2005 Volvo S40 Problems

What owners report

Owners of the 2005 Volvo S40 most often report sudden stalling traced to the fuel pump electronic module, along with intermittent electrical faults that can leave the car unable to start. Many of these stalling complaints were filed at 70,000-100,000 miles and often mention that the dealership said the vehicle was not covered by the fuel pump recall. A smaller but consistent group of complaints covers the engine oil trap and cooling system, air conditioning that stops cooling in hot weather, and seat belt or airbag sensor problems.

1. 1
   Fuel system

   Sudden stalling from fuel pump module (PEM)

   • 22 complaints (32%)
   • median 81,000 mi at 7.7 yrs old (22 state mileage)
   • filed 2008–2024

   Owners describe the engine cutting out without warning at highway speeds or while pulling away from a stop, sometimes with the check engine light or a message on the dash. In several cases a mechanic or dealer diagnosed the fuel pump electronic module and replaced it, and some owners report the module was corroded or rusted. Complaints frequently mention that the dealer said the vehicle was not included in the fuel pump recall, and some owners who had the recall repair still reported the same stalling afterwards. Filed mostly between about 40,000 and 170,000 miles, with many in the 70,000-100,000 mile range, and several owners tie it to wet or damp conditions.

   Recall 08V033000

   What to check: Ask whether the fuel pump electronic module has been replaced and whether the recall 08V033000 work was done, and where the module is mounted. Check for a history of stalling or a check engine light on a test drive, especially in wet weather.

   2 excerpts from owner complaints in NHTSA records

   “My vehicle shuts off while im driving it. I took it to a mechanic 3 times and was advised its an issue with the fuel pump. I was also advised this is an known issue with this particular vehicle and was provided a NHTSA campaign id # 08v033000.”

   NHTSA complaint #11327540, filed 2020-06, 168,505 miles

   “Every time I drive the car it misses a little then it just shuts down like it's not getting any fuel the car don't die just won't pull out I tried to cross a 4 lane and it stalled in the first lane and I about got hit in the side it also did it on the interstate.it is very dangerous I was told it's the electronic fuel module,or pen and was told there was a recall on that part all over the internet but Volvo said there wasn't which I don't believe why would the internet say there was on like 5or notre websites”

   NHTSA complaint #11111408, filed 2018-07, 200,011 miles
2. 2
   Electrical system

   Dash warnings, flickering lights and electrical cutouts

   • 12 complaints (17%)
   • median 83,500 mi at 8.1 yrs old (10 state mileage)
   • filed 2006–2024

   Owners describe the dashboard lighting up with brake failure, immobilizer or crash mode messages while the car is running, along with the radio cutting out, wipers that will not switch off and gauges dropping out. Some say the car stalled during these episodes and had to be coasted to the side of the road, and in one case the key could not be turned off. Complaints also cover headlamp bulbs failing repeatedly because of wiring damage in the lamp assemblies, and door lock actuators that stopped locking or unlocking. Mostly reported between roughly 40,000 and 135,000 miles, with no clear seasonal pattern in the sample.

   2 related service bulletins

   What to check: With the engine running, check that every warning lamp behaves normally and that the wipers, radio and door locks all work. Ask whether the battery and charging system have been tested recently.

   2 excerpts from owner complaints in NHTSA records

   “(S40 2.4i) initial car message: brake failure, pull over safely. I continued to drive home since I was a few blocks away. Message changed to anti skid service required then back to brake failure again. Difficulty accelerating after stopping, felt like the parking brake was on but drove ok once accelerated. Attempted to turn off car but message changed to immobilizer, check manual and could not turn key to off position. From what I read in the manual, it appeared that the card didn't recognize it was in park. …”

   NHTSA complaint #10598364, filed 2014-06, 62,700 miles

   “While driving on the highway my car began to show signs of an electrical problem. Different warnings were coming up on the control panel, alerting me to brake fluid low, as well as my current mileage disappearing. When I pulled off the highway, shut the car off, and removed the key the windshield wipers continued to run. The display messages including brake failure, stop car safely and immobilizer see manual. The brakes are fine, because they worked when stopping the car and work while this message is displayed. …”

   NHTSA complaint #10460439, filed 2012-06, 110,000 miles
3. 3
   Electrical system

   Key error message and no-start

   • 5 complaints (7%)
   • median 78,250 mi at 6.5 yrs old (4 state mileage, few)
   • filed 2010–2017

   Owners report the dash showing a key error message and the car refusing to start, sometimes with nothing electrical working at all. Some describe repeated attempts or jiggling the key before the car finally starts, and in a few cases the car shut down completely and had to be towed. Complaints mention the starter control unit failing to read the key and being replaced, sometimes more than once, and that the problem occurred with both of the car's keys. Filed from very low mileage up to about 115,000 miles, spread across the year rather than tied to one season.

   2 related service bulletins

   What to check: Start the car several times cold with each key and watch for any key error message. Ask whether the starter control unit or ignition switch has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The starter control unit (scu) on my 2005 Volvo S40 has ceased to function twice in the 5 years that I've had it (50,000 miles). Essentially, this means that the scu does not read the key (the car tells me I have a key error ), and therefore the car shuts down completely and does not turn on (the steering locks, the car does not start, it is unusable). The first time it happened, it was under warranty, therefore it was fixed free of charge. …”

   NHTSA complaint #10353966, filed 2010-09, 48,000 miles

   “Ignition switch malfunctioning. When you insert the key, which is an electronic key the message display will display key error try again. When this happens the car will not start at all. Thus far repeatedly jiggling the key fob while in the switch, and/or turning on/off multiple times gets the system to eventually recognize the key. There are 2 keys to my car and this happens with both keys, so I know it isn't the key. I have researched this online and found it to be a common problem. …”

   NHTSA complaint #10435217, filed 2011-11, 66,500 miles
4. 4
   Air bags

   Airbag warning light and seat sensor faults

   • 6 complaints (9%)
   • median 86,500 mi at 8.4 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2008–2017

   Owners report the airbag warning light or the passenger air bag off light appearing with someone sitting in the passenger seat, and mechanics diagnosing a failed passenger weight sensor that needs replacing. One owner said the vehicle did not deploy its airbags in a frontal impact. Some complaints pair the airbag light with a seat belt buckle that clicks but can still be pulled free. Filed between roughly 40,000 and 195,000 miles, with several around 80,000 miles.

   What to check: Turn the ignition on and confirm the airbag warning light goes out after the self-check, and test that the seat belt buckles hold firm when tugged. Ask whether the passenger seat weight sensor has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “On november 14, 2007, my daughter, had a accident with my car, a 2005 Volvo s.40, 24.1. She hit a medium size tree head on. The airbags did not deployed.”

   NHTSA complaint #10222885, filed 2008-03

   “[this is a preventative complaint. No injury sustained.] this car has a failed passenger seat sensor that when depressed activates the passenger side air bag. This vehicle also has a driver side seat belt that clicks and then can be pulled out of the locking harness. These items are not recalled by the manufacture but, in my opinion, should be for customer safety.”

   NHTSA complaint #10944096, filed 2017-01, 80,000 miles
5. 5
   Engine cooling

   Oil trap whine and oil in the cooling system

   • 7 complaints (10%)
   • median 93,000 mi at 9.5 yrs old (4 state mileage, few)
   • filed 2007–2019

   Owners report a high-pitched screeching or whistling noise at idle with the check engine light coming on, diagnosed as a failed oil trap or flame trap box. One owner said a leaking flame box was replaced under warranty once and the dealer would not replace it again when it failed later. Complaints also describe oil entering the cooling system and a service bulletin describing a cleaning method for that condition. Reported from about 47,000 miles up past 100,000 miles, with one owner noting it happened on two cars at around 58,000-61,000 miles.

   3 related service bulletins

   What to check: Listen for a whistle or screech at idle with the hood open and check the coolant for an oily film. Ask whether the oil trap or flame trap box has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “In august of 08 my 2004.5(new body style) Volvo S40 t5's engine began to make a high screeching noise at idle and the check engine light came on. It had 61,000miles and I brought it to the dealership where they diagnosed that it needed a new oil trap. The problem has not recurred. My wife's 05 S40 t5 has 58,000miles and the same problem has occurred in her's. There must be an issue with this vehicle.”

   NHTSA complaint #10246584, filed 2008-10, 60,000 miles

   “I have a 2005 Volvo S40 2.4i with about 47k miles and I am having problems with the A/C. I live in houston (tx) where it gets very hot so I have to have the A/C on constantly. When I first turn the car on and drive off, the A/C starts cooling and working just fine. However, when it is 90f or above, the A/C begins to blow warm air after a few minutes. When that happens I have to turn it off and back on a few times to get it working again but it only works for a few minutes before I have to repeat on/off ritual. …”

   NHTSA complaint #10356303, filed 2010-09

Buying note. Check the service history for the fuel pump electronic module and the recall 08V033000 work, since stalling is the most commonly reported problem on this model year. A pre-purchase inspection that includes a cold start, a scan for stored codes and a check of the airbag and seat belt systems is worth the cost on these cars.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.