
|---|---|---|
| Lamps, reflectors and electrical equipment | 23.6% | 21.8% |
| Suspension | 19.2% | 17.2% |
| Brakes | 15.6% | 13.8% |
| Tyres | 8.8% | 6.7% |
| Body, chassis, structure | 8.4% | 9.1% |
| Noise, emissions and leaks | 6.9% | 7.5% |
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
1,389 of these cars first registered in 2004 were in use in Finland on 30 Jun 2026, with an average of 271,000 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
36 2004 cars are on the New Zealand register; 53% arrived as used imports, 42% 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
6 Transport Canada recalls for the 2004 Volvo S40.
| 2010396 8 Nov 2010 | Accessories On certain vehicles, there is a possibility of overheating issues of batteries in the Garmin nüvi® 760 when certain batteries manufactured within a limited date… |
| 2008023 28 Jan 2008 | Fuel System On certain vehicles, insufficient sealing of the Fuel Pump Electronic Module may lead to water ingress corrosion, possibly causing the unit to fail. This may r… |
| 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… |
| 2004370 12 Oct 2004 | Brakes On certain vehicles, the vacuum valve and hose assembly at the brake booster could develop a vacuum leak due to an incorrect welding process during assembly. A… |
| 2003261 27 Oct 2003 | Fuel System On certain vehicles, improper welding of the end cover that secures the service nipple to the fuel rail may eventually cause a fuel leak. A fuel leak in the pr… |
| 2003226 12 Sept 2003 | Other Certain vehicles do not comply with CMVSS 210.2. The symbol indicating the presence of a lower universal anchorage system, and a reproduction of this symbol we… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
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.
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.
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
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 2004 Volvo S40: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 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 |
| 10205650 | News Letter 69 |
| 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. |
| 10169390 | Effective immediately, all 12V batteries may be tested using the hand held battery tester 9513030 (BT3300). The VIDA test is still available but no longer required. For battery replacements under warranty, the code generated by the BT3300 must be manually copied into the repair order text. It must also be printed and attached to the hard copy of the repair order. |
NHTSA manufacturer communications (public domain)