2004 Volvo S40: Recalls, Problems & MPG
Here are the deets on the 2004 Volvo S40: 6 recalls, 48 owner complaints and up to 23 mpg combined.
Recalls
6 vehicle recalls from the manufacturer. Repairs are free. Check your VIN to see if one is still open on your car.
Equipment Vehicle recall #03V284000 · 2003 · 220,407 vehicles
What's wrong: 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.
Why it matters: This does not meet the requirements of the standard.
The fix: 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…
Fuel system Vehicle recall #03V424000 · 2003 · 15,067 vehicles
What's wrong: On certain sedans and station wagons, there May be a fuel leak from the fuel rail due to inadequate welding.
Why it matters: Fuel leakage in the presence of an ignition source could result in a fire.
The fix: 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.
Brakes (hydraulic) Vehicle recall #04V493000 · 2004 · 1,719 vehicles
What's wrong: On certain passenger vehicles, the non-return valve May crack due to a poor weld causing a vacuum leak.
Why it matters: 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.
The fix: 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.
Fuel system Vehicle recall #06V137000 · 2006 · 16,175 vehicles
What's wrong: 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.
Why it matters: This May potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
The fix: Dealers will change the fuel line material to teflon free of charge. The recall began on June 5, 2006.
Fuel system Vehicle recall #08V033000 · 2008 · 23,000 vehicles
What's wrong: 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…
Why it matters: 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.
The fix: Dealers will replace the pem and install it in a new location to prevent corrosion. The recall began on February 20, 2008.
Equipment Vehicle recall #10V566000 · 2010 · 416 vehicles
What's wrong:
Why it matters: An overheated battery could lead to a fire.
The fix: 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…
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 1 mention a fire, 4 injuries and 0 deaths were reported.
What owners describe
- Airbags (11): the most common themes are warning light on (5).
- Electrical (11): the most common themes are electrical failure (7), door / lock issues (4), warning light on (3).
- Brakes (hydraulic) (8): no single recurring theme in the descriptions.
- Engine & cooling (5): the most common themes are warning light on (5), stalls / loses power (2).
The 2004 Volvo S40 has 48 owner complaints, ranking #5 of 12 S40 model years for complaints (about average; the typical year has 41). Complaints peaked in 2005 (6 filed that year). The typical problem showed up when the car was about 6 years old, at a median of 64,000 miles. Neighboring years: 2003 (18 complaints, 2 recalls), 2005 (69 complaints, 3 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 2.5 L 5-cyl turbo | Automatic (S5) | Front-Wheel Drive | 19 | 28 | 23 | Premium |
| 1.9 L 4-cyl turbo | Automatic 5-spd | Front-Wheel Drive | 19 | 27 | 22 | Premium |
| 2.4 L 5-cyl | Automatic (S5) | Front-Wheel Drive | 19 | 28 | 22 | Premium |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 2004 Volvo S40.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
From $19.99/mo · $39.99/yrOEM procedures, specs and recall/TSB info, the same source many shops use.
From $19.99/mo · $59.99/yrStep-by-step photos written from a real teardown. Great for first-timers.
Books ~$30–$40 · AllAccess $34.99/moHeads up: we may earn a commission if you buy through these links, at no extra cost to you. Prices checked 2026-10 and can change. We never host or link to pirated manuals. Disclosure
FAQ
Does the 2004 Volvo S40 have any recalls?
Yes. NHTSA lists 6 vehicle recalls for the 2004 Volvo S40. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 2004 Volvo S40 problems?
Owners have filed 48 complaints with NHTSA. The most-reported areas are airbags (11), electrical (11), brakes (hydraulic) (8).
What gas mileage does the 2004 Volvo S40 get?
EPA ratings run up to 23 mpg combined (2.5 L, Automatic (S5)), across 3 engine and transmission combos.
Where can I get a 2004 Volvo S40 repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.