The Verdict
Worst problem area
Brakes
Brakes leads by volume: 12 of 48 complaints (25%) mention it. Complaints mentioning Airbags & Restraints include more reported injuries (3) than those mentioning any other identified area.
Complaints filed rose from 18 in 2003 to 48 in 2004.
At a glance
- NHTSA complaints
- 48
- Recall campaigns
- 6
- EPA fuel cost per year
- $3,350–$3,500
- Combined MPG
- 22–23
Complaints by model year
Where owners report problems
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Cost, Fuel Economy & Complaint History
| Category | 2002 | 2003 | 2004 | 2005 | 2006 | vs. 2004 Compact Cars |
|---|---|---|---|---|---|---|
| Annual fuel cost ($) | 3,500 | 3,500 | 3,350–3,500 | 3,500–3,850 | 3,350–3,850 | |
| Combined MPG | 22 | 22 | 22–23 | 20–22 | 20–23 | |
| City / Highway MPG | 19 / 27 | 19 / 27 | 19 / 27–28 | 17–19 / 25–29 | 18–20 / 25–29 | |
| CO₂ tailpipe (g/mi) | 404 | 404 | 386–404 | 404–444 | 386–444 | |
| Complaints filed | 27 | 18 | 48 | 69 | 58 | |
| Recalls issued | 1 | 2 | 6 | 3 | 3 | |
| Crash-involved complaints | 4 | 0 | 5 | 2 | 1 | |
| Fire-involved complaints | 0 | 1 | 1 | 0 | 0 | |
| Injuries reported | 2 | 0 | 4 | 1 | 1 | |
| Deaths reported | 0 | 0 | 0 | 0 | 0 | |
| Configurations compared | 1 | 1 | 3 | 6 | 6 |
Not compared: this database has no vehicle sales or registration figures, so a raw count mostly reflects how many were sold, not how safe the vehicle is.
Common questions
How many recalls does the 2004 Volvo S40 have?
6 NHTSA recall campaigns as of Nov 7, 2026. Check your VIN with NHTSA to see whether one applies to your car.
What is the most common complaint about the 2004 Volvo S40?
Brakes: 12 of 48 NHTSA complaints (25%) mention it.
What gas mileage does the 2004 Volvo S40 get?
EPA rates it 22–23 MPG combined across 3 configurations.
How much does it cost to fuel a 2004 Volvo S40?
EPA estimates $3,350–$3,500 a year in fuel costs, using EPA's assumptions.
Similar Vehicles
EPA-Rated Configurations (3)
| Configuration | Transmission | Cylinders | Displacement | Drivetrain | Fuel Type | Vehicle Class | City | Highway | Combined | Annual Fuel Cost | CO₂ |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Configuration 1 | Automatic 5-spd | 4 | 1.9L | Front-Wheel Drive | Premium | Compact Cars | 19 mpg | 27 mpg (low) | 22 mpg (low) | $3,500 (high) | 404 g/mi (high) |
| Configuration 2 | Automatic (S5) | 5 | 2.4L | Front-Wheel Drive | Premium | Compact Cars | 19 mpg | 28 mpg (high) | 22 mpg (low) | $3,500 (high) | 404 g/mi (high) |
| Configuration 3 | Automatic (S5) | 5 | 2.5L | Front-Wheel Drive | Premium | Compact Cars | 19 mpg | 28 mpg (high) | 23 mpg (high) | $3,350 (low) | 386 g/mi (low) |
Complaints by Category
| Category | Complaints | Crash-Involved | Fire-Involved | Injuries | Deaths |
|---|---|---|---|---|---|
| Engine | 7 | 0 | 0 | 0 | 0 |
| Transmission & Drivetrain | 1 | 0 | 0 | 0 | 0 |
| Fuel System | 8 | 1 | 0 | 1 | 0 |
| Electrical | 11 | 0 | 1 | 0 | 0 |
| Brakes | 12 | 2 | 1 | 2 | 0 |
| Steering | 4 | 0 | 0 | 0 | 0 |
| Suspension, Wheels & Tires | 2 | 0 | 0 | 0 | 0 |
| Airbags & Restraints | 11 | 3 | 0 | 3 | 0 |
| Driver Assistance & Speed Control | 5 | 1 | 0 | 0 | 0 |
| Body, Seats & Latches | 3 | 0 | 0 | 0 | 0 |
| Visibility & Lighting | 4 | 0 | 0 | 0 | 0 |
| Other | 3 | 0 | 0 | 0 | 0 |
A complaint that names more than one category is counted in each, so the rows can add up to more than the total number of complaints.
Recalls (6)
EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
- Defect
- VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
- Consequence
- AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
- Remedy
- 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 PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
- Defect
- 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 POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.
- Consequence
- 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.
- Remedy
- DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
FUEL SYSTEM, GASOLINE
- Defect
- 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.
- Consequence
- THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
- Remedy
- DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM:HOSES, LINES/PIPING, AND FITTINGS
- Defect
- ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
- Consequence
- 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.
- Remedy
- 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, GASOLINE
- Defect
- ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
- Consequence
- FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
- Remedy
- 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.
EQUIPMENT:OTHER:LABELS
- Defect
- 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.
- Consequence
- THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
- Remedy
- 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 TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.