hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
46,875 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 engine problems

engine problem

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2005 Volvo S40 Owner Comments

problem #8

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 #7

Apr 042012


  • 100,000 miles
The contact owns a 2005 Volvo S40. The contact stated that the engine trap flame box was leaking oil and exhibited a whistling noise when the engine was started. The manufacturer was made aware of the failure and advised the contact that the engine flame trap box was previously replaced under the warranty and would not be replaced again. The vehicle was not repaired. The failure mileage was 100,000 and the current mileage was 121,000.

- Dallas , TX, USA

problem #6

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 #5

Oct 172010


  • 39,000 miles


The contact owns a 2005 Volvo S40. The contact stated that while driving approximately 55 mph when the vehicle completely stalled. There were no warning lights prior to the failure. The contact was able to coast to the side of the road. She restarted the vehicle and was able to drive to her destination where the vehicle stalled again. The vehicle was taken to an authorized dealer where the battery cables were replaced for a second time in fourteen months. The contact was driving when the failure occurred. The vehicle was at the dealer at the time of the complaint; the dealer could not diagnose the problem. The contact called the manufacturer who advised her to take the vehicle to the dealer. The VIN was unavailable. The current mileage was approximately 40,000. The failure mileage was approximately 39,000.

- Lower Gwynedd, PA, USA

problem #4

Sep 182010


  • 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. Usually, if I leave it off for a few minutes it works for a bit longer time before it stops again. This problem 1st appeared when it was about a year old @ about 9-10K miles but it only happened once and was fine after I turned off and back on. 2nd time happened about 1-1/2 yrs ago when it was around 35K miles but was the same as the first time and was ok after turning off and back on. Now for the past year it is constant!! this happens daily!! the car is only now 47K. I took it to the car dealership yesterday and I barely began explaining the problem and before I even finished describing it, the service advisor finished by telling me the rest. He told me he knew the story B/C he heard it many times before. He said it was most likely the compressor clutch, compressor, or both. He said that it is a constant problem with that vehicle and that they do the same repairs repeatedly and that it seemed like a specific problem on those vehicles. Today, I began doing some research and found several sites where people are asking online advisors what this problem could be. Per my online research and the dealership's service advisor this is a very common problem with this car. Since this is such a common problem with the car can you please look into doing a product recall for these faulty parts so that we're not stuck paying the estimated $1500 at the dealership! thank you ([xxx]) information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Houston, TX, USA

problem #3

Aug 102008


  • miles
The contact owns a 2005 Volvo S40. While driving low speeds, the engine makes a howling noise. The noise stops while driving higher speeds. The dealer stated that there was an oil trap (PCV system) in the intake manifold that was clogged and could cause the crank case to fail. The failure mileage was unknown.

- Gresham, OR, USA

problem #2

Jun 232008


  • 75,000 miles
The contact owns a 2005 Volvo S40. While accelerating from a stop, the vehicle stalls and hesitates. The failure also occurs at highway speeds and has occurred for approximately 8 months to a year. The failure gradually worsens whenever the vehicle is driven. The dealer stated that the VIN was not included in NHTSA campaign id number 08V033000 (fuel system, gasoline:delivery:fuel pump). The failure mileage was 75,000.

- Merryfield, VA, USA

problem #1

Jul 312007

S40 5-cyl

  • Automatic transmission
  • miles
2005 Volvo S40 T5 : multiple failures of oil trap housing at 22,500 and 68,330 miles. First failure occurred 10 months after purchase. Volvo checked valve (30677524), and replaced oil housing (30684381), hose clamp (976561) upgraded ECM petrol (30668282)...all under warranty. Second failure occurred at 68,330 miles, Volvo again upgraded ECM (30668282), replaced hose clamp (976561), hose (8670008), and again replaced oil trap housing (30684381) due to clogged lines releasing air pressure. Cost of repair: $505 labor + $242 parts= $747.17, no longer under warranty.

- Valencia, CA, USA

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