2004 Volvo S40: recalls and complaints

NHTSA lists 6 recall campaigns for the 2004 Volvo S40. The newest campaign is 10V566000. NHTSA received the report on 8 Nov 2010. The NHTSA record gives the component Equipment / Electrical / Navigational System(Global Positioning System). NHTSA has 26 complaints on file for this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 10V566000, in the NHTSA record

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 charge. The safety recall began on november 18, 2010. Owners may contact garmin at 866-957-1981 or visit garmin's website at www.garmin.com/nuvibatterypcbrecall.

NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.
NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on 1 Oct 2026. Complaint file through 29 Mar 2018. Recall file through 30 Sep 2026.

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

6 campaigns, newest first. 276,784 units in total.

10V5660008 Nov 2010Equipment / Electrical / Navigational System(Global Positioning System)
08V03300028 Jan 2008Fuel System, Gasoline / Delivery / Fuel Pump
06V13700024 Apr 2006Fuel System, Gasoline
04V49300014 Oct 2004Service Brakes, Hydraulic / Power Assist / Vacuum / Hoses, Lines/Piping, and Fittings
03V42400024 Oct 2003Fuel System, Gasoline
03V2840001 Aug 2003Equipment / Other / Labels

10V566000Received 8 Nov 2010. 416 units.
Equipment / Electrical / Navigational System(Global Positioning System)
Defect, in the NHTSA record
Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
Consequence, in the NHTSA record
An overheated battery could lead to a fire.
Remedy, in the NHTSA record
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 charge. The safety recall began on november 18, 2010. Owners may contact garmin at 866-957-1981 or visit garmin's website at www.garmin.com/nuvibatterypcbrecall.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number R231. Owner notification date in the NHTSA record: 18 Nov 2010.
08V033000Received 28 Jan 2008. 23,000 units.
Fuel System, Gasoline / Delivery / Fuel Pump
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
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, in the NHTSA record
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.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number 190. Owner notification date in the NHTSA record: 20 Feb 2008.
06V137000Received 24 Apr 2006. 16,175 units.
Fuel System, Gasoline
Defect, in the NHTSA record
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, in the NHTSA record
This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
Remedy, in the NHTSA record
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.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number R158. Owner notification date in the NHTSA record: 5 Jun 2006.
04V493000Received 14 Oct 2004. 1,719 units.
Service Brakes, Hydraulic / Power Assist / Vacuum / Hoses, Lines/Piping, and Fittings
Defect, in the NHTSA record
On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
Consequence, in the NHTSA record
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, in the NHTSA record
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.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number 137. Owner notification date in the NHTSA record: 29 Nov 2004.
03V424000Received 24 Oct 2003. 15,067 units.
Fuel System, Gasoline
Defect, in the NHTSA record
On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
Consequence, in the NHTSA record
Fuel leakage in the presence of an ignition source could result in a fire.
Remedy, in the NHTSA record
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.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number R128. Owner notification date in the NHTSA record: 28 Jan 2004.
03V284000Received 1 Aug 2003. 220,407 units.
Equipment / Other / Labels
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
This does not meet the requirements of the standard.
Remedy, in the NHTSA record
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 notification began on december 19, 2003. Owners should contact volvo at 1-800-458-1552.
Report filed by VOLVO CARS OF N.A. LLC.. Manufacturer campaign number 124. Owner notification date in the NHTSA record: 19 Dec 2003.

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

26 complaints, 48 component mentions.

A complaint can name more than one component. Each component that a complaint names is one component mention. This model year has fewer than 50 component mentions, so the table shows the number of mentions only.

2004 Volvo S40: component mentions in complaints
Component		Mentions
Electrical System		10
Air Bags		7
Service Brakes, Hydraulic		6
Engine and Engine Cooling		4
Steering		4
Visibility		3
Fuel System, Gasoline		3
Latches/Locks/Linkages		2
Vehicle Speed Control		2
Equipment		1

The table shows the 10 components with the most mentions, of 16.

Complaints that report a crash: 4
Complaints that report a fire: 1
Injuries in the complaints: 3
Deaths in the complaints: 0
Date of the newest complaint: 14 Sep 2010

These figures are the entries of the persons who sent the complaints.

Complaint: A report about a possible safety problem that a person sends to NHTSA. This site shows the number of complaints and not their text.

Complaints about the 2004 Volvo S40, by the year NHTSA received them. The largest year is 2005, with 6 complaints.

Investigations

The NHTSA investigation file has no investigation that names this model year.

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

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Official channels

NHTSA VIN lookupNHTSA shows the unrepaired recalls of one vehicle from its VIN or its license plate.
NHTSA: report a safety problemThe NHTSA form for a complaint about a vehicle, a tire, a child seat or equipment.
NHTSA page of the 2004 Volvo S40The recalls, the complaints and the investigations that NHTSA shows for this model year.

Cite this page

Recall Register. 2004 Volvo S40: recalls and complaints. https://recallregister.com/vehicle/volvo/s40/2004/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through 30 Sep 2026.

Sources

Source: NHTSA Office of Defects Investigation
Licence: US government work, public domain
Recall file through: 30 Sep 2026
Complaint file through: 29 Mar 2018
First complaint in the file: 1 Jan 1995
Manufacturer in the recall file: VOLVO CARS OF N.A. LLC.

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 2004 Volvo S40?: 276,784 units in 6 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the Volvo S40 have for all model years?: NHTSA lists 12 recall campaigns for the Volvo S40, model years 2000 to 2011. 6 of them name the 2004 model year.
Which component do the complaints about the 2004 Volvo S40 name most often?: Electrical System: 10 of 48 component mentions.
Is an NHTSA investigation of the 2004 Volvo S40 open?: The NHTSA investigation file has no investigation that names this model year.