RecallRepo

2005 Volvo S40 Recalls

Recalls on record Updated July 2026

The 2005 Volvo S40 has 3 NHTSA recall campaigns affecting an estimated 39,591 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 91 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.

Recall campaigns

EQUIPMENT 10V566000 2010-11-08 416 affected
Defect

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

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…

FUEL SYSTEM, GASOLINE 08V033000 2008-01-28 23,000 affected
Defect

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,…

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, GASOLINE 06V137000 2006-04-24 16,175 affected
Defect

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.

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.

Complaints by component

ELECTRICAL SYSTEM
19
ENGINE AND ENGINE COOLING
8
FUEL SYSTEM, GASOLINE
8
FUEL/PROPULSION SYSTEM
8
ENGINE
5
AIR BAGS
4
1crashes1injuries
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
4
ENGINE AND ENGINE COOLING:ENGINE
3
SEAT BELTS
3
SERVICE BRAKES
3
Total complaints91

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“The contact's wife owns a 2005 volvo s40. The contact stated the vehicle was difficult to start for several days. Eventually, the failure progressed and the vehicle was not able to start. The check engine warning light was illuminated. The vehicle was repaired by the contact, a previous volvo…”

POWER TRAIN · reported 2024-02-21

“The contact's wife owns a 2005 volvo s40. The contact stated the vehicle was difficult to start for several days. Eventually, the failure progressed and the vehicle was not able to start. The check engine warning light was illuminated. The vehicle was repaired by the contact, a previous volvo…”

ELECTRICAL SYSTEM · reported 2024-02-21

“The contact's wife owns a 2005 volvo s40. The contact stated the vehicle was difficult to start for several days. Eventually, the failure progressed and the vehicle was not able to start. The check engine warning light was illuminated. The vehicle was repaired by the contact, a previous volvo…”

FUEL/PROPULSION SYSTEM · reported 2024-02-21

“The drivers seat belt does not lock/latch in properly. Everytime I enter the vehicle I reach for my seat belt and buckle myself, well so I thought I did. When I insert the belt it seems as though its buckles however once I start to drive the belt comes un done and it I always have to pull over to…”

SEAT BELTS · reported 2023-04-03

“Tl* the contact owns a 2005 volvo s40. The contact stated that while driving at an undisclosed speed, the vehicle stalled without warning. The vehicle was towed to an independent mechanic who diagnosed that the fuel pump electronic module had failed due to rusting and corrosion. The fuel pump…”

FUEL SYSTEM, GASOLINE · reported 2021-03-15

“I was told by shop that work on my car that were a recall on the pvc vaul on the 2005 volv s40 2.4. *tr”

FUEL/PROPULSION SYSTEM · reported 2020-06-14

“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. *tr”

UNKNOWN OR OTHER · reported 2020-06-04

“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. *tr”

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP · reported 2020-06-04
Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2005 Volvo S40 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.