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definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
21,333 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Volvo S40 fuel system problems

fuel system problem

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2004 Volvo S40 Owner Comments

problem #3

Sep 132010


  • miles


Volvo S40 T5 2004 is not accelerating properly. Rpms increase drastically and speed does not increase. The vehicle has stalled twice while driving along with traffic. Repairs related to similar symptoms: Replaced and relocated pem in 2008, engine control module software was updated due to faulty software in 2008 same problems occurred a month ago and recurring at a more extreme level now. This faulty manufacturing does not include other problems that were fixed a few months ago while under warranty and now reappearing again.

- Mechanicsburg, PA, USA

problem #2

Aug 242010


  • 64,000 miles
On certain Volvo vehicles, insufficient sealing of the fuel pump electronic module may lead to water ingress corrosion, possibly causing the unit to fail. This may result in increased, decreased, or loss of fuel pressure. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a collision or serious physical injury. Correction: Dealers should replace and relocate the fuel pump electronic module. Relocation of pem is due to a design flaw and should not be limited to geographical areas of vehicle use. This design flaw presents a manufacturing defect that may affect the safe operation of the vehicle. Volvo extended the warranty but has not voluntarily recalled this component for the 2004 through 2007 Volvo. By extending the warranty they are avoiding their responsibility to replace a design flaw that may endanger occupants of Volvo. Please refer to Transport Canada's mandate regarding motor vehicle Safety Act.

- Lexington, KY, USA

problem #1

Mar 032010


  • miles
I live in Texas. I own a Volvo. 2004 S-40. Apparently have been several recalls on Volvo S-40's pertaining to the gasoline fuel pumps. These recalls only apply to certain states up North. I did speak to a customer service representative (bart) at Volvo. I feel like I am involved in a cat an mouse game when I talk to him. He says my VIN number is not involved in the recall. I told him it probably would not be involved in the recall since Volvo has only involved states up North. That was the purpose of my call. How is it that auto company's are allowed to get away with these glitches? the recall involves fuel pumps exposure (corrosion)to salt (chemical) on the roads that are mostly exposed in northern states. I think this is irresponsible. What if the owner moves from Texas up North to live? the person that moves from South to North still will never be aware of the recall notification because they bought the vehicle down South. What if the person is in a area of the state (other than up North) and the car is exposed to salty environment. I did not get anywhere with the representative because he was "playing with words" literally trying to confuse me. My point is this the recalls should not be placed on were you live when it comes to climate. People move all the time. Also sometimes they find that the problem has nothing to do with where people live it could be the overall problem with the car despite location. Do people have to die before this is figured our. I feel Volvo is being very deceptive by presenting this recall the way that it did. There are more than one recall pertaining to the fuel pump. There are several. Also I just recently saw today on tv about Toyota recalling Tundra trucks under very similar circumstances as I described with Volvo( climate exposure). The Tundra were rusting and the wheels and gas tanks were falling off(apparently it was only in 20 cold states) now they expanded to 50 states. Why?

- Houston, TX, USA

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