Model year
2004 Volvo S40
NHTSA lists 6 recalls and 48 complaints for the 2004 Volvo S40 (recall file dated Oct 23, 2026; complaint file dated Oct 23, 2026). NHTSA also lists 0 recalls and 2 complaints under S40N. Those counts are separate from the numbers above. The components listed on the most complaints are ELECTRICAL SYSTEM (9), AIR BAGS (6), SERVICE BRAKES, HYDRAULIC (4). NHTSA star ratings from before model year 2011 use an older method and are not shown here. EPA rates it 22–23 mpg combined depending on configuration (fuel economy file dated Sep 29, 2026). EPA's annual fuel-cost figures for these configurations are $3,550–$3,750, based on 15,000 miles and 55% city driving.
- 2000 122 complaints
- 2001 84 complaints
- 2002 27 complaints
- 2003 18 complaints
- 2004 48 complaints
- 2005 69 complaints
- 2006 58 complaints
- 2007 25 complaints
- 2008 16 complaints
- 2009 10 complaints
- 2010 9 complaints
- 2011 5 complaints
Recalls
10V566000 · Nov 8, 2010
EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
08V033000 · Jan 28, 2008
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
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,…
06V137000 · Apr 24, 2006
FUEL SYSTEM, GASOLINE
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.
04V493000 · Oct 14, 2004
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM:HOSES, LINES/PIPING, AND FITTINGS
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
03V424000 · Oct 24, 2003
FUEL SYSTEM, GASOLINE
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
03V284000 · Aug 1, 2003
EQUIPMENT:OTHER:LABELS
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…
Complaints
48 distinct complaints. Crash flag on 5, fire flag on 1, injury field 4, deaths field 0. A complaint can be counted under more than one component. The injury and death figures are the file's numbers (the highest value on each complaint, then added), not a separate verified count of people.
Other NHTSA names
These names matched the same EPA model but are not included in the headline counts above.
| Name | Recalls | Complaints |
|---|---|---|
| S40N | 0 | 2 |
Investigations
No investigations are matched to this name.
Safety ratings
NHTSA star ratings from before model year 2011 use an older method and are not shown here.
Fuel economy
| Configuration | Fuel | City | Hwy | Comb | kWh/100 mi | Range | Annual fuel cost |
|---|---|---|---|---|---|---|---|
| S40 FWD · 1.9L · Automatic 5-spd · Front-Wheel Drive | Premium Gasoline | 19 | 27 | 22 | — | — | $3,750 |
| S40 FWD · 2.4L · Automatic (S5) · Front-Wheel Drive | Premium Gasoline | 19 | 28 | 22 | — | — | $3,750 |
| S40 FWD · 2.5L · Automatic (S5) · Front-Wheel Drive | Premium Gasoline | 19 | 28 | 23 | — | — | $3,550 |
Open this model year in the fuel-cost calculator. The calculator starts with no fuel price filled in.
Check a vehicle
This page is not a VIN lookup. NHTSA's recall tool checks a specific vehicle: nhtsa.gov/recalls. NHTSA's page for this model year is 2004 Volvo S40 at NHTSA. Complaint narratives stay on NHTSA's site and are not copied here.