2004 Volvo S40 Recalls
NHTSA lists 6 recall campaigns for the 2004 Volvo S40. A recall applies only to vehicles built within the affected range, so check your own VIN at nhtsa.gov/recalls. Repairs for recalls are free at a franchised dealer.
- Equipment › Electrical › Navigational system(global positioning system)Covers: Volvo S40 2004–2010, S80 2000–2010, V70 2001–2010 +6 more
Reported issue: Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
Possible 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…
- Fuel system, gasoline › Delivery › Fuel pumpCovers: Volvo S40 2004–2006, V50 2004–2006
Reported issue: 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…
Possible 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.
- Fuel system, gasolineCovers: Volvo S40 2004–2006, V50 2004–2006
Reported issue: 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.
Possible 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.
- Service brakes, hydraulic › Power assist › Vacuum › Hoses, lines/piping, and fittingsCovers: Volvo S40 2004, V40 2004
Reported issue: On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
Possible 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.
- Fuel system, gasolineCovers: Volvo S40 2003–2004, V40 2003–2004
Reported issue: On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
Possible 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.
- Equipment › Other › LabelsCovers: Volvo S40 2001–2004, V40 2001–2004, V70 2001–2003 +3 more
Reported issue: 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.
Possible 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…
← All problems reported for the 2004 Volvo S40
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.