2004 Volvo S40: common problems and reliability

The 2004 Volvo S40 has 50 owner-filed NHTSA complaints and 6 recalls on record. The most-reported areas are air bags and service brakes. Owners most often flag major engine failure (head gasket, piston/cylinder scoring) in psa-sourced gasoline engines (1.6, 1.8, 2.0). frequency: very frequent.

Safety record for the 2004 model year

50
Owner complaints
6
Recalls
5
Crash reports
1
Fire reports

Source: NHTSA complaints and recalls filed for 2004 Volvo S40 vehicles (US, public record).

Where owners report problems

air bags
12
service brakes
12
electrical system
11
hydraulic
8
fuel system
6

Recalls affecting the 2004 S40

equipment:electrical:navigational system(global positioning system)

Campaign 10V566000

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

fuel system, gasoline

Campaign 06V137000

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.

fuel system, gasoline:delivery:fuel pump

Campaign 08V033000

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, OHI…

fuel system, gasoline

Campaign 03V424000

ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.

What owners say across generations

Sentiment is sharply divided and heavily dependent on the specific model year, engine, and maintenance history. For well-maintained examples with the correct powertrain, particularly the five-cylinder gasoline engines (2.4, 2.4i, T5), long-term owner reports d

  • Major engine failure (head gasket, piston/cylinder scoring) in PSA-sourced gasoline engines (1.6, 1.8, 2.0). Frequency: very frequent.
  • General reliability and high repair costs, leading to the "money pit" characterization, especially with age and high mileage. Frequency: very frequent.
  • Electrical gremlins, including faulty door lock mechanisms, ignition switch failures, and various sensor issues. Frequency: recurrent.
  • Coolant expansion tank cracking. Frequency: recurrent.
  • Automatic transmission failures or concerns, particularly with high-mileage units and certain GM-sourced gearboxes in related models. Frequency: recurrent.

Owner insights cover all generations of the S40.

Typical used price

Used S40 listings typically run $4,999–$6,999 across 2001 to 2011 model years.

Other S40 model years

2011 S402007 S402006 S402001 S402000 S40
Full Volvo S40 owner reportCompare against another car