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Volvo S40Model year report

2002 Volvo S40 Problems

Complaints
27filed with NHTSA
Median mileage
45,000miles, 16 complaints with mileage
Recalls
1campaigns on record
Trend
StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
22 mpgcombined, 1.9L 4-cyl FWD · 19 city / 27 hwy

Sources: NHTSA records for the 2002 Volvo S40 (complaints, recalls, investigations), EPA fuel economy. Report an error

NHTSA recorded 27 consumer complaints for the 2002 Volvo S40. The part named most often is brakes, with 7 complaints (26% of the total), followed by electrical system (5) and engine cooling (3). 16 of the complaints include a mileage, and 56% of those were filed for vehicles with under 50,000 miles; the median is 45,000 miles. Of all complaints, 4 involved a crash, 2 an injury, according to the filers. NHTSA lists 1 recall campaign and 153 technical service bulletins for this model year. Brakes complaints overlap with 2 technical service bulletins filed under the same part. Electrical system complaints overlap with 48 technical service bulletins filed under the same part.

Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Also reported: Seat belts (1), Vehicle speed control (1).

Example complaints

Brakes: “I was driving on a main road and my brakes failed. It was determined that a brake line corroded through. It appears that the vehicle has a single master brake cylinder. I asked a Volvo dealership about this, and they confirmed to me that the master brake cylinder is a single one. It is my understanding that in the 80's, all vehicles sold in the united states were to have a dual master brake cylinder.”

NHTSA complaint #10550701, filed 2013-11, 145,000 miles

Electrical system: “In september of 2004, I began experiencing problems with my Volvo S40 sedan. The vehicle would shut off while I was operating it for no apparent reason. I took the vehicle to the dealer twice and then contacted the Volvo customer care department following an incident when the vehicle shut off while I was in a very busy intersection in town. I narrowly avoided a very serious crash. They sent a regional technician to the Volvo dealer. Volvo had the car for an extended period of time and said while they could not determine the problem, they replaced several parts. …”

NHTSA complaint #10132646, filed 2005-08, 48,000 miles

Engine cooling: “- the contact owns a 2002 Volvo S40. The contact stated that the enginewas idling high. Volvo stated that the vehicle was operating normally. The RPM surge occurred frequently when the contactwas driving the vehicle. The check engine light came on periodically. There was a recall for this failure on all Volvo models, but not for the 240 model.”

NHTSA complaint #10181120, filed 2007-01, 30,000 miles

Exterior lighting: “Types of recurring issues with Volvo S40: headlights, driver front window motor, early brake pad wear. Headlight bulbs were replaced 2-3 times a year at consumer's cost. When brought to the attention of Volvo dealer they reported that it was probably due to lights being used during daylight. They check electrical and reported no issue. Had brake pad and rotor issued shortly after purchasing the vehicle. Volvo dealer reported Volvo rotors were built thin and soft. Cost of brake replacement was not covered under warranty as it was considered regular wear. …”

NHTSA complaint #10191517, filed 2007-05, 2,000 miles

Mileage when problems were reported

56% of the 16 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 30,000 and 104,000 miles.

19%0–106%10–2531%25–506%50–756%75–10025%100–1506%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (16 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 45,000 miles.

Complaints by year filed

Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.

2002200320042005820072009201120132017
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Fuel economy and running cost

EPA ratings for each 2002 Volvo S40 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
S40 FWD1.9L 4-cyl5-speed automatic192722$3,750

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

Recall details for the 2002 Volvo S40 → · Check a VIN at nhtsa.gov/recalls

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 153 on record; the latest 10 are shown.

See all 153 bulletins →

Other model years of the Volvo S40

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
2011599,5002—24—Not enough data
2010976,0002—24—Not enough data
20091065,0003—23—Not enough data
20081675,2652—23—Falling
20072557,5002—22Not compared (before 2008)Falling
20065875,0003—22Not compared (before 2008)Falling
20056976,5003—22Not compared (before 2008)Falling
20044864,0006—22Not compared (before 2008)Falling
20031885,1062—22—Falling
20022745,0001—22Not compared (before 2008)Stable
20018467,0002—23Not compared (before 2008)Falling
200012273,4581—21Not compared (before 2008)Falling

All Volvo S40 model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2002 Volvo S40 have?

NHTSA recorded 27 consumer complaints for the 2002 Volvo S40 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2002 Volvo S40 is reported most often?

Brakes is named most often, in 7 complaints (26% of the total), followed by electrical system with 5.

Has the 2002 Volvo S40 been recalled?

NHTSA lists 1 recall campaign for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2002 Volvo S40 get?

The EPA rates the 2002 Volvo S40 (S40 FWD, 1.9L 4-cyl) at 22 mpg combined, 19 city and 27 highway, with an estimated annual fuel cost of $3,750 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2002 Volvo S40 reported?

Among the 16 complaints that include a mileage, the median is 45,000 miles and the middle half falls between 30,000 and 104,000 miles; 56% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.