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NHTSA — Fuel System, Gasoline Problems


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
80,034 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.

2005 Volvo S40 fuel system problems

fuel system problem

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2005 Volvo S40 Owner Comments

problem #7

Jun 112013

S40 5-cyl

  • 93,000 miles


My car was making a pumping noise from the rear of the car and the check engine light would come on. I took it to a local mechanic and they informed me of the pem recall/extended warranty. I took the car to the Volvo dealership to have repaired and they said the pem was not the problem and that it was a fuel pressure sensor and possibly the fuel pump itself. I declined the repair and exactly 2 weeks later the car failed to start. I had it towed to my local mechanic since I live 70 miles from the Volvo dealership. My mechanic replaced and moved the pem to a new location, which was exactly what the recall/extended warranty was for! the dealership gave me a form for reimbursement from Volvo, but Volvo refused to pay the $634 that I paid for the repair. They first tried to say it was not a "genuine Volvo part" but I verified it was. Then they said since I declined the repair for the fuel pressure sensor, they could not pay! the reimbursement form is for the pem and has nothing to do with the fuel pressure sensor. So this pem became faulty in a 2 week period? I think not! obviously Volvo does not stand behind their cars and I feel like they lied to me.

- Jackson, TN, USA

problem #6

Jun 282013

S40 5-cyl

  • 116,740 miles
I have researched Volvo forums and found that Volvo completed recall #181 for a fuel pressure sensor. ( while I don't own a vehicle included in Volvo recall 181, I do own a Volvo which shares the same fuel pressure sensor. Here is the background: I drive a 2005 Volvo S40, T5 AWD. I am the only person whom has ever owned this car. In September 2011 my fuel pressure sensor failed and I was charged approximately $550 at the dealership to have it replaced. It failed while I was driving on the highway. I had also experienced power-surge type behaviors during start-up, after the car had set overnight or during my workday. Yesterday, with the kids in the car, I was driving along about 60mph and all of a sudden is was like my car had stalled out. The brakes worked and turn signals worked. However, the steering had tightened up. All of the lights on the dashboard were lit. I coasted to the far right lane and turned on my caution lights, still being in the actual road. I turned the key off and then restarted the car. The car started ok. As soon as I arrived home it happened again; this was not even 5 miles and 15 minutes later. The current fuel pressure sensor part number shows Bosch part- 31272730; which, again, was new as of 2011. I'm concerned that the replacement part is now failing- almost 2 years later and less than 7,000 miles later! recently I have also found the issues with the power-surge during start up have began recurring. Until researching the issue I was unaware there was a relation between the power-surge and fuel pressure sensor. I have an appointment on Monday to drop off my car at Volvo. At this point I don't have confidence that the root cause and complete scope have been identified in Volvo recall #181 or that replacing this part will correct the safety issue.

- Flower Mound, TX, USA

problem #5

Mar 012011

S40 5-cyl

  • 83,000 miles
The vehicle exhibited stalling and misfires the first time at 65 mph. The check engine light (cel) came on and the diagnostic indication was that fuel pressure sensor needed replaced. It continued with stall and misfire at intermittent times with the cel staying on and off intermittently. I bought a fuel pressure sensor and replaced the original, which has remedied the problem. When I replaced the fuel pressure sensor, I examined the original part and noted that it had a part number of 8699448 instead of 31272733 like the replacement part. Putting in fuel pressure sensor 8699448 on the internet, I quickly found Volvo recall 181 which covers this part for Volvo 2003 - 2004 S60/V70 cars (48,000 plus). My motor is a slight variant of the motors used and not included. It is obvious that the major part of consideration is the fuel pressure sensor 8699448 but Volvo did not see their way to include all motors using this part and the danger is no different for the S40 than the S60/V70. The internet shows many other examples of this failure within 2005 S40S. This is probably the tip of the iceberg with many more to follow and possible potential dangerous accidents impending. All information I relayed in this complaint has been told to my local Volvo dealer and Volvo customer service (national).

- Huntsville, AL, USA

problem #4

May 102011


  • 71,000 miles


The contact owns a 2005 Volvo S40. The contact stated that the vehicle would stalls randomly with the illumination of the power service warning light. The contact took the vehicle to a mechanic and was told that the pump electronic module was failing and that there was a recall for the failure (NHTSA campaign id number: 08V033000-fuel system gasoline: Delivery: Fuel pump). The contact spoke with the manufacturer and was told that the vehicle was not included in the recall. The failure mileage was 71,000.

- Sparks, NV, USA

problem #3

Jan 202011


  • 75,000 miles
A 2005 Volvo S40 T5 model has repeating fuel line leakage. The car was serviced to replace the original polyamide fuel line to a teflon fuel line in line with recall R158. After four years the teflon fuel line was become worn and fuel has begun to flow from the line. The average fuel line life is well beyond four years. There is an underlying issue with the fuel line with the 2005 Volvo S40 T5.

- Centreville, VA, USA

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problem #2

Oct 202010

S40 5-cyl

  • 68,000 miles
The contact owns a 2005 Volvo S40. The contact stated that the check engine light illuminated and the vehicle stalled while she was driving. The vehicle was taken to an authorized dealer where it was repaired according to recall 08V033000 (fuel system, gasoline: Delivery:fuel pump) but the contact still experienced the same failure after the repair. The dealer also informed her that she needed to have a fuel pump sensor needed to be replaced. The vehicle had not been repaired again. The manufacturer had not been notified. The current mileage was approximately 69,000. The failure mileage was approximately 68,000. Updated 03/15/11 also, there was an internal fault with the ignition which caused the vehicle to shut down. Updated 04/28/11

- College Park, GA, USA

problem #1

Apr 102009


  • 53,500 miles
Purchased a Volvo overseas in 2005 and it recently broke down last week in the middle of an intersection. I had it towed to the Volvo dealer in fort walton beach and they told me my part was faulty and will have it running by the next day. I called my warranty company and they told me that part had been recalled and Volvo should pay for it but they denied there was a recall and called it an extended warranty. My warranty company american guardian sent a 3rp party mechanic to Volvo and verified it was corroded. The recall is all over the webs/including yours NHTSA campaign id #08V033000 so I called Volvo and they say there is no recall. The part and labor was $800. My VIN wasn't loaded in the us system until this week. Currently the Volvo dealer replace the part and moved it to a different location and says it can't cover it unless Volvo put that specific VIN number and load it against it (extended warranty) but how if there is no recall. Neither Volvo or the warranty company will pay for the part. If its an official recall and it happened just like the description on the recall states they should be obligated to cover it. Its only got 53000 miles on it which is 3000 over the manufacture warranty. I feel Volvo needs to add my VIN to the list because obviously its a problem to mine also. I have refused to pick up the car the last week until I heard back form Volvo but they said there is nothing they can do and I have to pay for it.

- Crestview, FL, USA

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